SEN06109-00
HYDRAULIC EXCAVATOR
PC200 -8M0 PC200LC -8M0 PC220 -8M0 PC220LC -8M0 SERIAL NUMBERS
PC200PC200LCPC220PC220LC-
400001 400001 and up 100001 100001
SEN06111-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
00 Index and foreword
1
100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
PC200, 200LC, 220, 220LC-8M0
00-100
1
SEN06111-00
100 Index Composition of shop manual
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN06109-00
00 Index and foreword 100 Index 200 Foreword and general information
SEN06110-00 SEN06111-00 SEN06112-00
01 Specification 100 Specification and technical data
SEN06113-00 SEN06114-00
10 Structure, function and maintenance standard 100 Engine and cooling system 200 Power train 300 Undercarriage and frame 401 Hydraulic system, Part 1 402 Hydraulic system, Part 2 403 Hydraulic system, Part 3 500 Work equipment 600 Electrical system
SEN06115-00 SEN06116-00 SEN06117-00 SEN06118-00 SEN06119-00 SEN06120-00 SEN06121-00 SEN06122-00 SEN06123-00
20 Standard value table 100 Standard service value table
SEN06124-00 SEN06125-00
30 Testing and adjusting 101 Testing and adjusting, Part 1 102 Testing and adjusting, Part 2 103 Testing and adjusting, Part 3
SEN06126-00 SEN06127-00 SEN06128-00 SEN06129-00
00-100
2
PC200, 200LC, 220, 220LC-8M0
100 Index Composition of shop manual
SEN06111-00
40 Troubleshooting 100 Failure code table and fuse locations 200 General Information on troubleshooting 301 Troubleshooting by failure code, Part 1 302 Troubleshooting by failure code, Part 2 303 Troubleshooting by failure code, Part 3 304 Troubleshooting by failure code, Part 4 305 Troubleshooting by failure code, Part 5 400 Troubleshooting of electrical system (E-mode) 500 Troubleshooting of hydraulic and mechanical system (H-mode) 600 Troubleshooting of engine (S-mode)
SEN06130-00 SEN06131-00 SEN06132-00 SEN06133-00 SEN06134-00 SEN06135-00 SEN06136-00 SEN06137-00 SEN06138-00 SEN06139-00 SEN06140-00
50 Disassembly and assembly 100 General information on disassembly and assembly 200 Engine and cooling system 300 Power train 400 Undercarriage and frame 500 Hydraulic system 600 Work equipment 700 Cab and its attachments 800 Electrical system
SEN06141-00 SEN06142-00 SEN06143-00 SEN06144-00 SEN06145-00 SEN06146-00 SEN06147-00 SEN06148-00 SEN06149-00
80 Appendix 100 Air conditioner
SEN06150-00 SEN06151-00
90 Diagrams and drawings 100 Hydraulic diagrams and drawings 200 Electrical diagrams and drawings
SEN06152-00 SEN06153-00 SEN06154-00
PC200, 200LC, 220, 220LC-8M0
00-100
3
SEN06111-00
Table of contents
100 Index Table of contents
1
00 Index and foreword 100 Index SEN06111-00 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 200 Foreword and general information SEN06112-00 Foreword, safety and general information ............................................................................... 2 How to read the shop manual.................................................................................................. 9 Explanation of terms for maintenance standard ...................................................................... 11 Handling equipment of fuel system devices ............................................................................ 13 Handling of intake system parts............................................................................................... 14 Handling of hydraulic equipment ............................................................................................. 15 Method of disconnecting and connecting of push-pull type coupler ........................................ 17 Handling of electrical equipment.............................................................................................. 20 How to read electric wire code................................................................................................. 29 Precautions when performing operation .................................................................................. 32 Practical use of KOMTRAX ..................................................................................................... 35 Standard tightening torque table.............................................................................................. 36 List of abbreviation................................................................................................................... 40 Conversion table...................................................................................................................... 45 01 Specification 100 Specification and technical data SEN06114-00 Specification dimension drawings............................................................................................ 2 Working range diagram ........................................................................................................... 3 Specifications........................................................................................................................... 4 Weight table ............................................................................................................................. 8 Table of fuel, coolant and lubricants ........................................................................................ 12 10 Structure, function and maintenance standard 100 Engine and cooling system SEN06116-00 Engine related parts................................................................................................................. 2 Radiator, oil cooler, aftercooler and fuel cooler........................................................................ 3 200 Power train SEN06117-00 Power train............................................................................................................................... 2 Final drive ................................................................................................................................ 4 Swing machinery ..................................................................................................................... 8 Swing circle.............................................................................................................................. 12 300 Undercarriage and frame SEN06118-00 Track frame and recoil spring .................................................................................................. 2 Idler.......................................................................................................................................... 4 Carrier roller............................................................................................................................. 6 Track roller ............................................................................................................................... 7 Track shoe ............................................................................................................................... 8 401 Hydraulic system, Part 1 SEN06119-00 Hydraulic equipment layout drawing........................................................................................ 2 Hydraulic tank and filter ........................................................................................................... 4 Hydraulic pump........................................................................................................................ 6 Pilot oil filter ............................................................................................................................. 28 402 Hydraulic system, Part 2 SEN06120-00 Control valve............................................................................................................................ 2 CLSS ....................................................................................................................................... 13 Functions and operation by valve ............................................................................................ 17 403 Hydraulic system, Part 3 SEN06121-00 Swing motor............................................................................................................................. 2
00-100
4
PC200, 200LC, 220, 220LC-8M0
100 Index Table of contents
SEN06111-00
Center swivel joint ................................................................................................................... 10 Travel motor............................................................................................................................. 12 PPC valve................................................................................................................................ 22 Valve control ............................................................................................................................ 42 Solenoid valve ......................................................................................................................... 44 PPC accumulator..................................................................................................................... 46 Return oil filter ......................................................................................................................... 47 Attachment circuit selector valve ............................................................................................. 48 Hydraulic cylinder .................................................................................................................... 50 500 Work equipment SEN06122-00 Work equipment ...................................................................................................................... 2 Dimensions of arm................................................................................................................... 10 Dimensions of bucket .............................................................................................................. 12 600 Electrical system SEN06123-00 Engine control.......................................................................................................................... 2 Electrical control system.......................................................................................................... 12 Machine monitor system.......................................................................................................... 35 Sensor ..................................................................................................................................... 56 KOMTRAX system .................................................................................................................. 60 20 Standard value table 100 Standard service value table SEN06125-00 Standard value table for engine related parts .......................................................................... 2 Standard value table for chassis related parts......................................................................... 4 30 Testing and adjusting 101 Testing and adjusting, Part 1 SEN06127-00 Tools for testing, adjusting, and troubleshooting ..................................................................... 3 Sketch of special tool............................................................................................................... 7 Testing engine speed............................................................................................................... 8 Testing intake air pressure (boost pressure) ........................................................................... 9 Testing exhaust gas color ........................................................................................................ 10 Adjusting valve clearance........................................................................................................ 11 Testing compression pressure................................................................................................. 13 Testing blowby pressure .......................................................................................................... 16 Testing engine oil pressure...................................................................................................... 17 Handling fuel system parts ...................................................................................................... 18 Releasing residual pressure from fuel system......................................................................... 18 Testing fuel pressure ............................................................................................................... 19 Handling reduced cylinder mode operation ............................................................................. 22 Handling no-injection cranking operation ................................................................................ 22 Testing fuel discharge, return and leak amount....................................................................... 23 Bleeding air from fuel circuit .................................................................................................... 26 Testing fuel circuit for leakage ................................................................................................. 27 Handling controller high voltage circuit.................................................................................... 28 Testing and adjusting air conditioner compressor belt tension ................................................ 29 Replacing alternator belt.......................................................................................................... 30 Testing swing circle bearing clearance .................................................................................... 31 Testing and adjusting track tension ......................................................................................... 32 Testing and adjusting oil pressure in work equipment, swing, and travel circuits .................... 34 Testing control circuit source pressure .................................................................................... 37 Testing and adjusting oil pressure in pump PC control circuit ................................................. 38 Testing and adjusting oil pressure in pump LS control circuit.................................................. 41 Testing solenoid valve output pressure ................................................................................... 46 Testing PPC valve output pressure ......................................................................................... 49 Adjusting play of work equipment and swing PPC valves ....................................................... 51 Testing parts which cause hydraulic drift of work equipment................................................... 52 PC200, 200LC, 220, 220LC-8M0
00-100
5
SEN06111-00
100 Index Table of contents
Releasing remaining pressure from hydraulic circuit ............................................................... 54 Testing oil leakage ................................................................................................................... 55 Bleeding air from each part...................................................................................................... 58 Testing cab tipping stopper ...................................................................................................... 60 Adjusting mirrors...................................................................................................................... 61 Installation and adjustment of mirrors ...................................................................................... 62 Angle adjustment of rear view camera .................................................................................... 65 102 Testing and adjusting, Part 2 SEN06128-00 Special functions of machine monitor ...................................................................................... 2 103 Testing and adjusting, Part 3 SEN06129-00 Handling voltage circuit of engine controller ............................................................................ 2 Preparation work for troubleshooting of electrical system ....................................................... 3 Procedure for testing diodes.................................................................................................... 8 Pm Clinic service ..................................................................................................................... 9 40 Troubleshooting 100 Failure code table and fuse locations SEN06131-00 Failure codes table .................................................................................................................. 2 Fuse locations.......................................................................................................................... 9 200 General Information on troubleshooting SEN06132-00 Symptom and troubleshooting numbers .................................................................................. 2 Sequence of events in troubleshooting.................................................................................... 4 Checks before troubleshooting ................................................................................................ 6 Classification and procedures for troubleshooting................................................................... 8 Symptom and troubleshooting numbers .................................................................................. 10 Information in troubleshooting table......................................................................................... 12 Connector list and layout ......................................................................................................... 14 Connection table for connector pin numbers ........................................................................... 24 T- branch box and T- branch adapter table.............................................................................. 60 Troubleshooting method for open circuit in wiring harness of pressure sensor system .......... 63 301 Troubleshooting by failure code, Part 1 SEN06133-00 Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................... 3 Failure code [879AKB] A/C Inner Sensor Short Circuit ........................................................... 3 Failure code [879BKA] A/C Outer Sensor Open Circuit .......................................................... 3 Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................... 3 Failure code [879CKA] Ventilating Sensor Open Circuit.......................................................... 3 Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................... 4 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit............................................... 4 Failure code [879EMC] Ventilation Damper Abnormality......................................................... 4 Failure code [879FMC] Air Mix Damper Abnormality .............................................................. 4 Failure code [879GKX] Refrigerant Abnormality...................................................................... 4 Failure code [989L00] Engine Controller Lock Caution1 ......................................................... 5 Failure code [989M00] Engine Controller Lock Caution2 ........................................................ 6 Failure code [989N00] Engine Controller Lock Caution3......................................................... 7 Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 8 Failure code [AB00KE] Charge Voltage Low ........................................................................... 10 Failure code [B@BAZG] Eng Oil Press Low............................................................................ 12 Failure code [B@BAZK] Engine Oil Level Low........................................................................ 13 Failure code [B@BCNS] Eng Water Overheat ........................................................................ 14 Failure code [B@BCZK] Radiator Coolant Level Low ............................................................. 16 Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 18 Failure code [CA111] ECM Critical Internal Failure.................................................................. 19 Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 19 Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 20 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 22 Failure code [CA131] Throttle Sensor High Error .................................................................... 24 Failure code [CA132] Throttle Sensor Low Error..................................................................... 26
00-100
6
PC200, 200LC, 220, 220LC-8M0
100 Index Table of contents
SEN06111-00
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 28 Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 30 Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 32 Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 34 Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 36 Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 38 Failure code [CA221] Ambient Press Sens High Error............................................................ 40 Failure code [CA222] Ambient Press Sens Low Error............................................................. 42 Failure code [CA227] Sens 2 Supply Volt High Error .............................................................. 44 Failure code [CA234] Eng Overspeed..................................................................................... 44 Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 45 Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 46 Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 48 302 Troubleshooting by failure code, Part 2 SEN06134-00 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 4 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................ 6 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................ 8 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................ 10 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................ 12 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................ 14 Failure code [CA342] Calibration Code Incompatibility ........................................................... 16 Failure code [CA351] Injectors Drive Circuit Error................................................................... 17 Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 18 Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 20 Failure code [CA428] Water in Fuel Sensor High Error........................................................... 22 Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 24 Failure code [CA435] Eng Oil Press Sw Error......................................................................... 26 Failure code [CA441] Battery Voltage Low Error ..................................................................... 28 Failure code [CA442] Battery Voltage High Error .................................................................... 30 Failure code [CA449] Rail Press Very High Error .................................................................... 31 Failure code [CA451] Rail Press Sensor High Error................................................................ 32 Failure code [CA452] Rail Press Sensor Low Error ................................................................ 34 Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 36 Failure code [CA553] Rail Press High Error ............................................................................ 37 Failure code [CA559] Rail Press Low Error............................................................................. 38 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 40 Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 42 Failure code [CA757] All Continuous Data Lost Error ............................................................. 43 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 44 Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 48 Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 50 Failure code [CA2249] Rail Press Very Low Error................................................................... 51 Failure code [CA2311] lMV Solenoid Error .............................................................................. 51 Failure code [CA2555] Grid Htr Relay Open Circuit Error ....................................................... 52 Failure code [CA2556] Grid Htr Relay Short Circuit Error ....................................................... 54 303 Troubleshooting by failure code, Part 3 SEN06135-00 Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................ 4 Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 6 Failure code [D811MC] KOMTRAX Error ................................................................................ 8 Failure code [D862KA] GPS Antenna Open Circuit ................................................................ 9 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................... 10 Failure code [DA22KK] Pump Solenoid Power Low Error ....................................................... 12 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 14 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................ 16 Failure code [DA29KQ] Model Selection Abnormality ............................................................. 18 Failure code [DA2QKR] CAN2 Discon (Pump Con) ................................................................ 23 Failure code [DAF0MB] Monitor ROM Abnormality................................................................. 26 Failure code [DAF0MC] Monitor Error ..................................................................................... 27 PC200, 200LC, 220, 220LC-8M0
00-100
7
SEN06111-00
100 Index Table of contents
Failure code [DAF8KB] Camera Power Supply Short Circuit .................................................. 28 Failure code [DAF9KQ] Model Selection Abnormality ............................................................. 30 Failure code [DAFGMC] GPS Module Error ............................................................................ 31 Failure code [DAFQKR] CAN2 Discon .................................................................................... 32 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...................................................... 33 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .............................................................. 34 Failure code [DB2QKR] CAN2 Discon (Engine Con) .............................................................. 36 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ............................................................. 40 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit............................................... 42 Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 44 Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 46 304 Troubleshooting by failure code, Part 4 SEN06136-00 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 4 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................. 6 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 8 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality................................... 10 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 12 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 14 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ..................................... 16 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................. 18 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ................................... 20 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality .................................. 22 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality................................... 24 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ................................... 26 Failure code [DHX1MA] Overload Sensor Abnormality ........................................................... 28 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ......................................... 30 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ......................................... 32 Failure code [DV20KB] Travel Alarm Short Circuit .................................................................. 34 Failure code [DW43KA] Travel Speed Sol Open Circuit .......................................................... 36 Failure code [DW43KB] Travel Speed Sol Short Circuit .......................................................... 38 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit ................................................ 40 Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................... 42 Failure code [DW91KA] Travel Neutral Sol Open Circuit......................................................... 44 Failure code [DW91KB] Travel Neutral Sol Short Circuit......................................................... 46 305 Troubleshooting by failure code, Part 5 SEN06137-00 Failure code [DWA2KA] Attachment Sol Open Circuit............................................................. 4 Failure code [DWA2KB] Attachment Sol Short Circuit............................................................. 6 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ........................................................ 8 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit......................................................... 10 Failure code [DWK2KA] Variable Back Press Sol Open Circuit .............................................. 12 Failure code [DWK2KB] Variable Back Press Sol Short Circuit............................................... 14 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ............................................................ 16 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................. 18 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................ 20 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................ 22 Failure code [DXE0KA] LS-EPC Sol Open Circuit................................................................... 24 Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................... 26 Failure code [DXE4KA] Attachment Flow EPC Open Circuit................................................... 28 Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................... 30 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit .................................................. 32 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .................................................. 34 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ..................................................... 36 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit...................................................... 38 Failure code [DY20KA] Wiper Working Abnormality................................................................ 40 Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 42 Failure code [DY2CKB] Washer Drive Short Circuit ................................................................ 44 Failure code [DY2DKB] Wiper Drive (Fwd) Short .................................................................... 46 Failure code [DY2EKB] Wiper Drive (Rev) Short..................................................................... 48 00-100
8
PC200, 200LC, 220, 220LC-8M0
100 Index Table of contents
SEN06111-00
400 Troubleshooting of electrical system (E-mode) SEN06138-00 Fuse locations ......................................................................................................................... 4 Information contained in troubleshooting table ........................................................................ 6 E-1 Engine does not start (Engine does not crank) ................................................................. 8 E-2 Preheater does not operate .............................................................................................. 13 E-3 When starting switch is turned to ON position, machine monitor displays nothing ........... 17 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up. ................................................................................... 20 E-5 Precaution monitor lights up while engine is running ........................................................ 21 E-6 Emergency stop monitor lights up while engine is running ............................................... 23 E-7 Fuel level gauge does not indicate properly ..................................................................... 24 E-8 Engine coolant temperature gauge does not indicate properly......................................... 26 E-9 Hydraulic oil temperature gauge does not indicate properly............................................. 27 E-10 Displays on machine monitor are different from those for actual machine ..................... 30 E-11 Some areas of machine monitor screen are not displayed ............................................. 31 E-12 Function switch does not operate ................................................................................... 31 E-13 Automatic warm-up system does not operate (in cold season) ...................................... 32 E-14 Auto-decelerator does not operate properly ................................................................... 33 E-15 Working mode does not change ..................................................................................... 34 E-16 Travel speed does not change........................................................................................ 35 E-17 Alarm buzzer cannot be canceled................................................................................... 36 E-18 When starting switch is turned OFF, service meter is not displayed ............................... 36 E-19 Service mode cannot be selected................................................................................... 36 E-20 Any of work equipment, swing and travel do not operate or cannot be locked............... 37 E-21 Swing holding brake does not operate properly.............................................................. 39 E-22 One-touch power maximizing function does not operate properly.................................. 42 E-23 Travel alarm does not sound or does not stop sounding ................................................ 45 E-24 Horn does not sound or does not stop............................................................................ 46 E-25 Windshield wiper and window washer do not operate .................................................... 48 E-26 BOOM DOWN indicator is not displayed properly with monitoring function ................... 50 E-27 ARM DUMP indicator is not displayed properly with monitoring function ....................... 50 E-28 ARM IN indicator is not displayed properly with monitoring function .............................. 50 E-29 BOOM RAISE indicator is not displayed properly with monitoring function .................... 51 E-30 BUCKET CURL indicator is not displayed properly with monitoring function ................. 51 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function................. 51 E-32 SWING indicator is not displayed properly with monitoring function............................... 52 E-33 TRAVEL indicator is not displayed properly with monitoring function ............................. 52 E-34 ATTACHMENT indicator is not displayed properly with monitoring function................... 53 E-35 Attachment hydraulic circuit cannot be changed ............................................................ 55 E-36 KOMTRAX system does not operate properly................................................................ 56 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06139-00 System diagram of hydraulic and mechanical system............................................................. 4 Failure mode and cause table ................................................................................................. 6 Information in troubleshooting table ........................................................................................ 8 H-1 Speed or power of whole work equipment, swing, and travel is low................................. 9 H-2 Engine speed lowers significantly or engine stalls............................................................ 11 H-3 Work equipment, swing, and travel systems do not work ................................................. 12 H-4 Unusual noise comes out from around hydraulic pump.................................................... 13 H-5 Fine control performance or response is low.................................................................... 14 H-6 Speed or power of boom is low......................................................................................... 15 H-7 Speed or power of arm is low ........................................................................................... 16 H-8 Speed or power of bucket is low ....................................................................................... 17 H-9 Work equipment does not move in its single operation .................................................... 18 H-10 Hydraulic drift of work equipment is large ....................................................................... 19 H-11 Time lag of work equipment is large ............................................................................... 21 H-12 Other work equipment moves when one of work equipment is relieved......................... 22 H-13 One-touch power maximizing function does not work .................................................... 23
PC200, 200LC, 220, 220LC-8M0
00-100
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SEN06111-00
100 Index Table of contents
H-14 In combined operation of work equipment, equipment having heavier load moves slower........................................................... 24 H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................ 25 H-16 Travel speed drops largely in combined operation of swing and travel .......................... 26 H-17 Machine does not travel straight ..................................................................................... 27 H-18 Travel speed is low ......................................................................................................... 28 H-19 Machine is hard to steer or travel power is low............................................................... 29 H-20 Travel speed does not change or travel speed is low/high ............................................. 30 H-21 One of tracks does not run.............................................................................................. 31 H-22 Upper structure does not swing ...................................................................................... 32 H-23 Swing acceleration is poor or swing speed is low........................................................... 34 H-24 Upper structure overruns remarkably when it stops swinging ........................................ 36 H-25 Shock is large when upper structure stops swinging ...................................................... 37 H-26 Large sound is made when upper structure stops swinging ........................................... 38 H-27 Hydraulic drift of swing is large ....................................................................................... 39 H-28 Attachment circuit cannot be changed............................................................................ 40 H-29 Oil flow in attachment circuit cannot be controlled.......................................................... 41 600 Troubleshooting of engine (S-mode) SEN06140-00 Method of using troubleshooting chart..................................................................................... 2 S-1 Startability is poor .............................................................................................................. 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operation .......................................................................................... 11 S-5 Engine runs rough or is unstable ...................................................................................... 12 S-6 Engine lacks power ........................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15 S-9 Oil becomes contaminated early ....................................................................................... 16 S-10 Fuel consumption is excessive ....................................................................................... 17 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)....................................... 18 S-12 Oil pressure drops........................................................................................................... 19 S-13 Oil level rises (coolant or fuel in oil) ................................................................................ 20 S-14 Coolant temperature rises too high (overheating)........................................................... 21 S-15 Unusual noise is made.................................................................................................... 22 S-16 Vibration is excessive...................................................................................................... 23 50 Disassembly and assembly 100 General information on disassembly and assembly SEN06142-00 How to read this manual .......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tools list ....................................................................................................................... 7 Sketches of special tools ......................................................................................................... 12 200 Engine and cooling system SEN06143-00 Removal and installation of fuel supply pump assembly ......................................................... 2 Removal and installation of fuel injector assembly .................................................................. 6 Removal and installation of engine front oil seal ..................................................................... 13 Removal and installation of engine rear oil seal ...................................................................... 18 Removal and installation of cylinder head assembly ............................................................... 21 Removal and installation of radiator assembly ........................................................................ 36 Removal and installation of hydraulic oil cooler assembly....................................................... 38 Removal and installation of aftercooler assembly ................................................................... 40 Removal and installation of fuel cooler assembly.................................................................... 43 Removal and installation of engine and hydraulic pump assembly ......................................... 44 300 Power train SEN06144-00 Removal and installation of final drive assembly ..................................................................... 2 Disassembly and assembly of final drive assembly................................................................. 4 Removal and installation of swing motor and swing machinery assembly .............................. 22
00-100
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PC200, 200LC, 220, 220LC-8M0
100 Index Table of contents
400
500
600 700
800
SEN06111-00
Disassembly and assembly of swing motor and swing machinery assembly.......................... 24 Removal and installation of swing circle assembly.................................................................. 34 Undercarriage and frame SEN06145-00 Disassembly and assembly of carrier roller assembly............................................................. 2 Disassembly and assembly of track roller assembly ............................................................... 5 Removal and installation of idler and idler cushion assembly ................................................. 7 Disassembly and assembly of idler ......................................................................................... 8 Disassembly and assembly of idler cushion............................................................................ 11 Removal and installation of sprocket ....................................................................................... 13 Separation and connection of track shoe assembly ................................................................ 14 Removal and installation of revolving frame assembly............................................................ 18 Removal and installation of counterweight assembly .............................................................. 20 Hydraulic system SEN06146-00 Removal and installation of center swivel joint assembly ........................................................ 2 Disassembly and assembly of center swivel joint assembly ................................................... 4 Removal and installation of hydraulic tank assembly .............................................................. 5 Removal and installation of control valve assembly ................................................................ 9 Disassembly and assembly of control valve............................................................................ 14 Removal and installation of hydraulic pump assembly ............................................................ 19 Removal and installation of oil seal in hydraulic pump input shaft........................................... 23 Disassembly and assembly of work equipment PPC valve assembly..................................... 24 Disassembly and assembly of travel PPC valve ..................................................................... 26 Disassembly and assembly of work equipment cylinder ......................................................... 28 Work equipment SEN06147-00 Removal and installation of work equipment assembly ........................................................... 2 Cab and its attachments SEN06148-00 Removal and installation of operator's cab assembly.............................................................. 2 Removal and installation of operator cab glass (stuck glass).................................................. 5 Removal and installation of front window assembly ................................................................ 15 Removal and installation of floor frame assembly ................................................................... 22 Removal and installation of air conditioner unit assembly ....................................................... 26 Electrical system SEN06149-00 Removal and installation of machine monitor assembly.......................................................... 2 Removal and installation of engine controller assembly.......................................................... 4 Removal and installation of pump controller assembly ........................................................... 6 Removal and installation of KOMTRAX terminal assembly..................................................... 8
80 Appendix 100 Air conditioner SEN06151-00 Precautions for refrigerant........................................................................................................... 3 Air conditioner component .......................................................................................................... 4 Configuration and function of refrigeration cycle......................................................................... 6 Outline of refrigeration cycle ....................................................................................................... 7 Air conditioner unit ...................................................................................................................... 9 Air conditioner controller ............................................................................................................. 15 Compressor................................................................................................................................. 16 Condenser and Modulator........................................................................................................... 17 Sensor......................................................................................................................................... 18 Procedure for testing and troubleshooting .................................................................................. 20 Circuit diagram and arrangement of connector pins ................................................................... 22 System diagram .......................................................................................................................... 24 Parts and connectors layout........................................................................................................ 26 Testing air leakage (duct) ............................................................................................................ 29 Testing with self-diagnosis function............................................................................................. 31 Testing vent (mode) changeover................................................................................................. 33 Testing FRESH/RECIRC air changeover .................................................................................... 34 Testing sunlight sensor................................................................................................................ 35 PC200, 200LC, 220, 220LC-8M0
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SEN06111-00
100 Index Table of contents
Testing (dual) pressure switch for refrigerant .............................................................................. Testing relays .............................................................................................................................. Troubleshooting chart 1............................................................................................................... Troubleshooting chart 2............................................................................................................... Information in troubleshooting table ............................................................................................ Failure code list related to air conditioner.................................................................................... Failure code [879AKA] A/C Inner sensor Open Circuit ............................................................... Failure code [879AKB] A/C Inner sensor Short Circuit................................................................ Failure code [879BKA] A/C Outer sensor Open Circuit............................................................... Failure code [879BKB] A/C Outer sensor Short Circuit............................................................... Failure code [879CKA] Ventilating sensor Open Circuit.............................................................. Failure code [879CKB] Ventilating sensor Short Circuit .............................................................. Failure code [879DKZ] Sunlight sensor Open or Short Circuit.................................................... Failure code [879EMC] Ventilating Damper Abnormality ............................................................ Failure code [879FMC] Air Mix Damper Abnormality .................................................................. Failure code [879GKX] Refrigerant Abnormality ......................................................................... Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) ............................................................................................... Troubleshooting for compressor and refrigerant system (Air is not cooled) ................................ Troubleshooting for blower motor system (No air comes out or air flow is abnormal)................. Troubleshooting for FRESH/RECIRC air changeover................................................................. Troubleshooting with gauge pressure ......................................................................................... Connection of service tool ........................................................................................................... Precautions for disconnecting and connecting air conditioner piping.......................................... Handling of compressor oil.......................................................................................................... Desiccant replacement procedure...............................................................................................
36 37 38 40 42 43 44 45 46 48 50 51 52 54 55 56 58 60 63 65 67 69 71 73 75
90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN06153-00 Symbols in hydraulic circuit diagram ........................................................................................... 2 Hydraulic circuit diagram ............................................................................................................. 5 200 Electrical diagrams and drawings SEN06154-00 Symbols in electric circuit diagram .............................................................................................. 2 Electrical circuit diagram ............................................................................................................. 5
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100 Index Table of contents
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SEN06111-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06111-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
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SEN06112-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
00 Index and foreword
1
200 Foreword and general information Foreword, safety and general information ...................................................................................................... 2 How to read the shop manual ......................................................................................................................... 9 Explanation of terms for maintenance standard ............................................................................................11 Handling equipment of fuel system devices.................................................................................................. 13 Handling of intake system parts .................................................................................................................... 14 Handling of hydraulic equipment................................................................................................................... 15 Method of disconnecting and connecting of push-pull type coupler ............................................................. 17 Handling of electrical equipment................................................................................................................... 20 How to read electric wire code...................................................................................................................... 29 Precautions when performing operation ....................................................................................................... 32 Practical use of KOMTRAX........................................................................................................................... 35 Standard tightening torque table ................................................................................................................... 36 List of abbreviation........................................................................................................................................ 40 Conversion table ........................................................................................................................................... 45
PC200, 200LC, 220, 220LC-8M0
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200 Foreword and general information Foreword, safety and general information
SEN06112-00
Foreword, safety and general information
1
Important safety notice q Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. q The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. General precautions k Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. q Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. q Locate a place in the repair workshop to keep the 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, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. q When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. q When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator's compartment. q Only qualified workers must perform the work and operation which require license or qualification. q Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
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q
q q
If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place. Safety points 1 Good arrangement 2 Correct work clothes 3 Observance of work standard 4 Practice of making and checking signals 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
Preparation q Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving. q Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.
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200 Foreword and general information Foreword, safety and general information
q
q
When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work. Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing.
Precautions during work q For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to the OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first. q Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out. q When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit. q Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently. q Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, engine speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment. q The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
PC200, 200LC, 220, 220LC-8M0
SEN06112-00
q
q
q
q
q
q
q
q
q q
q
When removing the part which is under internal pressure or reaction force of the spring, always leave two bolts in diagonal positions. Loosen those two bolts gradually and alternately and release the pressure, then, remove the part. When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires. When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular. Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated. When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct. When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly. When aligning two holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole. When measuring hydraulic pressure, check that the measuring tools are correctly installed. Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track. If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well.
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200 Foreword and general information Foreword, safety and general information
SEN06112-00
Precautions for slinging work and making signals q Only one appointed worker must make signals and co-worker must communicate with each other frequently. The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. 1. Do not stand under the load. 2. Do not step on the load. q Check the slings before starting sling work. q Keep putting on the gloves during sling work. (Put on the leather gloves, if available.) q Measure the weight of the load by the eye and check its center of gravity. q Use the proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. q Do not sling a load with one wire rope only. If do so, the load may rotate or the sling gets loose and the sling may slip off. Install two or more wire ropes symmetrically. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident. q Hanging angle must be 60 degrees or smaller as a rule. q When hanging a heavy load (25kg or heavier), the hanging angle of the rope must be narrower than that of the hook. a When slinging a load with two ropes or more, the larger the hanging angle is, the larger the tension of each rope. The figure bellow shows the variation of allowable load in kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000kg} a load vertically, at various hanging angles. When the two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1000 kg} when the two ropes make a hanging angle of 120 degrees. If the two ropes sling a 19.6 kN {2000 kg} load at a hanging angle of 150 degrees, each rope is subjected to a force as large as 39.2 kN {4000 kg}.
q
q q
q q
q
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4
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc. Apply wire ropes to the middle portion of the hook. a Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle part.
Do not use twisted or kinked wire ropes. When slinging up a load, observe the following. 1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught. 2. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. 3. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. 4. Do not lift up the load at an angle. When lowering a load, pay attention to the following.
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Foreword, safety and general information
1.
2. 3.
When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. Check that the load is stable, and then remove the sling. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane k The hoist or crane must be used to sling the components weighing 25 kg or heavier. A part weighing 25 kg or heavier in “disassembly and assembly” section is indicated with the symbol of 4. q
q q q
q q q q q q q q
q
q
Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collis ion pr eve ntio n de vi ce, and ener gi zi ng warning lamp, and check the following safety items. Observe the signals for sling work. Operate the hoist at a safe place. Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button. Do not sling a load at an angle. Do not move the crane while the slung load is swinging. Do not raise or lower a load while the crane is moving longitudinally or laterally. Do not drag a sling. When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. Consider the travel route in advance and lift up a load to a safe height. Place the control switch in a position where it will not be an obstacle to work and passage. After operating the hoist, do not swing the control switch. Remember the position of the main switch so that you can turn off the power immediately in an emergency. Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupter for electric shock prevention, check that the devices related to that switch are not in operating condition. If you find an obstacle around the hoist, stop the operation.
PC200, 200LC, 220, 220LC-8M0
SEN06112-00
q
After finishing the work, stop the hoist at the specified position and raise the hook to at least two meters above the floor. Do not leave the sling attached to the hook.
Selecting wire ropes q Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below Wire ropes (standard “Z” twist ropes without galvanizing) (JIS G3525, Type 6x37-A) Nominal diameter of rope mm 10 12 14 16 18 20 25 30 40 50 60
a
Allowable load kN 8.8 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6 221.6 318.3
ton 0.9 1.3 1.7 2.3 2.9 3.6 5.6 8.1 14.4 22.6 32.4
The allowable load is calculated as one sixth of the breaking load of the rope to be used (safety coefficient: 6).
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit Disconnection k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working cloth with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
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200 Foreword and general information Foreword, safety and general information
SEN06112-00
q
When loosening the nuts fixing air conditioner hoses and tubes, be sure to use two wrenches; use one wrench to fix and use the other one to loosen the nut.
Connection q When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and water into the hose. q Check that the O-rings are fitted to the joints when connecting the air conditioner piping. q Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. q When removing the O-rings, use a soft tool so that the piping is not damaged. q Check that the O-ring is not damaged or deteriorated. q Apply compressor oil for refrigerant (R134a) to the O-ring. a However, do not apply oil to the threaded portion of a bolt, nut or union. Manufacturer DENSO VALEO THERMAL SYSTEMS SANDEN q
a
For tightening torques, see “Others”, “Precautions for disconnection and connection of air conditioner piping”.
Part name
ND-OIL8 ZXL100PG (equivalent to PAG46) SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use two wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). Example of fitting of O-ring q An O-ring is fitted to every joint of the air conditioner piping.
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200 Foreword and general information Foreword, safety and general information
SEN06112-00
Fire prevention Action if fire occurs q Turn the starting switch to the OFF position to shutdown the engine. q Use the handrails and steps to get off the machine. q Do not jump off the machine. You may fall or suffer serious injury. q The fume generated by a fire contains harmful materials which have a bad influence on a human body when they are sucked. Don't breathe a fume. q After a fire, there may be harmful compounds left. If it touches your skin it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton-work-gloves, wear rubber gloves under them. Prevent fire q Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid.There is danger that they may catch fire. Always observe the following. q Do not smoke or use any flame near fuel or other flammable substances. q Shut down the engine before adding fuel. q Do not leave the machine when adding fuel or oil. q Tighten all the fuel and oil caps securely. q Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. q After adding fuel or oil, wipe up any spilled fuel or oil. q Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace. q When washing parts with oil, use a nonflammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire. q Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. q Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
PC200, 200LC, 220, 220LC-8M0
q
When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
q
Fire caused by accumulation or attachment of flammable material q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers. q To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
q
Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. q Keep all the electric wiring connections clean and securely tightened. q Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
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q
Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
q
Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. The exhaust gas discharged during the purification process (regeneration) can be higher temperature than that of existing models. Do not bring any flammable material close to the outlet of the exhaust pipe. q If there are thatched houses, dry leaves or pieces of paper around the job site, set the system to the “Regeneration Disable” before starting operation to prevent fire hazard of highly heated exhaust gas caused by KDPF regeneration. See the operation and maintenance manual for the setting procedure.
q
Explosion caused by lighting equipment q When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. q When taking the electrical power for the lighting equipment from the machine itself, follow the instructions in the operation and maintenance manual.
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200 Foreword and general information Foreword, safety and general information
Dispose of waste materials To prevent pollution, pay full attention to the way to dispose of waste materials. q Always put the oil and coolant drained from the machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. q Observe the related laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce poisonous gas harmful to human body when they are burned. q As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations.
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information How to read the shop manual
SEN06112-00
How to read the shop manual q q q
1
Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. Materials and specifications are subject to change without notice. The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual q This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use. 00. Index and foreword This section includes the index, foreword, safety and basic information.
q
01. Specification This section explains the specifications of the machine.
q
10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
q
20. Standard value table The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
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30. Testing and adjusting This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
q
40. Troubleshooting This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
q
50. Disassembly and assembly This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
q
80. Appendix The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
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90. Diagrams and drawings This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work. Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
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200 Foreword and general information How to read the shop manual
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q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically. Symbol
Item
k
Safety
a
Caution
The special technical precautions or other precautions for preserving standards required when performing work are described.
4
Weight
3
The weight of part or component and the cautions required when selecting hoisting wire or when working posture is important are described.
Tightening torque
The tightening torques that require special attention during assembly work are described.
Coat
The places to be coated with adhesives, etc. during assembling are indicated.
2 5
Oil, coolant
6
Drain
Remarks The special safety precautions required for performing work are described.
The places to which oil is supplied and the quantity of the oil are indicated. The places from which oil is drained and quantity of the oil are indicated.
Unit q q
In this shop manual, the units are indicated with International System of units (SI). For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
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200 Foreword and general information Explanation of terms for maintenance standard
SEN06112-00
Explanation of terms for maintenance standard q
The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance q To be accurate, the finished dimension of a part is slightly different from one to another. q To specify the finished dimension of a part, a certain dimension is set for the part and an allowable difference from that dimension is indicated. q The above dimension set is called the “standard dimension” and the range of difference from the standard dimension is called the “tolerance”. q The standard dimension and tolerance are indicated by attaching the symbols of + or and a number on the right side of the standard dimension. Example: Standard dimension
q
q
The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/lower limit of tolerance).” Example: 120(-0.022/-0.126) Usually, the dimension of a hole and the dimension of a shaft to be inserted into the hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of dimension of rotating shaft and hole and their related drawing. Example: Standard dimension 60
q
When some parts are repaired, the value of performance/function is set to the standard value.
Tolerance –0.022 –0.126
120 q
1
Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
Standard clearance and standard value q The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q The values indicating performance and function of new products or equivalent are called the “standard value”, which is indicated by a range or a target value. PC200, 200LC, 220, 220LC-8M0
Standard interference When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the “interference”. q Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is the “standard interference”. q After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range. q
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SEN06112-00
200 Foreword and general information Explanation of terms for maintenance standard
Repair limit and allowable value or allowable dimension q The dimensions of parts change because of the wear or deformation while they are used. When the dimension changes exceeding certain value, the parts can not be used any longer. This value is called “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of the products lower while they are used. When the value of the performance and function lowers exceeding a certain limit and it influences the operation etc., this value is called the allowable value or allowable dimension. q A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgement must be made in consideration of the operating condition and customer’s requirement. Allowable clearance q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “allowable clearance”. q If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired. Allowable interference The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “allowable interference”. q The allowable interference shows the repair limit of the part of smaller tolerance. q The parts whose interferences are out of the allowable interference must be replaced or repaired. q
00-200
12
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling equipment of fuel system devices
SEN06112-00
Handling equipment of fuel system devices q
1
The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Use care for working environment q Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust. Sealing openings Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.
q
How to clean parts when dirt is stuck . q If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. q The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter element other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter element. q
PC200, 200LC, 220, 220LC-8M0
00-200
13
SEN06112-00
Handling of intake system parts q
200 Foreword and general information Handling of intake system parts
1
The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.
Be careful of working environment q Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust. Sealing openings Plug the pipes and the openings of the components which are removed, with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left open or plugged with rag since foreign material may enter.
q
00-200
14
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling of hydraulic equipment
SEN06112-00
Handling of hydraulic equipment q
1
With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or wh en di s as s em bl in g or a s se mb li ng th e hydraulic components.
Be careful of working environment q Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust. Disassembly and maintenance work in the field When disassembly or maintenance work of the hydraulic is performed in the field, there is danger of dust entering the components. It is also difficult to check the performance of the components after repairs, so it is desirable to use the component exchange service. The disassembly and assembly of the hydraulic components must be performed in the specially arranged dustproof workshop and the performance test of the components must be performed with the special testing equipment.
Preventing intrusion of foreign materials during refilling operations. q Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible to remove the dirt that is collected during storage. It is a surer means.
Sealing openings Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never leave the openings of the pipes and hoses without being covered or plugged with cloth as foreign material may enter them or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.
Replacing hydraulic oil while its temperature is high q When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil.
q
q
PC200, 200LC, 220, 220LC-8M0
00-200
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SEN06112-00
200 Foreword and general information Handling of hydraulic equipment
Flushing operations q After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them. Normally, flushing is performed twice. Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil.
Cleaning operations q After repairing the hydraulic equipment (pump, control valve, etc.) or when the machine is in operation, perform oil cleaning to remove the sludge or contaminant in the hydraulic oil circuit. The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device.
00-200
16
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Method of disconnecting and connecting of push-pull type
SEN06112-00
Method of disconnecting and connecting of push-pull type coupler k k
1
Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 Disconnection 1. Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a It can be pushed in by approximately 3.5mm. a Do not hold rubber cap portion (4). 2. While pushing hose joint (2) into adapter (3), push rubber cap (4) against adapter (3) until “click” is heard. (Fig. 2) 3. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.
PC200, 200LC, 220, 220LC-8M0
Connection 1. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3) aligning them with each other. (Fig. 4) a Do not hold rubber cap part (4). 2. After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition. (Fig.4) a When the hose fitting is pulled back, the rubber cap will move toward the hose, however, it is not a problem.
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SEN06112-00
200 Foreword and general information Method of disconnecting and connecting of push-pull type
Type 2 Disconnection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side. (Fig. 6) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8)
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18
Connection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side to connect it. (Fig. 9)
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Method of disconnecting and connecting of push-pull type
SEN06112-00
Type 3 Disconnection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male side. (Fig. 10) 2. While keeping the condition of Step 1, push cover (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 11) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12)
PC200, 200LC, 220, 220LC-8M0
Connection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (a) at the hexagonal portion on the male side to connect them. (Fig. 13)
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200 Foreword and general information Handling of electrical equipment
SEN06112-00
Handling of electrical equipment q
1
To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.
Precautions for handling electric equipment Handling wiring harnesses and connectors q Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. q Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling the wiring harnesses.
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female connectors) q Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or bec aus e on e or bo th of con necto rs ar e deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately ten times.
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20
Defective crimping or soldering of connectors q The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joining area may become loose, which may result in a defective connection or breakage.
Disconnections in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, the crimping of the connector may separate, or the soldering may be damaged, or the wiring harness may be broken.
q
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling of electrical equipment
High-pressure water entering connector q The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to spray water over the connector. The connector is designed to prevent water from entering, but once water does enter, it is difficult to drain it. If water should get into the connector, the pins will be short-circuited by the water. So if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
Entry of water, mud or dirt when disconnecting a connector q If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air.
PC200, 200LC, 220, 220LC-8M0
SEN06112-00
Oil, mud or dirt stuck to connector q If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the oil and water from the compressed air completely before cleaning the connector with the compressed air.
Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors 1. Hold the connectors when disconnecting. q Disconnect connectors by holding the connector bodies. For the connectors held by a screw, loosen the screw fully, then hold the male and female connectors with each hand respectively and pull them apart horizontally. For the connectors with lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull the connector with one hand.
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200 Foreword and general information Handling of electrical equipment
SEN06112-00 a
2.
If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is connected.
q
q
3.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the right and left, the housing may break.
Action to take after removing connectors q After removing the connector, cover it with the vinyl bag to prevent entry of dust, dirt,oil or water in the contact portion.
00-200
22
Connecting connectors 1. Check the connector visually. q Check that there is no oil, dirt or water stick to the connector pins (joint portion). q Check that the connector pins are free from deformation, defective contact, corrosion, or damage. q Check that external surfaces of the connectors are free from damage or breakage. a If any oil, water or dirt is stuck to the connector, wipe it off with a dry cloth. If any water is inside the connector, warm the connector and the inside of the wiring harness with a dryer. But be careful not to make it too hot as it causes short circuit. a If there is any damage or breakage, replace the connector. 2. Fix the connector securely. q Align the connectors correctly, and fit them securely. For the connectors with the lock stopper, push in the connectors until “click” is heard.
3.
Correct the protrusion of the boot and misalignment of the wiring harness PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling of electrical equipment
q
For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the position, put it in its original position. a If the connector cannot be corrected easily, remove the clamp and adjust the position.
q
If the connector clamp is removed, be sure to return it to its original position. And check that it is securely installed.
Deutsch connector (DT8-pin, DT12-pin) Disconnection 1. While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
PC200, 200LC, 220, 220LC-8M0
SEN06112-00
Connection 1. Push in female connector (2) horizontally until the lock clicks. (Arrow: x) 2. Since locks (a) and (b) may not be set completely, push in female connector (2) with curving movement until the locks are set normally. (Arrow: x, y, and z) a Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
Drying wiring harness q If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing by using steam. If the wire harness must be washed in water, do not apply high pressure water or steam directly to the wiring harness. If water gets directly on the connector, do as follows. 1. Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown with dry compressed air, there is a risk that oil in the air may cause defective contact of the conditioner, remove oil and water in the air before starting air blow.
00-200
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SEN06112-00
2.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time to use hot air in order to prevent the connector or related parts from becoming too hot, as it causes deformation or damage to the connector.
3.
Perform a continuity test on the connector.After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them.
200 Foreword and general information Handling of electrical equipment
Handling of connectors used on engine Slide lock type (Type 1) (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right. 2. While pressing lock (L2), pull out connector (1) toward you. a In the case that even if lock (L2) is pressed, connector (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
Connection 1. Insert the connector securely until a click is heard. Slide lock type (Type 2) (FRAMATOME-24) Disconnection 1. Slide down lock (red) (L1).
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24
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling of electrical equipment
2.
While pressing lock (L2), pull out connector (1).
SEN06112-00
Connection 1. Insert the connector securely until a click is heard. Push lock type (1) (BOSCH-3) Disconnection 1. While pressing lock (C), pull out connector (3) in the direction of the arrow. q 114 series
a
Lock (L2) is located in the back of connector (1).
q
107 series
a
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Connection 1. Insert the connector securely until a click is heard. Pull lock type (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
PC200, 200LC, 220, 220LC-8M0
00-200
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SEN06112-00
Connection 1. Insert the connector securely until a click is heard.
200 Foreword and general information Handling of electrical equipment
Example) Injection pressure control valve of supply pump: PCV (SUMITOMO-2)
Push lock type (2) (SUMITOMO-4) Disconnection 1. While pressing lock (C), pull out connector (4) in the direction of the arrow. Connection 1. Insert the connector securely until a click is heard.
Example) Speed sensor of supply pump: G (SUMITOMO-3) a Pull the connector straight up.
Push lock type (3) (AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc (AMP-3)
Connection 1. Insert the connector securely until a click is heard.
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PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Handling of electrical equipment
Turn-housing type (Round green connector) (CANNON-4) Disconnection 1. Turn housing (H1) in the direction of the arrow. a Unlock the connector by turning housing (H1). When the lock is release the housing is felt tight to turn. 2. Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
SEN06112-00
Handling controller q The electronic circuits for control including the microcomputers are assembled in the controller. These electronic circuits in the controller must be handled with care as they control the machine. q Do not place objects on top of the controller.
q q q
Connection 1. Insert the connector to the end while aligning its grove to the other. 2. Turn housing (H1) in the direction of the arrow until it “clicks”.
q
PC200, 200LC, 220, 220LC-8M0
Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts. During rainy weather, do not leave the controller in a place where it is exposed to rain. Do not place the controller on oil, water, or soil, or in a place that can be heated to a high temperature even for a short period of time. (Place it on a suitable dry stand.)
Precautions when performing arc welding When performing arc welding on the machine body, disconnect all the wiring harness connectors connected to the controller. Put the arc welding ground to the place close to the welding point.
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SEN06112-00
200 Foreword and general information Handling of electrical equipment
Precautions for troubleshooting electrical circuits q Be sure to turn the starting switch to the “OFF” position before disconnecting or connecting the connectors. q Before performing troubleshooting, check all the related connectors for loose connection. a Check the related connectors for their performance by disconnecting and connecting them several times. q Be sure to connect all the disconnected connectors before proceeding to the next step. a If the starting switch is turned to the “ON” position with the connectors disconnected, the failure which is not related to the part which is actually failed. q When performing the troubleshooting for the c i rc u i t (m e as ur e me nt of v ol ta ge , r es i s tance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. a If there is any value change on the multimeter, there may be a defective contact in the circuit.
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PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information How to read electric wire code
SEN06112-00
How to read electric wire code
1
In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
q
AEX
0.85 L
Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.) Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates color of wire by color code. Color codes are shown in Table 3.
Type, symbol, and material AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating.
q
(Table 1) Type
Symbol
Conductor Material
Low-voltage wire for AV automobile Thin-cover low-voltage AVS wire for Soft polyvinyl chloride automobile Annealed (Type 1) copper for elecThin-cover tric applilow-voltage ance wire for CAVS automobile Type 2 Heat-resistant low-voltHeat-resistant crosslinked AEX age wire for polyethylene automobile
PC200, 200LC, 220, 220LC-8M0
Temperature range (°C) in use
Example of use For large current wiring (nominal No. 5 and above)
–30 to +60
General wiring (nominal No. 3 and lower)
For mid- to small-size excavators (nominal No. 1.25 and lower)
–50 to +110
(Safety factor: Wiring at high-temperature place
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200 Foreword and general information How to read electric wire code
SEN06112-00
Dimension (Table 2)
Coating D
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Crosssectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – AV Standard – – – – – – – 4.6 AEX
Standard
Coating D
Nominal No. Number of strands/Diameter of strand Conductor Crosssectional area (mm2) d (approx.) AVS Standard AV Standard AEX
Standard
Coating D
Nominal No. Number of strands/Diameter of strand CrossConductor sectional area (mm2) d (approx.)
a
CAVS
Standard
2.0
2.2
2.7
3.0
3.1
50
–
60
3.8
85
4.6
8
15
20
30
40
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5
4.8 – 7.0
6.0 – 8.2
8.0 – 10.8
8.6 – 11.4
9.8 – 13.0
10.4 – 13.6
12.0 – 16.0
13.6 – 17.6
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
108/0.80 127/0.80 169/0.80 217/0.80
0.5f
0.5
0.75f
0.85
1.25f
1.25
–
7/round compression
–
11/round compression
–
16/round compression
–
0.56
–
0.88
–
1.29
–
0.9
–
1.1
–
1.4
–
1.6
–
1.8
–
2.1
“f” of nominal No. denotes flexible”.
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PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information How to read electric wire code
SEN06112-00
Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR a
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of two colors, the first color is the color of the background and the second color is the color of the marking. Examples) GW means that the background is “Green” and marking is “White”.
Types of circuits and color codes Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Appendix
AVS, AV, CAVS R B R RW Y G L Br Lg O Gr P Sb Dg Ch
PC200, 200LC, 220, 220LC-8M0
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
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200 Foreword and general information Precautions when performing operation
SEN06112-00
Precautions when performing operation q
1
When performing “removal or installation” and “disassembly or assembly” of the components, observe the following general cautions.
Precautions for removal work q If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the sewage rashly. q After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering. q When draining oil, prepare a container with sufficient capacity. q Check the match marks which indicate the installing position, and put match marks on the places where they seem necessary before removal of the components to prevent any mistake when assembling. q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. q Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing. q Check the number and thickness of the shims, and keep them in a safe place. q When hoisting the components, prepare the slings with sufficient strength. q When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately. q Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal. a Precautions when handling piping during disassembly Use the plugs indicated below for the pipes disconnected at the disassembly. Face seal type hoses and tubes Nominal No. 02 03 04 05 06
Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628
Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628
Split flange type hoses and tubes Nominal No. 04 05
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Flange (hose end) 07379-00400 07379-00500
Sleeve head (tube end) 07378-10400 07378-10500
Split flange 07371-30400 07371-30500
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200 Foreword and general information Precautions when performing operation
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If the part is not under hydraulic pressure, the following corks can be used. Nominal No.
Part Number
06 08 10 12 14 16 18 20 22 24 27
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734
D 6 8 10 12 14 16 18 20 22 24 27
Dimensions d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5
L 8 11 12 15 18 20 22 25 28 30 34
Precautions for installation work q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES). q Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are. q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts. q Bend the cotter pins and lock plates securely. q When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the threaded portion. q When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage. q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them. q Coat the rotating parts and sliding parts with engine oil. q Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P). q After installing the snap ring, check that the snap ring is settled in the ring groove completely. q When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then connect them securely. q Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook. q When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side. a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure. 1. Start and run the engine at low idle. 2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm before the stroke end four to five times. PC200, 200LC, 220, 220LC-8M0
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a
3. Operate the hydraulic cylinder three to four times to the end of its stroke. After the completion of repair and when operating the machine which is stored long term, perform the air bleeding with the same procedure as the one described above.
Precautions at the time of completing work Refilling of coolant, oil and grease q When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again. q When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again. q If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to “Testing and adjusting”. q Supply the specified amount of grease to the work equipment parts. Check of installed condition of cylinder heads and manifolds q Check the cylinder head and intake and exhaust manifold mountings for looseness. q If any bolt is loose, retighten it. a For the tightening torques, see the “Disassembly and assembly”. Check of engine piping for damage and looseness Intake and exhaust system Cooling system
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosely installed or damaged, retighten the bolts or repair the part. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage. If any part is loosely installed or damaged, retighten the bolts or repair the part. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. q Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts for looseness. If any part is loosely installed, retighten the bolts. q
Check of KDPF or muffler function q Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.If any unusual noise is heard, repair KDPF or muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
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Practical use of KOMTRAX
1
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX operator can refer this information in the office and provide various services to the customers. When KOMTRAX is installed on the machine, the machine information can be checked through the KOMTRAX system and the testing and troubleshooting can be performed efficiently. (KOMTRAX may not be installed on the machine in some countries or areas.) Merit of using KOMTRAX q The working place of the machine can be checked in the map on PC. q Operation information such as service meter reading, operating hours, fuel consumption, occurred caution and failure code can be checked. q The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil can be checked. q The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.) can be checked and the machine operating condition can be presumed with these information. q Various reports such as “Fuel saving operation support”, “Summary of operation”, etc. can be generated and utilized as an advice tool for the user and operator. How to use KOMTRAX practically With KOMTRAX, following support activities will be available. 1. Quick response to sudden request of repair 1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through KOMTRAX. 2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there. 2. Proactive maintenance 1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure code indicated by a red or yellow flag. 2) Check the condition of the machine with the customer and make a plan to visit. 3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3. Practice of periodic maintenance and periodic inspection service 1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for the consumable parts indicated by red flags are over. 2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer. 3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see “KOMTRAX basic operation manual”.
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Standard tightening torque table
1
Table of tightening torque for bolts and nuts Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below. 1. The following table applies to the bolts in Fig. A. Thread diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats (mm) 10 (10) 13 (12) 17 (14) 19 (17) 22 24 27 30 32 36 41 46 50 55 60
Tightening torque (Nm) 11.8 to 14.7 27 to 34 59 to 74 98 to 123 157 to 196 245 to 309 343 to 427 490 to 608 662 to 829 824 to 1,030 1,180 to 1,470 1,520 to 1,910 1,960 to 2,450 2,450 to 3,040 2,890 to 3,630
(kgm) 1.2 to 1.5 2.8 to 3.5 6.0 to 7.5 10.0 to 12.5 16 to 20 25 to 31.5 35 to 43.5 50 to 62 67.5 to 84.5 84 to 105 120 to 150 155 to 195 200 to 250 250 to 310 295 to 370
a 2.
Values with ( ) in the “Width across flats” column are for (*) marked bolt (flange bolt) shown in Fig. A. The following table applies to the bolts in Fig. B.
Thread diameter (mm) 6 8 10 12 Fig. A
a
Width across flats (mm) 10 12 14 17
Tightening torque (Nm) 5.9 to 9.8 13.7 to 23.5 34.3 to 46.1 74.5 to 90.2
(kgm) 0.6 to 1.0 1.4 to 2.4 3.5 to 4.7 7.6 to 9.2
Fig. B
Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
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Table of tightening torque for split flanged bolts a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below. Thread diameter (mm) 10 12 16
Width across flats (mm) 14 17 22
Tightening torque (Nm) 59 to 74 98 to 123 235 to 285
(kgm) 6.0 to 7.5 10.0 to 12.5 23.5 to 29.5
Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below. Nominal No. 02 – 03,04 05,06 10,12 14
Thread diameter (mm) 14 18 20 24 33 42
Width across flats mm
Tightening torque (Nm {kgm}) Range Target 35 to 63 {3.5 to 6.5} 44 {4.5} 59 to 98 {6.0 to10.0} 78 {8.0} Varies depending 84 to 132 {8.5 to13.5} 103 {10.5} on type of connec128 to 186 {13.0 to19.0} 157 {16.0} tor. 363 to 480 {37.0 to 49.0} 422 {43.0} 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter Width across flats (mm) mm 8 14 10 17 12 19 14 22 16 24 18 27 20 30 24 32 30 32 33 – 36 36 42 – 52 –
PC200, 200LC, 220, 220LC-8M0
Tightening torque (Nm {kgm}) Range Target 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75} 9.81 to 12.74 {1.0 to 1.3} 11.27 {1.15} 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8} 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3} 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0} 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0} 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0} 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0} 93.1 to 122.5 { 9.5 to 12.5} 107.8 {11.0} 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0} 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5} 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5} 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
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Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table. a The table is applied to the threads coated with engine oil (wet threads) Nominal No. of hose
Width across flats (mm)
02
19 22 24 27 32 36 41 46 55
03 04 05 06 (10) (12) (14)
Tightening torque (Nm {kgm})
Taper seal
Range
Target
Thread size (mm)
34 to 54 { 3.5 to 5.5} 34 to 63 { 3.5 to 6.5} 54 to 93 { 5.5 to 9.5} 59 to 98 { 6.0 to 10.0} 84 to 132 { 8.5 to 13.5} 128 to 186 {13.0 to 19.0} 177 to 245 {18.0 to 25.0} 177 to 245 {18.0 to 25.0} 197 to 294 {20.0 to 30.0} 246 to 343 {25.0 to 35.0}
44 { 4.5} 44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
– 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread root threads per diameter inch, type of (reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torque for face seal joints a The tightening torque table below applies to the seal joint (sleeve nut type) a The table is applied to the threads coated with engine oil (wet threads). Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 {16} 22 {20}
19 22 24 {27} 30 {32} 36
Tightening torque (Nm {kgm}) Range
Target
14 to 16 {1.4 to 1.6} 24 to 27 {2.4 to 2.7} 43 to 47 {4.4 to 4.8} 60 to 68 {6.1 to 6.8} 90 to 95 {9.2 to 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread root Nominal No. – diameter threads per inch, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
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Tightening torque table for bolts and nuts on 102, 107 and 114 series engines a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table. Thread diameter (mm) 6 8 10 12 14
Tightening torque (Nm) 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
(kgm) 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
Tightening torque table for I-joints on 102, 107 and 114 series engines a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the torque shown in the following table. Thread size (mm) 6 8 10 12 14
Tightening torque (Nm) 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
(kgm) 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Tightening torque table for tapered screws on 102, 107 and 114 series engines a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series engines to the torques shown in the following table. Material Thread diameter (inch) 1/16 1/8 1/4 3/8 1/2 3/4
PC200, 200LC, 220, 220LC-8M0
In cast iron or steel Tightening torque (Nm) (kgm) 15 ± 2 1.53 ± 0.20 20 ± 2 2.04 ± 0.20 25 ± 3 2.55 ± 0.31 35 ± 4 3.57 ± 0.41 55 ± 6 5.61 ± 0.61 75 ± 8 7.65 ± 0.82
In aluminum Tightening torque (Nm) (kgm) 5±1 0.51 ± 0.10 15 ± 2 1.53 ± 0.20 20 ± 2 2.04 ± 0.20 25 ± 3 2.55 ± 0.31 35 ± 4 3.57 ± 0.41 45 ± 5 4.59 ± 0.51
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200 Foreword and general information List of abbreviation
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List of abbreviation
1
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. Abbreviations that are used in general society may not be included. Special abbreviations which appear infrequently are noted in the text(marked wit a). This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
q
q q q
List of abbreviations used in the shop manual Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
Explanation
ABS
Anti-skid Brake System
Function with which when the tires skid (wheels Travel and brake (HD, stop rotating), the brakes are released, and when HM) the wheels start to rotate, the brakes are applied again.
AISS
Automatic Idling Setting System
Engine
Automatic setting function of idling speed
AJSS
Advanced Joystick Steering System
Steering (WA)
Function that a lever can perform the steering operations, shifting gear speed operation and changing direction operation instead of a steering wheel.
ARAC
Automatic Retarder Accelerator Control
Function that the retarder works automatically with Travel and brake (HD, a certain braking force when the accelerator pedal HM) is released while the machine travels downhill.
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake cooling oil control valve Controller Area Network Crankcase Depression Regulator Closed-center Load Sensing System
CAN CDR
CLSS
Common Rail Injection
CRI
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Function that the retarder works automatically with a certain braking force so that the machine travels Travel and brake (HD, with the speed not exceeding the speed set by the HM) operator when the accelerator pedal is released while the machine travels downhill. Function with which, when the rear wheels spin on Travel and brake (HD, soft ground surfaces, this function automatically HM) uses the optimum braking force to drive both wheels. A device that can be fixed onto a machine in order Work equipment to enable it to do different jobs. Valve that bypasses part of the brake cooling oil to Brake (HD) reduce the load on the hydraulic pump when the retarder is not being used. Communication and One of communication standards that is used in electronic control the network on the machine Regulator valve that is installed to the KCCV Engine ventilator It is not used independently and described CDR valve. System that can simultaneously actuate multiple Oil pressure actuators regardless of the load (provides better combined operation comparing to OLSS). Function to maintain optimum fuel injection amount and fuel injection timing by using engine Engine controller to perform electronic control of supply pump, common rail, and injector.
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200 Foreword and general information List of abbreviation
Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
ECM
Electronic Control Electronic control Module system
ECMV
Electronic Control Transmission (D, HD, Modulation Valve WA, etc.)
ECSS
Electronically Controlled Suspension System
ECU
Electronic Control Electronic control Unit system
EGR
Exhaust Gas Recirculation
EMMS
EPC
FOPS F-N-R
Equipment Management Monitoring System Electromagnetic Proportional Control Falling Object Protective Structure Forward-NeutralReverse
Travel (WA)
Engine
Machine monitor
SEN06112-00
Explanation Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators . (Same as ECU) Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of machine during travel Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators. (Same as ECM) Function to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature and to control emission of NOx. System that allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor.
Oil pressure
Electromagnetic proportional control Mechanism that actuator works in proportion to current
Cab and canopy
Structure that protects operator's head from falling objects. (Structure to protect operator) Performance standardized in ISO 3449
Operation
Forward - NEUTRAL - REVERSE
GPS
Communication Global Positioning (KOMTRAX System §KOMTRAX Plus)
Global Positioning System Satellite positioning system that is used to determine the current location on the earth Steering function that uses a combination of hydraulic motor and bevel shaft to control Steering (D) difference in travel speed of right and left tracks to turn machine without using steering clutch. Hydraulic transmission system that uses a Transmission (D, WA) combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. Valve that adjusts fuel intake amount at inlet port Engine of pump in order to control fuel discharge amount of supply pump. Same meaning as IMV Valve adjusting fuel intake amount at inlet port of Engine pump in order to control fuel discharge amount of supply pump. Described IMV (IMA) This mechanism separates oil in blowby gas and Engine returns it to the intake side to afterburn it there. It primarily consists of filters.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
IMA
Inlet Metering Actuator
IMV
Inlet Metering Valve
KCCV
Komatsu Closed Crankcase Ventilation
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Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
Komatsu Catalyzed Soot Engine Filter Komatsu Diesel Engine Oxidation Catalyst
KCSF KDOC
KDPF
Komatsu Diesel Particulate Filter
KTCS
Komatsu Traction Travel and brake (HM Control System system)
KVGT
Komatsu Variable Geometry Engine Turbocharger
LCD
Liquid Crystal Display
Machine monitor
LED
Light Emitting Diode
Electronic parts
LIN
Local Interconnect Communication and Network electronic control
LS
Load Sensing
Oil pressure
LVDS
Low Voltage Differential Signaling
Communication and electronic control
Engine
MAF
Mass Air Flow
Engine
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
Electric and hydraulic
NO
Normally Open
Electric and hydraulic
Open-center Load Oil pressure Sensing System Pressure Oil pressure Compensation
OLSS PC
PCCS
Palm command control system
PCV
Pre-stroke Control Engine Valve
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Steering (D)
Explanation This filter is used to capture soot in exhaust gas. It is built in to KDPF. The catalyst used for purifying exhaust gas. It is built in to KDPF. This component with built-in KDOC (catalyst) and KCSF purifies exhaust gas. Part building in (sootcapturing filter) It is installed in place of the currently used muffler. Function that recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road. The turbocharger on which the cross-section area of the exhaust passage is made variable. Liquid Display Image display equipment such as the monitor which assembles in the liquid crystal element. Light Emitting Diode Semi-conductor element that emits light when the voltage is applied in the normal direction. One of communication standards that is used in the network on the machine Function that detects differential pressure of pump and controls discharge amount according to load. One of communication standards that is used in the network on the machine It means the intake air flow of the engine. It is not used independently but used together with the sensor. The mass air flow sensor may be called MAF sensor. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. A function used to correct oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information List of abbreviation
Abbreviation PPC PPM PTO PTP
Full Spelling Proportional Pressure Control Piston Pump and Motor Power Take Off Power Tilt and power Pitch dozer
Purpose of use (major applicable machine (*), or equipment/device) Oil pressure Oil pressure (D, PC, etc.) Power transmission Work equipment (D)
ROPS
Roll-Over Protective Structure
Cab and canopy
SI
International unit system
Unit
SOL
Solenoid
Electric
TWV
Two Way Valve
Hydraulic and electric
SEN06112-00
Explanation Proportional pressure control Mechanism that actuator works in proportion to hydraulic pressure Piston pump and motor. Power take-off mechanism Function that performs hydraulic control of the tilt and pitch of the bulldozer blade. Structure that protects operator fastening seat belt from being crushed when machine tips over (Structure to protect operator when machine tips over) Performance standardized in ISO 3471 Abbreviation for “International system of units” Unit system that is employed worldwide, and “one unit against one factor” Actuator that moves a part with a movable iron core in the coil (solenoid), which is moved by energizing the coil. Solenoid valve that switches the direction of flow.
*1: Code for applicable machine family D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC S/T STRG SIG
Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actuator No Connection Steering Signal
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Abbreviation SOL STD OPT OP PRESS SPEC SW TEMP T/C T/M
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Actual word spelled out Solenoid Standard Option (if equipped) Pressure Specification Switch Temperature Torque Converter Transmission
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200 Foreword and general information Conversion table
SEN06112-00
Conversion table
1
Method of using the conversion table q The unit conversion table enables the simple conversion in the figures between the different units. For further details of the method of use of the conversion table, see the examples given below. Example: Method of using the conversion table to convert a unit from millimeters to inches Conversion of 55 mm into inches 1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B). 3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit from millimeters to inches. Therefore, 55 mm = 2.165 in. Conversion of 550 mm into inches 1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Then convert 55 mm to 2.165 in by the same procedure as above. 3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65 in.
Millimeters to inches
(A)
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
PC200, 200LC, 220, 220LC-8M0
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-200
45
200 Foreword and general information Conversion table
SEN06112-00
Millimeters to inches
0 10 20 30 40 50 60 70 80 90
0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.283 2.323 2.638 2.677 2.717 3.032 3.071 3.110 3.425 3.465 3.504 3.819 3.858 3.898
2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83
3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03
4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24
5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44
6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64
7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85
6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361
1 l = 0.2642 U.S.Gal 7 8 9 1.849 2.113 2.378 4.491 4.755 5.019 7.133 7.397 7.661 9.774 10.039 10.303 12.416 12.680 12.944 15.058 15.322 15.586 17.700 17.964 18.228 20.341 20.605 20.870 22.983 23.247 23.511 25.625 25.889 26.153
Kilogram to pound
0 10 20 30 40 50 60 70 80 90
0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42
1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62
1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 130.07 149.91 152.12 171.96 174.17 194.01 196.21 216.05 218.26
l to U.S. Gallons
0 10 20 30 40 50 60 70 80 90
00-200
0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775
46
1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040
2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304
3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568
4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832
5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Conversion table
SEN06112-00
l to U.K. Gallons
0 10 20 30 40 50 60 70 80 90
0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797
1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017
2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237
3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457
4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677
5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897
6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117
1 l = 0.21997 U.K.Gal 7 8 9 1.540 1.760 1.980 3.740 3.950 4.179 5.939 6.159 6.379 8.139 8.359 8.579 10.339 10.559 10.778 12.528 12.758 12.978 14.738 14.958 15.178 16.938 17.158 17.378 19.137 19.357 19.577 21.337 21.557 21.777
1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5
2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7
3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0
4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2
5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4
6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7
7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9
kgm to ft.lb
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3
PC200, 200LC, 220, 220LC-8M0
1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 426.8 491.8 499.1 564.2 571.4 636.5 643.7 708.8 716.1 781.2 788.4 853.5 860.7 925.8 933.1 998.2 1005.4 1070.5 1077.7 1142.8 1150.0 1215.1 1222.4 1287.5 1294.7 1359.8 1367.0 1432.1 1439.4
00-200
47
200 Foreword and general information Conversion table
SEN06112-00
kg/cm2 to lb/in2
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
00-200
0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414
48
1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428
2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442
3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456
4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470
5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485
6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 825.0 839.2 953.0 967.2 981.4 1,095 1,109 1,124 1,237 1,252 1,266 1,380 1,394 1,408 1,522 1,536 1,550 1,664 1,678 1,693 1,806 1,821 1,835 1,949 1,963 1,977 2,091 2,105 2,119 2,233 2,247 2,262 2,375 2,389 2,404 2,518 2,532 2,546 2,660 2,674 2,688 2,802 2,816 2,830 2,944 2,958 2,973 3,086 3,101 3,115 3,229 3,243 3,257 3,371 3,385 3,399 3,513 3,527 3,542
PC200, 200LC, 220, 220LC-8M0
200 Foreword and general information Conversion table
SEN06112-00
Temperature Conversion of Fahrenheit to Celsius q A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures on the following table show the temperatures in both Fahrenheit and Celsius. q When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. q When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C –11.7 –11.1
°F
°C
11 12
51.8 53.6
7.8 8.3
1°C = 33.8°F °F
°F
°C
46 47
114.8 116.6
27.2 27.8
81 82
177.8 179.6
–40.4 –37.2
–40 –35
–40.0 –31.0
–34.4
–30
–22.0
–10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
–31.7
–25
–13.0
–10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
–28.9
–20
–4.0
–9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
–28.3
–19
–2.2
–8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
–27.8
–18
–0.4
–8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
–27.2
–17
1.4
–7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
–26.7
–16
3.2
–7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
–26.1
–15
5.0
–6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
–25.6
–14
6.8
–6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
–25.0
–13
8.6
–5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
–24.4
–12
10.4
–5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
–23.9
–11
12.2
–4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
–23.3
–10
14.0
–3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
–22.8
–9
15.8
–3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
–22.2
–8
17.6
–2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
–21.7
–7
19.4
–2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
–21.1
–6
21.2
–1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
–20.6
–5
23.0
–1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
–20.0
–4
24.8
–0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
–19.4
–3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
–18.9
–2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
–18.3
–1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
–17.8
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
–17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
–16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
–16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
–15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
–15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
–14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
–13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
–13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
–12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
–12.2
PC200, 200LC, 220, 220LC-8M0
00-200
49
SEN06112-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06112-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
00-200
50
SEN06114-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
01 Specification
1
100 Specification and technical data Specification dimension drawings ................................................................................................................... 2 Working range diagram................................................................................................................................... 3 Specifications .................................................................................................................................................. 4 Weight table .................................................................................................................................................... 8 Table of fuel, coolant and lubricants.............................................................................................................. 12
PC200, 200LC, 220, 220LC-8M0
01-100
1
100 Specification and technical data Specification dimension drawings
SEN06114-00
Specification dimension drawings
1
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Check item
Unit
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
A
Overall length
mm
9,425
9,425
9,885
9,885
B
Overall height
mm
3,040
3,040
3,185
3,185
C Overall width
mm
2,800
3,080
2,980
3,280
D Shoe width
mm
600
700
600
700
E
Cab height
mm
3,040
3,040
3,055
3,055
F
Tail swing radius
mm
2,750
2,750
2,940
2,940
G Overall track length
mm
4,070
4,450
4,260
4,640
Length of track on ground
mm
3,275
3,655
3,460
3,845
Min. ground length
mm
440
440
440
440
H
01-100
2
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Working range diagram
SEN06114-00
Working range diagram
1
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Check item
Unit
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
A
Max. digging reach
mm
9,875
9,875
10,180
10,180
B
Max. digging depth
mm
6,620
6,620
6,920
6,920
C Max. digging height
mm
10,000
10,000
10,000
10,000
D
Max. vertical wall digging depth
mm
5,980
5,980
6,010
6,010
E
Max. dumping height
mm
7,110
7,110
7,035
7,035
F
Min. dumping height
mm
2,645
2,645
2,530
2,530
G
Max. digging reach at ground level
mm
9,700
9,700
10,020
10,020
PC200, 200LC, 220, 220LC-8M0
01-100
3
100 Specification and technical data Specifications
SEN06114-00
Specifications
1
PC200-8M0, PC200LC-8M0 Machine model
PC200-8M0
Serial number
400001 and up
Operating weight Working range
m
Performance
Bucket capacity
3
0.8
0.8
kg
19,900
21,100
Max. digging depth
mm
6,620
6,620
Max. vertical wall digging depth
mm
5,980
5,980
Max. digging radius
mm
9,875
9,875
Max. reach at ground level
mm
9,700
9,700
Max. digging height
mm
10,000
10,000
Max. dumping height
mm
7,110
7,110
kN {kg}
138.3 {14,100} (149.1 {15,200})
138.3 {14,100} (149.1 {15,200})
min-1 {rpm}
12.4 {12.4}
12.4 {12.4}
Max. digging force (when power max. function is turned on) Swing speed Swing operation max. slope angle
degree
25
25
km/h
Lo: 3.0 Mi: 4.1 Hi: 5.5
Lo: 3.0 Mi: 4.1 Hi: 5.5
35
35
kPa {kg/cm }
46.1 {0.47}
37.3{0.38}
Overall length
mm
9,425
9,425
Overall width
mm
2,800
3,080
Travel speed Gradability Ground pressure (Standard shoe)
Dimensions
PC200LC-8M0
degree 2
Overall crawler width
mm
2,800
3,080
Overall height (During transportation) (*)
mm
3,040
3,040
Machine overall height (*)
mm
3,040
3,040
Ground clearance of upper structure bottom
mm
1,085
1,085
Min. ground clearance
mm
440
440
Tail swing radius
mm
2,750
2,750
Work equipment min. swing radius
mm
3,040
3,040
Top height at min. swing radius of work equipment
mm
8,005
8,005
Length of track on ground
mm
3,275
3,655
Track gauge
mm
2,200
2,380
Cab height
mm
2,390
2,390
Width of standard shoe
mm
600
700
*: Grouser height (26 mm) included.
01-100
4
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Specifications
SEN06114-00
Machine model Serial number
PC200-8M0
Model
Performance
Number of cylinders – bore x stroke Piston displacement Rated hosepower • SAE J1995 [gross] • ISO 14396 • ISO 9249/SAE J1349 [net]
mm l {cc}
kW {HP}/ min-1 {rpm}
110 {147} / 2000 {2000} 110 {147} / 2000 {2000} 103 {138} / 2000 {2000}
Max. torque
Nm {kgm} / min-1 {rpm}
602 {61.4} / 1,500 {1,500}
Max. speed with no load
min-1 {rpm}
2,060 {2,060}
Min. speed with no load Min. fuel consumption ratio Starting motor Alternator Battery Radiator type Carrier roller Track roller
-1
Control Hydraulic valve pump
Type and numbers Discharge
Hydraulic motor
Travel motor
Set pressure
1,050 {1,050} 215 {155} 24 V, 4.5 kW 24 V, 35 A 12 V, 110 Ah x 2 CF90-4 2 on one side
min {rpm} g/kWh{g/HPh}
7 on one side
9 on one side
Assembly-type triple grosser Assembly-type triple grosser 45 on one side 49 on one side
Track shoe
Hydraulic cylinder
Hydraulic system
Undercarriage
Engine
Type
PC200LC-8M0 400001 and up SAA6D107E-1 4-cycle, water-cooled in-line, direct injection with turbocharger and air-cooled aftercooler 6 – 107 x 124 6.69 {6,690}
l/min
HPV95+95, Variable displacement piston type: 2 Piston: 219.5 x 2
MPa {kg/cm2}
Piston: 37.2 {380}
Type and number
6-spool type: 1
Operating method
Hydraulic
Swing motor
Type
HMV120, piston type: 2 (with brake valve and parking brake) KMF125ABE-6, piston type: 1 KMF125AB-6, piston type: 1 (*3) (with safety valve and parking brake) Boom (*1) Arm (*1) (*2) Bucket Double-acting Double-acting Double-acting piston piston piston 120 135 115 85 95 80 1,334.5 1,490 1,120 3,204.5 3,565 2,800 1,870 2,075 1,680 Box-shaped sealed type Tank return side CF91-1 (Air-cooling type)
Cylinder inner diameter mm Piston rod diameter mm Stroke mm Max. distance between pins mm Min. distance between pins mm Hydraulic tank Hydraulic oil filter Hydraulic oil cooler *1: Cushion is provided on the head side *2: Cushion is provided on the bottom side *3: Asian specification a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine.
PC200, 200LC, 220, 220LC-8M0
01-100
5
100 Specification and technical data Specifications
SEN06114-00
PC220-8M0, PC220LC-8M0 Machine model
PC220-8M0
Serial number
100001 and up
Operating weight Working range
m
Performance
Bucket capacity
3
1.0
1.0
kg
23,200
24,600
Max. digging depth
mm
6,920
6,920
Max. vertical wall digging depth
mm
6,010
6,010
Max. digging radius
mm
10,180
10,180
Max. reach at ground level
mm
10,020
10,020
Max. digging height
mm
10,000
10,000
Max. dumping height
mm
7,035
7,035
kN {kg}
158.9 {16,200} (171.6 {17,500})
158.9 {16,200} (171.6 {17,500})
min-1 {rpm}
11.7 {11.7}
11.7 {11.7}
Max. digging force (when power max. function is turned on) Swing speed Swing operation max. slope angle
degree
25
25
km/h
Lo: 3.1 Mi: 4.2 Hi: 5.5
Lo: 3.1 Mi: 4.2 Hi: 5.5
35
35
kPa {kg/cm }
51 {0.52}
42.2 {0.43}
Overall length
mm
9,885
9,885
Overall width
mm
2,980
3,280
Travel speed Gradability Ground pressure (Standard shoe)
Dimensions
PC220LC-8M0
degree 2
Overall crawler width
mm
2,980
3,280
Overall height (During transportation) (*)
mm
3,185
3,185
Machine overall height (*)
mm
3,055
3,055
Ground clearance of upper structure bottom
mm
1,100
1,100
Min. ground clearance
mm
440
440
Tail swing radius
mm
2,940
2,940
Work equipment min. swing radius
mm
3,450
3,450
Top height at min. swing radius of work equipment
mm
8,110
8,110
Length of track on ground
mm
3,460
3,845
Track gauge
mm
2,380
2,580
Cab height
mm
2,405
2,405
Width of standard shoe
mm
600
700
*: Grouser height (26 mm) included.
01-100
6
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Specifications
SEN06114-00
Machine model Serial number
PC220-8M0
Model
Performance
Number of cylinders – bore x stroke Piston displacement Rated hosepower • SAE J1995 [gross] • ISO 14396 • ISO 9249/SAE J1349 [net]
mm l {cc}
kW {HP}/ min-1 {rpm}
129 {173} / 2000 {2000} 129 {173} / 2000 {2000} 123 {164} / 2000 {2000}
Max. torque
Nm {kgm} / min-1 {rpm}
690 {70.4} / 1,500 {1,500}
Max. speed with no load
min-1 {rpm}
2,160 {2,160}
min-1 {rpm} g/kWh{g/HPh}
1,060 {1,060} 215 {153} 24 V, 4.5 kW 24 V, 35 A 12 V, 110 Ah x 2 CF90-4 2 on one side 8 on one side 10 on one side
Min. speed with no load Min. fuel consumption ratio Starting motor Alternator Battery Radiator type Carrier roller Track roller
Assembly-type triple grosser Assembly-type triple grosser 47 on one side 51 on one side
Control Hydraulic valve pump
Type and numbers Discharge
Hydraulic motor
Track shoe
Travel motor
Hydraulic cylinder
Hydraulic system
Undercarriage
Engine
Type
PC220LC-8M0 100001 and up SAA6D107E-1 4-cycle, water-cooled in-line, direct injection with turbocharger and air-cooled aftercooler 6 – 107 x 124 6.69 {6,690}
Set pressure
l/min
HPV95+95, Variable displacement piston type: 2 Piston: 219.5 x 2
MPa {kg/cm2}
Piston: 37.2 {380}
Type and number
6-spool type: 1
Operating method
Hydraulic
Swing motor
Type
HMV120, piston type: 2 (with brake valve and parking brake) KMF125ABE-6, piston type: 1 KMF125AB-6, piston type: 1 (*3) (with safety valve and parking brake) Boom (*1) Arm (*1) (*2) Bucket Double-acting Double-acting Double-acting piston piston piston 130 190 130 90 80 90 1,335 1,635 1,020 3,205 2,235 2,625 1,870 3,870 1,605 Box-shaped sealed type Tank return side CF91-1 (Air-cooling type)
Cylinder inner diameter mm Piston rod diameter mm Stroke mm Max. distance between pins mm Min. distance between pins mm Hydraulic tank Hydraulic oil filter Hydraulic oil cooler *1: Cushion is provided on the head side *2: Cushion is provided on the bottom side *3: Asian specification a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine.
PC200, 200LC, 220, 220LC-8M0
01-100
7
100 Specification and technical data Weight table
SEN06114-00
Weight table k
1
This weight table is prepared for your reference when handling or transporting the components.
PC200-8M0, PC200LC-8M0 Unit: kg Machine model
PC200-8M0
Serial number
PC200LC-8M0 400001 and up
Engine assembly
733
733
• Engine
575
575
• Damper
6
6
152
152
• Hydraulic pump Radiator and oil cooler assembly
115
115
Hydraulic tank and filter assembly (not including hydraulic oil)
131
131
Fuel tank assembly (not including fuel)
141
141
1,721
1,721
Cab
480
480
Operator’s seat
35
35
Counterweight
3,735
3,735
174
174
Revolving frame
Swing machinery Control valve
235
235
Swing motor
51.5
51.5
Travel motor
93 x 2
93 x 2
36
36
Track frame assembly (not including piping)
4,264
4,862
• Track frame
2,260
2,649
• Swing circle
273
273
• Idler
101 x 2
101 x 2
• Idler cushion
118 x 2
129 x 2
• Carrier roller
14 x 4
14 x 4
• Track roller
36 x 14
36 x 18
• Final drive (including travel motor)
330 x 2
330 x 2
• Standard triple shoe (600 mm)
1,215 x 2
1,325 x 2
• Standard triple shoe (700 mm)
1,405 x 2
1,530 x 2
• Wide triple shoe (800 mm)
1,530 x 2
1,670 x 2
• Road liner (Rubber pad type) (600 mm)
1,470 x 2
1,600 x 2
Center swivel joint
Track shoe assembly
01-100
8
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Weight table
SEN06114-00
Unit: kg Machine model
PC200-8M0
Serial number Boom assembly
PC200LC-8M0 400001 and up
1,541
1,541
Arm assembly
794
794
Bucket assembly
633
633
176 x 2
176 x 2
Arm cylinder assembly
228
228
Bucket cylinder assembly
137
137
Link (large) assembly
83
83
Link (small) assembly
22 x 2
22 x 2
42 + 8 x 2 + 28 + 10 + 26
42 + 8 x 2 + 28 + 10 + 26
Arm pin
12 + 8
12 + 8
Bucket pin
20 x 2
20 x 2
Link pin
13 x 2
13 x 2
Boom cylinder assembly
Boom pin
PC200, 200LC, 220, 220LC-8M0
01-100
9
100 Specification and technical data Weight table
SEN06114-00
PC220-8M0, PC220LC-8M0 Unit: kg Machine model
PC220-8M0
Serial number
PC220LC-8M0 100001 and up
Engine assembly
733
733
• Engine
575
575
• Damper
6
6
152
152
• Hydraulic pump Radiator and oil cooler assembly
115
115
Hydraulic tank and filter assembly (not including hydraulic oil)
131
131
Fuel tank assembly (not including fuel)
141
141
2,023
2,023
Cab
480
480
Operator’s seat
35
35
Counterweight
5,056
5,056
218
218
Revolving frame
Swing machinery Control valve
235
235
Swing motor
51.5
51.5
Travel motor
93 x 2
93 x 2
36
36
Center swivel joint Track frame assembly (not including piping)
4,785
5,411
• Track frame
2,573
3,080
• Swing circle
293
293
• Idler
101 x 2
101 x 2
• Idler cushion
129 x 2
129 x 2
• Carrier roller
14 x 4
14 x 4
• Track roller
36 x 14
36 x 18
• Final drive (including travel motor)
350 x 2
350 x 2
• Standard triple shoe (600 mm)
1,340 x 2
1,455 x 2
• Standard triple shoe (700 mm)
1,470 x 2
1,595 x 2
• Wide triple shoe (800 mm)
1,600 x 2
1,735 x 2
• Road liner (Rubber pad type) (600 mm)
1,535 x 2
—
Track shoe assembly
01-100
10
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Weight table
SEN06114-00
Unit: kg Machine model
PC220-8M0
Serial number Boom assembly
PC220LC-8M0 100001 and up
1,947
1,947
Arm assembly
950
950
Bucket assembly
722
722
203 x 2
203 x 2
Arm cylinder assembly
269
269
Bucket cylinder assembly
167
167
Link (large) assembly
78
78
Link (small) assembly
22 x 2
22 x 2
51 + 8 x 2 + 31 + 10 + 26
51 + 8 x 2 + 31 + 10 + 26
Boom cylinder assembly
Boom pin Arm pin
12 + 10
12 + 10
Bucket pin
20 x 2
20 x 2
Link pin
17 x 2
17 x 2
PC200, 200LC, 220, 220LC-8M0
01-100
11
SEN06114-00
100 Specification and technical data Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants a
1
For details of the notes (Notes 1, Note 2...) in the table, see Operation and Maintenance Manual.
01-100
12
PC200, 200LC, 220, 220LC-8M0
100 Specification and technical data Table of fuel, coolant and lubricants
SEN06114-00
Unit: l Refilling points
PC200, 200LC-8M0
PC220, 220LC-8M0
Specified capacity
Refill capacity
Specified capacity
Refill capacity
Engine oil pan
25.4
23.1
25.4
23.1
Swing machinery case
7.1
6.5
8.2
7.2
Final drive case (each of right and left)
3.8
3.6
5.4
5.0
Damper case
0.65
0.65
0.65
0.65
Hydraulic oil system
237
135
244
135
Fuel tank
400
—
400
—
Cooling system
20.3
20.3
19.9
19.9
PC200, 200LC, 220, 220LC-8M0
01-100
13
SEN06114-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06114-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
01-100
14
SEN06116-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
100 Engine and cooling system Engine related parts ............................................................................................................................. 2 Radiator, oil cooler, aftercooler and fuel cooler .................................................................................... 3
PC200, 200LC, 220, 220LC-8M0
10-100
1
SEN06116-00
100 Engine and cooling system Engine related parts
Engine related parts
1. 2. 3. 4. 5. 6. 7. 8.
Drive plate Torsion spring Stopper pin Friction plate Muffler Rear engine mount Front engine mount Damper assembly
10-100
2
1
Outline A damper assembly is wet type. Oil capacity: 0.65 l
PC200, 200LC, 220, 220LC-8M0
100 Engine and cooling system Radiator, oil cooler, aftercooler and fuel cooler
SEN06116-00
Radiator, oil cooler, aftercooler and fuel cooler
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Radiator Oil cooler Aftercooler Fuel cooler Reservoir tank Fan Shroud Radiator cap Radiator inlet hose Net Radiator outlet hose
PC200, 200LC, 220, 220LC-8M0
1
Specifications Radiator : CF90-4 Oil cooler : CF91-1 Aftercooler : Aluminum wave type Fuel cooler : Drawn cup type
10-100
3
SEN06116-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06116-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-100
4
SEN06117-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
200 Power train Power train ........................................................................................................................................... 2 Final drive............................................................................................................................................. 4 Swing machinery.................................................................................................................................. 8 Swing circle ........................................................................................................................................ 12
PC200, 200LC, 220, 220LC-8M0
10-200
1
SEN06117-00
Power train
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
200 Power train Power train
1
Idler Center swivel joint Control valve Final drive Travel motor (HMV120) Hydraulic pump (HPV95 + 95) Engine (SAA6D107E-1) Travel speed solenoid valve Swing brake solenoid valve Swing motor (KMF125ABE-6) Swing machinery Swing circle
10-200
2
PC200, 200LC, 220, 220LC-8M0
200 Power train Power train
PC200, 200LC, 220, 220LC-8M0
SEN06117-00
10-200
3
SEN06117-00
Final drive
200 Power train Final drive
1
PC200-8M0, PC200LC-8M0
10-200
4
PC200, 200LC, 220, 220LC-8M0
200 Power train Final drive
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
SEN06117-00
Level plug No. 1 planetary gear (No. of teeth: 42) Drain plug No. 1 sun gear shaft (No. of teeth: 10) No. 2 sun gear (No. of teeth: 21) No. 1 planetary carrier Cover Ring gear (No. of teeth: 95) No. 2 planetary carrier Ring nut Hub Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 36)
Specifications Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.000 Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Allowable clearance
0.06 to 0.25
1.00
16
Backlash between travel motor and No.2 planetary carrier
17
Backlash between No. 2 planetary gear and ring gear
0.17 to 0.57
1.10
18
Backlash between No. 2 planetary gear and No. 2 sun gear
0.15 to 0.49
—
19
Backlash between No. 1 planetary gear and ring gear
0.17 to 0.57
1.10
Backlash between No. 1 plane20 tary gear and No. 1 sun gear shaft
0.14 to 0.46
1.00
21
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.38 to 0.66
1.00
22
Amount of wear on sprocket tooth
23 Width of sprocket tooth
PC200, 200LC, 220, 220LC-8M0
Replace
Repair limit: 6 Standard dimension
Repair limit
71
68
Rebuild by buildup welding or replace
10-200
5
SEN06117-00
200 Power train Final drive
PC220-8M0, PC220LC-8M0
10-200
6
PC200, 200LC, 220, 220LC-8M0
200 Power train Final drive
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
SEN06117-00
Level plug No. 1 planetary gear (No. of teeth: 42) Drain plug No. 1 sun gear shaft (No. of teeth: 10) No. 2 sun gear (No. of teeth: 21) No. 1 planetary carrier Cover No. 2 planetary carrier Gear hub (No. of teeth: 95) Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 36)
Specifications Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.000 Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Allowable clearance
0.13 to 0.47
1.00
14
Backlash between travel motor and No.2 planetary carrier
15
Backlash between No. 2 planetary gear and ring gear
0.17 to 0.57
1.10
16
Backlash between No. 2 planetary gear and No. 2 sun gear
0.06 to 0.25
—
17
Backlash between No. 1 planetary gear and ring gear
0.14 to 0.46
1.00
Backlash between No. 1 plane18 tary gear and No. 1 sun gear shaft
0.16 to 0.56
1.10
19
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.38 to 0.66
1.00
20
Amount of wear on sprocket tooth
21 Width of sprocket tooth
PC200, 200LC, 220, 220LC-8M0
Replace
Repair limit: 6 Standard dimension
Repair limit
71
68
Rebuild by buildup welding or replace
10-200
7
SEN06117-00
Swing machinery
200 Power train Swing machinery
1
PC200-8M0, PC200LC-8M0
10-200
8
PC200, 200LC, 220, 220LC-8M0
200 Power train Swing machinery
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
SEN06117-00
Drain plug Swing pinion (No. of teeth: 13) No. 2 planetary carrier No. 2 planetary gear No. 2 sun gear No. 1 planetary carrier No. 1 planetary gear No. 1 sun gear Swing motor Oil level gauge Ring gear Case
Specifications Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) = 18.627 Unit: mm No.
Check item
13
Backlash between swing motor shaft and No. 1 sun gear
Backlash between No. 1 sun 14 gear and No.1 planetary gear
Criteria
Remedy
Standard clearance
Allowable clearance
0.18 to 0.28
—
0.16 to 0.50
1.00
15
Backlash between No. 1 planetary gear and ring gear
0.18 to 0.59
1.10
16
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.39 to 0.71
1.20
17
Backlash between No. 2 sun gear and No.2 planetary gear
0.16 to 0.50
0.90 Replace
Backlash between No. 2 plane18 tary gear and ring gear
0.18 to 0.59
1.00
19
Backlash between No. 2 planetary carrier and swing pinion
0.07 to 0.23
—
20
Backlash between swing pinion and swing circle
0.22 to 1.32
2.00
21
Clearance between plate and No. 2 planetary carrier
0.66 to 1.14
—
22
Clearance between No. 2 sun gear and plate
1.66 to 2.94
—
Wear of swing pinion surface contacting with oil seal
Standard dimension
Repair limit
23
ø125 (0/ – 0.100)
—
PC200, 200LC, 220, 220LC-8M0
Apply hard chrome plating or replace
10-200
9
SEN06117-00
200 Power train Swing machinery
PC220-8M0, PC220LC-8M0
10-200
10
PC200, 200LC, 220, 220LC-8M0
200 Power train Swing machinery
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
SEN06117-00
Drain plug Swing pinion (No. of teeth: 13) No. 2 planetary gear No. 2 sun gear No. 2 planetary carrier No. 1 planetary carrier No. 1 planetary gear No. 1 sun gear Swing motor Oil level gauge Ring gear Case
Specifications Reduction ratio: ((17 + 58)/17) x ((14 + 58)/14) = 22.689 Unit: mm No.
Check item
13
Backlash between swing motor shaft and No. 1 sun gear
Backlash between No. 1 sun 14 gear and No.1 planetary gear
Criteria
Remedy
Standard clearance
Allowable clearance
0.18 to 0.28
—
0.16 to 0.50
1.00
15
Backlash between No. 1 planetary gear and ring gear
0.18 to 0.59
1.10
16
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.35 to 0.64
1.20
17
Backlash between No. 2 sun gear and No.2 planetary gear
0.12 to 0.44
0.90 Replace
Backlash between No. 2 plane18 tary gear and ring gear
0.16 to 0.56
1.00
19
Backlash between No. 2 planetary carrier and swing pinion
0.08 to 0.23
—
20
Backlash between swing pinion and swing circle
0.23 to 1.37
2.00
21
Clearance between plate and No. 2 planetary carrier
0.58 to 1.62
—
22
Clearance between No. 2 sun gear and plate
2.56 to 3.84
—
Wear of swing pinion surface contacting with oil seal
Standard dimension
Repair limit
23
ø125 (0/ – 0.100)
—
PC200, 200LC, 220, 220LC-8M0
Apply hard chrome plating or replace
10-200
11
200 Power train Swing circle
SEN06117-00
Swing circle
1
PC200-8M0, PC200LC-8M0
1. 2. 3.
Swing circle inner race (No. of teeth: 96) Ball Swing circle outer race
a. b.
Inner race soft zone “S“ position Outer race soft zone “S“ position
Specifications Reduction ratio: –96/13 = –7.385 Amount of filled grease: 14.6 l (G2-LI)
Unit: mm No. 4
Check item Axial clearance of bearing (when mounted on chassis)
10-200
12
Criteria
Remedy
Standard clearance
Allowable clearance
0.5 to 1.6
3.2
Replace
PC200, 200LC, 220, 220LC-8M0
200 Power train Swing circle
SEN06117-00
PC220-8M0, PC220LC-8M0
1. 2. 3.
Swing circle inner race (No. of teeth: 92) Ball Swing circle outer race
a. b.
Inner race soft zone “S“ position Outer race soft zone “S“ position
Specifications Reduction ratio: –92/13 = –7.077 Amount of filled grease: 15.8 l (G2-LI)
Unit: mm No. 4
Check item Axial clearance of bearing (when mounted on chassis)
PC200, 200LC, 220, 220LC-8M0
Criteria
Remedy
Standard clearance
Allowable clearance
0.5 to 1.6
3.2
Replace
10-200
13
SEN06117-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06117-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-200
14
SEN06118-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
300 Undercarriage and frame Track frame and recoil spring............................................................................................................... 2 Idler ...................................................................................................................................................... 4 Carrier roller ......................................................................................................................................... 6 Track roller ........................................................................................................................................... 7 Track shoe............................................................................................................................................ 8
PC200, 200LC, 220, 220LC-8M0
10-300
1
300 Undercarriage and frame Track frame and recoil spring
SEN06118-00
Track frame and recoil spring
1. 2. 3. 4. 5. 6. 7. 8.
Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Front guard
10-300
2
1
q
q
The dimensions and the number of track rollers depend on the model, but the basic structure is not different. Number of track rollers Model
Q'ty (One side)
PC200-8M0
7
PC220-8M0
8
PC200LC-8M0
9
PC220LC-8M0
10
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Track frame and recoil spring
SEN06118-00
Standard shoe Models
PC200-8M0
PC220-8M0
PC200LC-8M0
PC220LC-8M0
Shoe width (mm)
600
600
700
700
Link pitch (mm)
190
190
190
190
Q'ty (One side)
45
47
49
51
Item
Unit: mm No.
9
Check item
Vertical width of idler guide
Horizontal 10 width of idler guide
Criteria Standard dimension
Tolerance
Repair limit
Track frame
107
+3 –1
111
Idler support
105
±0.5
103
Track frame
250
+4 –1
255
Idler support
247.4
—
245.4
Standard dimension
11 Recoil spring
Remedy
Rebuild by build-up welding or replace
Repair limit
Free length × Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
503 × 231
389
109.3 kN {11,150 kg}
480
87.4 kN {8,920 kg}
PC200LC-8M0 PC220-8M0 561 × 237 PC220LC-8M0
433
126.5 kN {12,900 kg}
535
101 kN {10,300 kg}
PC200-8M0
PC200, 200LC, 220, 220LC-8M0
Replace
10-300
3
300 Undercarriage and frame Idler
SEN06118-00
Idler
10-300
1
4
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Idler
SEN06118-00
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
Repair limit
538
—
2 Outside diameter of tread
500
488
3 Thickness of tread
26
20
4 Difference of tread
19
25
5 Total width
159
—
6 Width of tread
37.5
—
1 Outside diameter of protrusion
Clearance between shaft and 7 bushing
Interference between idler and 8 bushing Clearance between bushing 9 and support (Sum of clearance at both sides)
PC200, 200LC, 220, 220LC-8M0
Standard dimension 65 Standard dimension 72
Tolerance
Rebuild by buildup welding or replace
Shaft
Hole
Standard clearance
Allowable clearance
–0.250 –0.350
+0.164 –0.074
0.176 to 0.514
—
Tolerance Shaft
Hole
+0.108 +0.008
–0.032 –0.062
Standard Allowable interference interference Replace bushing 0.040 to 0.170
Standard clearance
Clearance limit
0.5 to 1.0
—
—
10-300
5
300 Undercarriage and frame Carrier roller
SEN06118-00
Carrier roller
1
Unit: mm No.
Check item
1 Outside diameter of flange
Criteria
Remedy
Standard dimension
Repair limit
143
—
2 Outside diameter of tread
120
106
3 Width of tread
43
—
4 Thickness of tread
23
16
5 Width of flange
14
—
Clearance between shaft and 6 bushing
Interference between roller and 7 bushing
8 Axial clearance of roller
10-300
6
Standard dimension 40 Standard dimension 47
Tolerance Shaft
Hole
Standard clearance
Allowable clearance
–0.170 –0.190
+0.301 +0.168
0.338 to 0.491
—
Tolerance Shaft
Hole
+0.061 +0.016
0 –0.040
Replace
Standard Allowable interference interference 0.016 to 0.101
—
Standard clearance
Allowable clearance
0.44 to 0.76
—
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Track roller
SEN06118-00
Track roller
1
Unit: mm No.
Check item
1 Outside diameter of flange
Criteria
Remedy
Standard dimension
Repair limit
188
—
2 Outside diameter of tread
156
144
3 Thickness of tread
44.5
38.5
4 Total width
225
—
5 Width of tread
44.5
—
6 Width of flange
25.5
Clearance between shaft and 7 bushing
8
Interference between roller and bushing
Clearance between bushing and 9 collar (Sum of clearance at both sides)
PC200, 200LC, 220, 220LC-8M0
Standard dimension 60 Standard dimension 67
Rebuild by buildup welding or replace
— Tolerance
Shaft
Hole
Standard clearance
Allowable clearance
–0.215 –0.315
+0.195 0
0.215 to 0.510
—
Tolerance Shaft
Hole
+0.153 +0.053
+0.030 0
Standard Allowable interference interference 0.023 to 0.153
Replace bushing
—
Standard clearance
Allowable clearance
0.5 to 1.0
—
Replace
10-300
7
SEN06118-00
Track shoe
a
300 Undercarriage and frame Track shoe
1
P portion shows the link of bushing press fitting end.
*1. Triple grouser shoe *2. Road liner *3. Swamp shoe *4. Flat shoe
10-300
8
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Track shoe
SEN06118-00
Unit: mm No.
Check item
Criteria
1 Link pitch 2 Outside diameter of bushing 3 Thickness of bushing metal 4 Link height 5
Thickness of link metal (bushing press-fitting portion)
Repair limit
190.3
193.3
Standard dimension
Turning limit
59.4
54.4
10.4
5.4
Standard dimension
Repair limit
105
97
28.5
20.5
6
160.4
7 Shoe bolt pitch
124.4
8 Inside width
84.8
10 Link
Overall width
45.4
11
Tread width
39.6
Regular
2.5
12 Protrusion of pin
Master
2.5 4.85
13
Protrusion of bushing
Regular Master
0.0
14
Overall length of pin
Regular
212
Master
212
Overall length of bushing
Regular
138.5
Master
128.7
16 Thickness of spacer
Repair or replace
Bushing
88.2 to 245 kN {9 to 25 ton}
18
Regular pin
127.4 to 274.4 kN {13 to 28 ton}
Master pin
78.4 to 147 kN {8 to 15 ton}
Press-fitting force
Adjust or replace
—
17 19 (*)
Turn 180 deg. or replace
62
9
15
Remedy
Standard dimension
—
* Dry type track link
PC200, 200LC, 220, 220LC-8M0
10-300
9
300 Undercarriage and frame Track shoe
SEN06118-00
Unit: mm No.
Check item
Criteria Tightening torque (Nm {kgm})
a. Regular link 20
Shoe bolt b. Master link
Triple grouser shoe
490 ± 49 {50 ± 5}
120 ± 10
Road liner (Rubber pad type)
549 ± 59 {56 ± 6}
—
22
Interference between regular pin and link
Clearance between regular pin 23 and bushing
24 Interference between master (*) pin and link
25 Clearance between master pin (*) and bushing
Retighten
Tightening torque (Nm {kgm})
Retightening angle (deg.)
Lower limit torque (Nm {kgm})
—
—
—
No. of shoes (each side) Interference between bushing 21 and link
Remedy
Retightening angle (deg.)
PC200-8M0: 45 PC200LC-8M0: 49 Standard dimension
Tolerance
Standard interference
Shaft
Hole
59
+0.434 +0.394
+0.074 0
0.320 to 0.434
38
+0.222 +0.162
–0.138 –0.200
0.300 to 0.422
Standard dimension 38 Standard dimension 37.8 Standard dimension 38
Tolerance Shaft
Hole
+0.222 +0.162
+0.902 +0.402
Tolerance Shaft
Hole
+0.280 +0.250
+0.062 0
Tolerance Shaft
Hole
–0.150 –0.350
+0.902 +0.402
—
Standard clearance 0.180 to 0.740
Adjust or replace
Standard interference 0.188 to 0.280 Standard clearance 0.552 to 1.252
* Dry type track link
10-300
10
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Track shoe
PC200, 200LC, 220, 220LC-8M0
SEN06118-00
10-300
11
SEN06118-00
300 Undercarriage and frame Track shoe
Triple grouser shoe
Swamp shoe
Road liner
10-300
12
PC200, 200LC, 220, 220LC-8M0
300 Undercarriage and frame Track shoe
SEN06118-00
Unit: mm No.
Check item
Criteria
1 Height 2 Thickness
Remedy
Standard dimension
Repair limit
26
16 10
(*)
8.5
3 Length of base
26
4 Length of base
19
5 Length at tip
20
6 Length at tip
14
7 Length at tip
19
8 Thickness (*) 9 Height 10 Thickness
Rebuild by buildup welding or replace
Standard dimension
Repair limit
36
26
34.5
24.5
102.5
90.5
17
5
11 Height
70
Replace
*: PC200-8M0, PC200LC-8M0: 600 mm width shoe
PC200, 200LC, 220, 220LC-8M0
10-300
13
SEN06118-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06118-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-300
14
SEN06119-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
401 Hydraulic system, Part 1 Hydraulic equipment layout drawing .................................................................................................... 2 Hydraulic tank and filter........................................................................................................................ 4 Hydraulic pump .................................................................................................................................... 6 Pilot oil filter........................................................................................................................................ 28
PC200, 200LC, 220, 220LC-8M0
10-401
1
401 Hydraulic system, Part 1 Hydraulic equipment layout drawing
SEN06119-00
Hydraulic equipment layout drawing 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
1
Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Hydraulic oil filter R.H. travel motor Swing motor Hydraulic pump Control valve Oil cooler L.H. travel motor L.H. PPC valve Lock lever Center swivel joint R.H. PPC valve Travel PPC valve Attachment PPC valve Accumulator Solenoid valve assembly 19A. PPC lock solenoid valve 19B. 2-stage relief solenoid valve 19C. Swing brake solenoid valve 19D. Travel speed solenoid valve 19E. Travel junction solenoid valve 19F. ATT selector solenoid valve
10-401
2
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic equipment layout drawing
PC200, 200LC, 220, 220LC-8M0
SEN06119-00
10-401
3
SEN06119-00
401 Hydraulic system, Part 1 Hydraulic tank and filter
Hydraulic tank and filter
1. 2. 3. 4. 5. 6. 7.
Hydraulic tank Oil filler port cap Filter element Strainer Bypass valve Suction strainer Sight gauge
10-401
4
1
Specifications Tank capacity : 190 l Amount of oil inside tank : 135 l Pressure valve Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Suction cracking pressure: 0 to 0.49 kPa {0 to 0.005 kg/cm2} Bypass valve set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic tank and filter
PC200, 200LC, 220, 220LC-8M0
SEN06119-00
10-401
5
SEN06119-00
Hydraulic pump
401 Hydraulic system, Part 1 Hydraulic pump
1
Model: HPV95+95
10-401
6
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Outline q This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve. IMF IMR ISIG PAF PAR PBF PD1F PD1R PD2F PD2R PENF PENR PEPC PEPCC PFC
: : : : : : : : : : : : : : :
PLSF PLSFC PLSR PLSRC PMF
: : : : :
PMR
:
PRC
:
PS PSIG
: :
1. 2. 3. 4. 5. 6.
Front PC mode selector current Rear PC mode selector current LS set pressure selector current Front pump discharge port Rear pump discharge port Pump pressure input port Case drain port Air bleeder Drain plug Drain plug Front control pressure detection port Rear control pressure detection port EPC basic pressure port EPC basic pressure detection port Front pump discharge pressure detection port Front load pressure input port Front load pressure detection port Rear load pressure input port Rear load pressure detection port Front PC mode selector pressure detection port Rear PC mode selector pressure detection port Rear pump discharge pressure detection port Pump suction port LS set selector pressure detection port
Front pump Rear pump LS valve PC valve LS-EPC valve PC-EPC valve
PC200, 200LC, 220, 220LC-8M0
10-401
7
SEN06119-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
401 Hydraulic system, Part 1 Hydraulic pump
Front shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Valve plate End cap Rear shaft Rear case Servo piston PC valve
10-401
8
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the discharge amount by changing the swash plate angle.
q
Structure q Cylinder block (7) is supported to shaft (1) by spline (14). q Shaft (1) is supported by front and rear bearings (15). q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. q Piston (6) and shoe (5) constitute the spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.
q
PC200, 200LC, 220, 220LC-8M0
q q
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside the respective cylinder chambers of cylinder block (7) is suctioned and discharged through valve plate (8).
10-401
9
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. q (a) is named the swash plate angle.
q
q
q q
q
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) suctions and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
10-401
10
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Control of discharge q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump discharge (Q) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) through slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
PC200, 200LC, 220, 220LC-8M0
10-401
11
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
1. LS valve
PA PDP PLP PLS PP PPL PSIG
: Pump port : Drain port : LS control pressure output port : LS pressure input port : Pump port : Control pressure input port : LS mode selector pilot port
1. 2. 3. 4. 5. 6. 7. 8.
Sleeve Piston Spool Spring Sheet Sleeve Plug Locknut
Function q The LS (load sensing) valve detects the load and controls the discharge amount. q This valve controls main pump discharge (Q) according to differential pressure (dPLS)[= PP — PLS], called the LS differential pressure (the difference between main pump pressure PP and control valve outlet port pressure PLS). q Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output, and pressure (PSIG) (called the LS selector pressure) from the proportional solenoid valve enter this valve. q The relationship between the LS differential pressure between the main pump pressure (PP) and LS pressure (PLS) (dPLS) [= (PP) — (PLS)] and the pump discharge (Q) changes as shown in the diagram according to LS selector current (ISIG) of the LS-EPC valve. q If (ISIG) changes from 0 to 1A, setting force the spring changes, too. As the result, the specified median of the pump discharge volume switching point changes as shown in the diagram. It will change in the range of 0.27 to 1.7 MPa {2.78 to 17.75 kg/cm2}.
10-401
12
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Operation
1) When the control valve is situated at neutral
q
q
q
q q
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (6). However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for the LS valve entering port (G) also changes the position of spool (6). (Setting force of the spring is changed) Before the engine is started, servo piston (12) is pushed to the left. (See the figure) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit through the control valve spool)
PC200, 200LC, 220, 220LC-8M0
q q q q
Spool (6) is pushed to the right, and port (C) and port (D) will be connected. Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). According to the difference in the areas on servo piston (12), the pressure moves in such that the swash plate angle may be minimized.
10-401
13
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
2) Action for the direction of maximizing the pump discharge
q
q
q
q
When the difference between the main pump pressure (PP) and LS pressure (PLS), in other wo r ds , L S d iff er e nti a l p re s s ur e ( d P L S) becomes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) enters port (J) at the small diameter end, so servo piston (12) is pushed to the left side. Therefore, the swash plate is moved in the direction to make the discharge amount larger.
10-401
14
q
q
If the output pressure of the EPC valve for the LS valve enters port (G), rightward force is generated on piston (7). If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected.
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
3) Action for the direction of minimizing the pump discharge
q
q
q
q
When LS differential pressure (dPLS) becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo piston (12), pump pressure (PP) pushes spool (6) to the right. When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large diameter end of the piston. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the right. As the result, the servo piston (12) moves into the direction of reducing the swash plate angle. As LS selector pressure (PSIG) is input to port (G), setting force of spring (4) is reduced.
PC200, 200LC, 220, 220LC-8M0
10-401
15
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
4) When servo piston is balanced
q
q
q
q
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position. The swash plate of the pump will be held at the intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 3 : 5, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 5 : 3.
10-401
16
q
q
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) — (PLS) = 1.7 MPa{17.75 kg/cm2} at the median of the specified value. If (PSIG) [Output pressure of LS-EPC valve, 0 to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the position of the balanced stop is changed in the range of (PP) — (PLS) = 1.7 to 0.27 MPa {17.75 to 2.78 kg/cm2} in proportion to (PSIG) pressure.
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
2. PC valve
PA PA2 PDP PM PPL
: : : : :
Pump port Pump pressure pilot port Drain port Mode selector pressure pilot port Control pressure output port (to LS valve)
Function q When the pump discharge pressure (PP1) (self-pressure) and (PP2) (other pump pressure) are high, the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. q If the pump discharge pressure increases due to increased load during operation, this valve decreases the pump discharge. q And if the pump discharge pressure goes low, it increases the pump discharge. q In this case, relation between the mean discharge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and the pump discharge (Q) will become as shown in the diagram if the relation is represented as the parameter the current value (X) to be given to PC-EPC valve solenoid. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load, the controller reduces the pump discharge to recover the speed.
PC200, 200LC, 220, 220LC-8M0
1. 2. 3. 4. 5. 6. 7. 8.
Plug Servo piston assembly Pin Spool Retainer Sheet Cover Wiring
q
If the engine speed goes below the specified value because of increased load, the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.
10-401
17
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Operation
1) When pump controller is normal (1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure). q The pressure [port (C) pressure] output from PC valve is changed depending on the above position. q The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
10-401
18
a
Other pump's pressure denotes the pressure of the pump situated on the opposite side. For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump pressure, the other pump's pressure is that of the front pump.
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
Action of spring q Load of springs (4) and (6) on the PC valve is determined by the swash plate position. q As servo piston (9) moves to right, spring (6) is retracted. q If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be fixed. q After that, spring (4) alone will operate. q The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6). The spring load changes as the servo piston (9) extends and contracts the springs (4) and (6). q If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2). q Spring load of springs (4) and (6) is also affected by the command current (X) to PCEPC valve solenoid. q Port (C) of the PC valve is connected to port (E) of the LS valve.
PC200, 200LC, 220, 220LC-8M0
SEN06119-00
q
q
q
q
q q
Self pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and other pump pressure (PP2) enters port (A). When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the left side. Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT). If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the left side. The pump discharge will be set to the increasing trend. Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker.
10-401
19
SEN06119-00
q
q
q
401 Hydraulic system, Part 1 Hydraulic pump
As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected. As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move of servo piston (9) is stopped. Servo piston (9) stop position (= Pump discharge) is decided by the position where the pushing force generated from the pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and (6) are balanced.
10-401
20
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
(2) When load on actuator is large and pump discharge pressure is high
Outline q When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right becomes larger and spool (3) will be moved to the position shown in above figure. q Part of the pressure to be conducted from port (C) to LS valve flows from port (B) to port (C) and (D) through LS valve. At the end of this flow, level of this pressure becomes approximately half of the main pump pressure (PP2).
q
Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to port (C) and acts to make the pump discharge the minimum.
q
PC200, 200LC, 220, 220LC-8M0
q q
q
When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, the opening of port (C) and port (D) becomes larger. As a result, the pressure on port (C) (= J) is decreased and the rightward move servo piston (9) is stopped. The position in which servo piston (9) stops at this time is further to the right than the position when pump pressures (PP1) and (PP2) are low. The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions can be represented by the broken line in the figure springs (4) and (6) form the double springs.
10-401
21
SEN06119-00
q
The relationship between the average pump pressure (PP1 + PP2)/2 and average pump discharge (Q) becomes as shown below.
q
If command voltage (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/ 2, and pump discharge (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. Namely, the force of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the pump discharge (Q) moves from (A) to (B) as the command current (X) is increased.
q
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22
401 Hydraulic system, Part 1 Hydraulic pump
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
2) As the emergency pump drive switch is turned on due to failure on the pump controller (1) When the main pump is under light load
q
q
q q
q
If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor side. In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1). The current becomes constant, so the force pushing piston (2) is also constant. If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left. The port (C) is connected to the drain pressure of the port (D), and the large diameter end of the servo piston (9) also becomes the drain pressure (PT) through the LS valve.
PC200, 200LC, 220, 220LC-8M0
q
Since the pressure on the small diameter end of the piston large, servo piston (9) moves in the direction to make the discharge amount larger.
10-401
23
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
(2) When the main pump is under heavy load
q
q q
q
q
If the emergency pump drive switch is turned on in the same way as in above, the command current (X) sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the right than when the main pump load is light, and is balanced at the position in the figure above. In this case, the pressure from port (B) flows to port (C), so servo piston (9) moves to the right (smaller pump discharge) and stops at a position to the further to the right then when the load on the pump is light. When the emergency pump drive switch is turned on, too, the pump pressure (PP) and pump discharge (Q) have a relationship as shown with the curve in the figure corresponding to the current sent to the PC-EPC valve solenoid through the resistor.
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24
q
The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A).
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
3. LS (PC)-EPC valve
C : To LS (PC) valve P : From self-pressure reducing valve T : To tank 1. 2. 3. 4. 5. 6. 7.
Connector Coil Body Spring Spool Rod Plunger
PC200, 200LC, 220, 220LC-8M0
10-401
25
401 Hydraulic system, Part 1 Hydraulic pump
SEN06119-00
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS (PC) valve.
Operation
1) When signal current is 0 (coil is deenergized) q
q q
q
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When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the LS (PC) valve. The pressurized oil from the LS (PC) valve is drained to the tank through port (C) and port (T).
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Hydraulic pump
2) When signal current is very small (coil is energized) q
q q
q q q
q
When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressure on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves up and down so that the propulsion force of plunger (7) may be balanced with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the LS (PC) valve is controlled in proportion to the size of the signal current.
PC200, 200LC, 220, 220LC-8M0
SEN06119-00
3) When signal current is maximum (coil is energized) q q
q q
q
As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and LS (PC) valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.
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27
SEN06119-00
401 Hydraulic system, Part 1 Pilot oil filter
Pilot oil filter
1
For breaker
1. 2. 3. 4.
Filter Case Head cover Relief valve
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28
Specifications Rated pressure : 6.57 MPa {67 kg/cm2} Flow rate : 16 l/min. Relief valve cracking pressure : 0.15 MPa {1.5 kg/cm2} Filter mesh size : 6 mm Filtering area : 450 cm2
PC200, 200LC, 220, 220LC-8M0
401 Hydraulic system, Part 1 Pilot oil filter
PC200, 200LC, 220, 220LC-8M0
SEN06119-00
10-401
29
SEN06119-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06119-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-401
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SEN06120-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
402 Hydraulic system, Part 2 Control valve ........................................................................................................................................ 2 CLSS.................................................................................................................................................. 13 Functions and operation by valve ...................................................................................................... 17
PC200, 200LC, 220, 220LC-8M0
10-402
1
402 Hydraulic system, Part 2 Control valve
SEN06120-00
Control valve a
1
In this section, only the 7-spool valve (6-spool valve + service valve) is shown.
10-402
2
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Control valve
A1: A2: A3: A4: A5: A6: A-1: ATT: B1: B2: B3: B4: B5: B6: B-1: BP1: BP5: C: P1:
To bucket cylinder head To L.H. travel motor To boom cylinder bottom To swing motor To R.H. travel motor To arm cylinder head To attachment From attachment To bucket cylinder bottom To L.H. travel motor To boom cylinder head To swing motor To R.H. travel motor To arm cylinder bottom To attachment From LS select solenoid valve From attachment selector solenoid valve To oil cooler From R.H. work equipment PPC valve (bucket DUMP) P2: From R.H. work equipment PPC valve (bucket CURL) P3: From travel PPC valve (L.H. travel REVERSE) P4: From travel PPC valve (L.H. travel FORWARD) P5: From R.H. work equipment PPC valve (boom RAISE) P6: From R.H. work equipment PPC valve (boom LOWER) P7: From L.H. work equipment PPC valve (swing RIGHT) P8: From L.H. work equipment PPC valve (swing LEFT) P9: From travel PPC valve (R.H. travel REVERSE) P10: From travel PPC valve (R.H. travel FORWARD) P11: From L.H. work equipment PPC valve (arm OUT) P12: From L.H. work equipment PPC valve (arm IN) P-1: From R.H. attachment PPC valve P-2: From R.H. attachment PPC valve PLS1: To rear pump LS valve PLS2: To front pump LS valve PLSC: LS pressure pickup port PP1: From rear pump PP2: From front pump PP1S: Front pump oil pressure sensor mounting port PPC: Pilot source pressure pickup port PP2S: Rear pump oil pressure sensor mounting port PPS2: To front pump LS valve PR: To solenoid valve, PPC valve, and EPC valve PST: From travel junction solenoid valve
PC200, 200LC, 220, 220LC-8M0
SEN06120-00
PX1: PX2: T: T1: TS: TSW: IS1:
From 2-stage relief solenoid valve From 2-stage relief solenoid valve To hydraulic tank To hydraulic tank To hydraulic tank From swing motor Pump merge-divider EPC valve (for main spool) drive signal IS2: Pump merge-divider EPC valve (for LS spool) drive signal IS3: Variable back pressure solenoid valve drive signal 1. Variable back pressure valve 2. Variable back pressure solenoid valve 3. Pump merge-divider EPC valve (for LS spool) 4. Pump merge-divider EPC valve (for main spool) 5. Arm check valve 6. Boom hydraulic drift prevention valve 7. Service valve 8. Cover A 9. 7-spool valve 10. Arm quick return valve 11. Cover B 12. Merge-divider valve
10-402
3
SEN06120-00
10-402
4
402 Hydraulic system, Part 2 Control valve
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Control valve
SEN06120-00
1. 2.
Pressure compensation valve (arm OUT) Pressure compensation valve (R.H. travel REVERSE) 3. Pressure compensation valve (swing RIGHT) 4. Pressure compensation valve (boom RAISE) 5. Pressure compensation valve (L.H. travel REVERSE) 6. Pressure compensation valve (bucket DUMP) 7. Pressure compensation valve (service) 8. Pressure compensation valve (bucket CURL) 9. Pressure compensation valve (L.H. travel FORWARD) 10. Pressure compensation valve (boom LOWER) 11. Pressure compensation valve (swing LEFT)
12. Pressure compensation valve (R.H. travel FORWARD) 13. Pressure compensation valve (arm IN) 14. Main relief valve 15. Unload valve 16. Main relief valve 17. Spool (service) 18. Spool (bucket) 19. Spool (L.H. travel) 20. Spool (boom) 21. Spool (swing) 22. Spool (R.H. travel) 23. Spool (arm)
Unit: mm No.
Check item
Criteria Standard dimension
24
Spool return spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
55.2 x 34.4
51.2
407 N {41.5 kg}
—
326 N {33.2 kg}
25
Spool return spring
54.5 x 34.8
51.2
393 N {40.1 kg}
—
315 N {32.1 kg}
26
Spool return spring
54.4 x 34.8
51.2
375 N {38.2 kg}
—
300 N {30.6 kg}
27
Spool return spring
54.6 x 34.8
51.2
421 N {42.9 kg}
—
336 N {34.3 kg}
PC200, 200LC, 220, 220LC-8M0
Replace spring if damaged or deformed
10-402
5
SEN06120-00
10-402
6
402 Hydraulic system, Part 2 Control valve
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Control valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SEN06120-00
Suction valve (arm OUT) Suction valve (R.H. travel REVERSE) Suction valve (boom RAISE) Suction valve (L.H. travel REVERSE) Suction safety valve (bucket DUMP) Suction safety valve (service) 2-stage suction safety valve (service) Suction safety valve (bucket CURL) Suction valve (L.H. travel FORWARD) Suction safety valve (boom LOWER)
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Suction valve (R.H. travel FORWARD) Suction safety valve (arm IN) LS shuttle valve (arm) LS shuttle valve (R.H. travel) LS selector valve LS shuttle valve (boom) LS shuttle valve (L.H. travel) LS shuttle valve (bucket) LS shuttle valve (service) LS check valve Unit: mm
No.
Check item
Criteria Standard dimension
21
22
Suction valve spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
46.8 x 7.5
40.6
5.5 N {0.56 kg}
—
4.4 N {0.45 kg}
11.5 x 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
Check valve spring
PC200, 200LC, 220, 220LC-8M0
Replace spring if damaged or deformed
10-402
7
SEN06120-00
10-402
8
402 Hydraulic system, Part 2 Control valve
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Control valve
1. 2. 3. 4.
SEN06120-00
Unload valve Safety valve for hydraulic drift prevention valve (boom “RAISE” and arm “OUT”) Main relief valve Variable back pressure valve
Arm valve 5. LS shuttle valve 6. Arm quick return valve 7. Pressure compensation valve (IN) 8. Spool 9. Suction safety valve (IN) 10. Cooler check valve 11. Regeneration circuit check valve 12. Suction valve (OUT) 13. Pressure compensation valve (OUT)
R.H. travel valve 14. LS shuttle valve 15. Pressure compensation valve (FORWARD) 16. Spool 17. Suction valve (FORWARD) 18. Suction valve (REVERSE) 19. Pressure compensation valve (REVERSE) Swing valve 20. LS selector valve 21. Pressure compensation valve (L.H.) 22. Spool 23. Pressure compensation valve (R.H.)
Unit: mm No.
Check item
Criteria Standard dimension
24
Check valve return spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
59.3 x 14.4
43
14.7 N {1.5 kg}
—
11.8 N {1.2 kg}
25
Check valve spring
33.8 x 6
29
13.7 N {1.4 kg}
—
11 N {1.12 kg}
26
Piston return spring
60.2 x 20
36
170 N {17.3 kg}
—
135 N {13.8 kg}
27
Check valve spring
31.5 x 10.3
19.5
5.9 N {0.6 kg}
—
4.71 N {0.48 kg}
28
Piston return spring
88.2 x 28.4
65
157 N {16 kg}
—
126 N {12.8 kg}
29
Piston return spring
18.0 x 9.3
13.4
36.1 N {3.68 kg}
—
28.8 N {2.94 kg}
PC200, 200LC, 220, 220LC-8M0
Replace spring if damaged or deformed
10-402
9
SEN06120-00
10-402
10
402 Hydraulic system, Part 2 Control valve
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Control valve
1. 2. 3. 4. 5. 6.
SEN06120-00
Return spring Merge-divider valve (for LS) Valve (sequence valve) Spring (sequence valve) Merge-divider valve (main) Return spring
L.H. travel valve 15. Merge-divider valve (travel junction valve) 16. Return spring 17. LS shuttle valve 18. Pressure compensation valve (FORWARD) 19. Spool 20. Suction valve (FORWARD) 21. Suction valve (REVERSE) 22. Pressure compensation valve (REVERSE)
Boom valve 7. Boom hydraulic drift prevention valve 8. LS shuttle valve 9. Pressure compensation valve (LOWER) 10. Spool 11. Suction safety valve (LOWER) 12. Regeneration circuit check valve 13. Suction valve (RAISE) 14. Pressure compensation valve (RAISE)
Bucket valve 23. LS shuttle valve 24. Pressure compensation valve (CURL) 25. Spool 26. Suction safety valve (CURL) 27. Suction safety valve (DUMP) 28. Pressure compensation valve (DUMP) Unit: mm
No.
Check item
Criteria Standard dimension
29
Spool return spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
36.4 x 21.8
33.0
121 N {12.3 kg}
—
96.5 N {9.84 kg}
30
Check valve spring
70.9 x 18.0
56.0
250 N {25.5 kg}
—
200 N {20.4 kg}
31
Spool return spring
64.5 x 32.3
63.0
178 N {18.1 kg}
—
142 N {14.5 kg}
32
Check valve spring
33.0 x 12.0
26.0
35.3 N {3.6 kg}
—
28.2 N {2.88 kg}
33
Check valve spring
33.8 x 6.0
29.0
13.7 N {1.4 kg}
—
11.0 N {1.12 kg}
34
Piston return spring
31.5 x 10.3
19.5
5.9 N {0.6 kg}
—
4.71 N {0.48 kg}
35
Piston return spring
30.7 x 20.5
23
50.0 N {5.1 kg}
—
40.0 N {4.08 kg}
PC200, 200LC, 220, 220LC-8M0
Replace spring if damaged or deformed
10-402
11
SEN06120-00
1. 2. 3. 4. 5. 6. 7. 8.
LS shuttle valve Pressure compensation valve Spool 2-stage suction safety valve Suction safety valve Unload valve Main relief valve LS bypass plug
10-402
12
402 Hydraulic system, Part 2 Control valve
Structure q The control valves of the following types are set. 6-spool valve (without service valve) 7-spool valve (6-spool valve with service valve) q This control valve consists of a 6-spool valve (unit type) and a set of service valve. A mergedivider valve, a variable back pressure valve and a boom hydraulic drift prevention valve are installed to it. q Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is compact and easy to maintain. q With one spool provided for one work equipment, this control valve is simple in structure.
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 CLSS
SEN06120-00
CLSS
1
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS CLSS: Abbreviation for Closed center Load Sensing System
Features q Fine control not influenced by load q Control performance that allows digging even when fine control operation is turned on q Ease of combined operation enabled by the flow divider function that is determined by the opening areas of spools during combined operations q Energy saving by variable pump control
PC200, 200LC, 220, 220LC-8M0
Configuration q CLSS consists of variable capacity piston pump, control valve, and actuators. q The main pump consists of pump itself, PC valve and LS valve.
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402 Hydraulic system, Part 2 CLSS
SEN06120-00
Basic principle Pump swash plate angle control q The pump swash plate angle (pump discharge) is controlled so that LS differential pressure (dPLS), which is the difference between pump discharge pressure (PP) and LS pressure (PLS)) (load pressure of actuator) at control valve outlet, is constant. q [LS differential pressure (dPLS) = Pump discharge pressure (PP) - LS pressure (PLS)]
q
LS differential pressure (dPLS) and pump swash plate angle
a
q
If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
See “Main pump” for the explanation of the operation.
The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high).
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 CLSS
SEN06120-00
Pressure compensation control
q q
q
A pressure compensation valve is installed to the outlet port side of each control valve to balance the load pressure. When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2) of each valve.
PC200, 200LC, 220, 220LC-8M0
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15
402 Hydraulic system, Part 2 CLSS
SEN06120-00
System diagram a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. 2. 3. 4. 5. 6. 7. 8.
Front pump Rear pump Main relief valve Unload valve Merge-divider valve Control valve Actuator Pump circuit
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16
9. 10. 11. 12. 13. 14. 15.
LS circuit Tank circuit Valve Spring LS bypass plug LS valve PC valve
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Functions and operation by valve
1
Hydraulic circuit diagram and name of valves
PC200, 200LC, 220, 220LC-8M0
10-402
17
SEN06120-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
Arm valve R.H. travel valve Swing valve Boom valve L.H. travel valve Bucket valve Service valve Spool (arm) Spool (R.H. travel) Spool (swing) Spool (boom) Spool (L.H. travel) Spool (bucket) Spool (service) Pressure compensation valve Suction valve Check valve (for boom regeneration circuit) Check valve (for arm regeneration circuit) Pump merge-divider EPC valve (for LS spool) Pump merge-divider EPC valve (for main spool) LS shuttle valve LS bypass plug LS selector valve Merge-divider valve Arm quick return valve Self-pressure reducing valve Travel junction valve Variable back pressure valve Variable back pressure solenoid valve Cooler check valve Boom hydraulic drift prevention valve Main relief valve (for boom, L.H. travel, bucket, and attachment circuits) Set pressure: 35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2} When one-touch power max. switch is set to ON position: 38.0 ± 0.3 MPa {387 ± 3 kg/cm2}
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18
402 Hydraulic system, Part 2 Functions and operation by valve
33. Main relief valve (for arm, R.H. travel, and swing circuits) Set pressure: 35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2} When one-touch power max. switch is set to ON position: 38.0 ± 0.3 MPa {387 ± 3 kg/cm2} 34. Unload valve (for boom, L.H. travel, bucket, and attachment circuits) Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2} 35. Unload valve (for arm, R.H. travel, and swing circuits) Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2} 36. Suction safety valve Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2} 37. Suction safety valve Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2} 38. Suction safety valve Set pressure: 31.4 ± 0.5 MPa {320 ± 5 kg/cm2} 39. Suction 2-stage safety valve 1st stage set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2} 2nd stage set pressure: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2} 40. Safety valve for hydraulic drift prevention valve Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Unload valve
1. 2. 3. 4. 5.
LS circuit Valve Pump circuit Tank circuit Spring
Function q When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump discharge with swash plate angle at the minimum. q The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred to as P1). q Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
q
q
During operation (when a given work is done within the discharge available with the minimum swash plate angle), the discharge pressure corresponding to the minimum pump swash plate angle is set to LS pressure + P1 pressure. The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation q Pressure of pump circuit (3) is received by the end of valve (2). q Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/ cm2}. q Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available. q If this pressure grows larger than the force of spring (5), valve (2) moves to the left. q Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4). q The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit (4). q When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure. q Since the pump discharge pressure - LS circuit pressure during unloading is larger than pump LS control pressure, the signal is output to minimize the pump swash plate angle.
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Operation of relief valve q When cylinder reaches its stroke end, main relief valve opens. q Pump discharge (Q) is relieved to the tank. (For details, see “System diagram” of “Structure of CLSS”.) q Since the pump discharge pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa {0 kg/cm2}. q As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to make the pump swash plate angle maximum. q Mechanically, operation of PC valve has priority over that of LS valve. q The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
10-402
20
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Introduction of LS pressure LS: Abbreviation for Load Sensing
1. 2. 3. 4. 5. 6. 7.
Main pump Main spool Pressure compensation valve Valve Check valve LS circuit LS shuttle valve
Function q The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is transmitted and led to LS shuttle valve (7) as LS pressure. q Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure. q In main spool (2), leading hole (a) with a small diameter also acts as an orifice. q LS pressure works as source pressure when closing unload vale while control lever is operated, and this pressure also functions as operating pressure when pressure compensation valve is compensated.
PC200, 200LC, 220, 220LC-8M0
Operation q When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and is led to LS circuit. q When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the pressurized oil flows.
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
LS bypass plug LS: Abbreviation for Load Sensing
1. 2. 3. 4. 5. 6.
Main pump Main spool Pressure compensation valve LS shuttle valve LS bypass plug LS circuit
Function q This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b). q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure. q Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit resistance from orifice (c) of main spool (2) to LS shuttle valve (4). q Effective LS differential pressure drops to improve a dynamic stability of the actuator.
10-402
22
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Pressure compensation valve When the work equipment is operated independently and the load pressure is the maximum (When the load pressure is higher than other work equipment during a combined operation)
1. 2. 3.
Main pump Valve 3.Shuttle valve
4. 5. 6.
Piston Spring LS shuttle valve
Function q Pressure compensation valve works as the load check valve. q If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure compensation valve piston (4) interconnects spring chamber (E) and port (C). q The force of spring (5) operates piston (4) and valve (2) to the closing direction. Integrated pressure compensation valve When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress in the parts. q To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used. q With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), and the service valve. q
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
When compensated (When the load pressure is lower than other work equipment during a combined operation)
Function q The pressure compensation valve closes by the LS pressure of port (D), and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment. q Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meterin differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure] becomes equivalent to all the spools in operation. q Pump flow is divided according to the ratio of the meter-in opening areas. Operation Spring chamber (E) is interconnected to port (D). q Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port (F) from other work equipment. q Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with the LS pressure. q
10-402
24
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Area ratio of pressure compensation valve
Function q The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2). Area ratio = (A2)/(A1) q When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum load pressure, the oil flow is divided in the ratio as same as the opening area ratio. q When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the maximum load pressure, the oil flow to the compensated side is divided in a ratio lower than the opening area ratio. q When the area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum load pressure, the oil flow to the compensated side is divided in a ratio higher than the opening area ratio.
PC200, 200LC, 220, 220LC-8M0
10-402
25
SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Shuttle valve in pressure compensation valve When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. 2. 3. 4. 5.
Main pump Valve Shuttle valve Piston Pressure compensation valve
Operation q Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is disconnected from port (C). q Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that piston (4) is not separated from valve (2).
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26
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When traveling
Structure q Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve without shuttle valve (5) is adopted.
PC200, 200LC, 220, 220LC-8M0
10-402
27
SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Boom regeneration circuit When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. 2. 3. 4. 5. 6. 7.
Main pump Boom valve spool Pressure compensation valve Suction safety valve Suction valve Check valve LS shuttle valve
Function q The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the cylinder head when the boom is lowered. Operation q When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of boom spool (2). q The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom through circuit (D). q Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
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28
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Arm regeneration circuit When cylinder head pressure is higher than bottom pressure
1. 2. 3. 4. 5. 6. 7.
Main pump Arm valve spool Pressure compensation valve Suction safety valve Suction valve Check valve LS shuttle valve
Function q The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing to the cylinder bottom (pump discharge + regeneration flow) during arm IN operation in order to accelerate the cylinder. Operation q When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the cylinder head flows to drain circuit (B) through the notch of arm spool (2). q The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder bottom through circuit (D). q Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
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30
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When cylinder head pressure is lower than bottom pressure
Function q Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder head to the bottom.
PC200, 200LC, 220, 220LC-8M0
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402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Merge-divider valve When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1) and (IS2) are OFF]
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Main spool Spring LS spool Spring LS circuit (for bucket valve) LS circuit (for bucket valve) LS circuit (for arm valve) LS circuit (for arm valve) Pump merge-divider EPC valve (for main spool changeover) Pump merge-divider EPC valve (for LS spool changeover)
Function q This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to flow to respective control valve groups). q This valve merges or divides LS circuit pressures as well.
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Operation q Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump merge-divider EPC valve is 0 MPa {0 kg/cm2}. q Main spool (1) is pressed to the right by spring (2). As a result, ports (E) and (F) are interconnected.
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
q
q
q
SEN06120-00
Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the control valve which requires the oil. Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right by spring (4). As a result, ports (A) and (B) are interconnected and ports (B) and (C) are interconnected. The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8) are transmitted to all the pressure compensation valves.
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1) and (IS2) are ON]
Operation q Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F). q The pressurized oil from the two pumps are sent to respective control valve groups. Pressure P1: To bucket, left travel, boom Pressure P2: To swing, right travel, arm q When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C) are interconnected, and other ports remain disconnected from each other. q The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8) are transmitted to respective control valves.
10-402
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
LS selector valve LS: Abbreviation for Load Sensing
SEN06120-00
Operation When pilot pressure (BP) is shut off q Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2). q If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A). q Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected. q Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
When pilot pressure (BP) is supplied When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of spring (2). q When piston (3) moves to the right, valve (1) disconnects ports (A) and (B). q Since ports (A) and (B) are disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve (8). q Swing LS pressure (P1) cannot affect other LS circuits, even if it rises. q
a
1. 2. 3. 4. 5. 6. 7. 8. 9.
The illustration shows the condition when the combined operation of swing and R.H. travel is performed. [When pilot pressure (BP) is supplied] Valve Spring Piston Piston Swing valve spool R.H. travel valve spool Arm valve spool LS shuttle valve LS circuit
Function q This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work equipment valves when the swing and work equipment are in combined operation. q This valve serves to improve operability of the work equipment by blocking the high pressure generated during swing operation.
PC200, 200LC, 220, 220LC-8M0
10-402
35
SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Self-pressure reducing valve Function q This valve serves to reduce the discharge pressure of main pump and provide it for solenoid valves, EPC valves, etc. for use as the control pressure. Operation When engine is stopped q Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS). q Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS). q Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
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36
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
When load pressure (P2) is low a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output pressure (PR) of the self-pressure reducing valve q
q
q
q q
q
q
Force of spring (8) and the force exerted by the pressure (PR) (0 MPa {0 kg/cm 2 }, when engine is stopped), are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2). When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds. The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure (PR). When pressure (PR) rises above the set pressure, poppet (11) opens. The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from the opening of poppet (11). Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the spool closes the opening between ports (P2) and (PR). Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as pressure (PR).
PC200, 200LC, 220, 220LC-8M0
SEN06120-00
When load pressure (P2) is high q As load pressure (A2) increases with the digging operation, etc, the pump discharge increases accordingly. q Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) + Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right. q Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces, reducing the engine horsepower loss. q When pressure (PR) rises above the set pressure, poppet (11) opens. q The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from the opening of poppet (11). q Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the spool closes the opening between ports (P2) and (PR). q Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as pressure (PR).
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
When abnormally high pressure is generated q If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring (15) and separates from the seat. q This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR). q As a result, components such as PPC valves and solenoid valves are protected from abnormally high pressure.
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Travel junction valve Function q When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability. q When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST) from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and independent amount of oil is supplied to right and left travel motors to secure turning ability.
PC200, 200LC, 220, 220LC-8M0
10-402
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Operation When pilot pressure (PST) is shut off (travel junction)
q
q
If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected. If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will be equalized.
10-402
40
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When pilot pressure (PST) is supplied (travel independent)
q q
When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2) compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected. The oil flow rate to both right and left motors becomes independent.
PC200, 200LC, 220, 220LC-8M0
10-402
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Travel PPC shuttle valve PPC: Abbreviation for Proportional Pressure Control Function q If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respective spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are restricted. q To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes through the internal circuit of respective control valves and acts on the spool. Operation When travel levers are in NEUTRAL
q q
The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3) and (4) build in the travel spring case, and then is drained through the travel PPC valve. When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves to the left until it contacts the end face of spring case (2) (st0).
10-402
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When travel lever is operated
q q q q q
If the right travel lever is moved to REVERSE (or FORWARD) position, the pilot pressure from the travel PPC valve moves spool (7) to the left (or right). Spool (7) pushes piston (3) and orifice (5) is closed. As a result, stroke limiting signal chamber (a) and the drain circuit from the travel PPC valve are disconnected. At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4), acts on the left end of piston (8) and pushes piston (8) to the right. When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves to the left. Maximum travel of the spool is limited to (st1) that has reduction in travel by the amount of movement (st2) of piston (8) to the right.
PC200, 200LC, 220, 220LC-8M0
10-402
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Boom hydraulic drift prevention valve Function q While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from drifting hydraulically. Operation In boom “RAISE” operation
q
q q
When operating boom “RAISE”, the pressurized oil from the control valve exerts a left-hand force on the right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat diameter (d2). The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left. As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows to the boom cylinder bottom.
10-402
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
In boom “NEUTRAL” operation
q q
q q
When the boom is operated to “NEUTRAL” position, the pressurized oil flowing inside poppet (5) through orifice (a) of poppet (5) is stopped by pilot piston (2). The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat diameter (d2). The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to the right. The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder bottom side is kept.
PC200, 200LC, 220, 220LC-8M0
10-402
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
In boom “LOWER” operation
q q q q q
When operating boom “LOWER”, the pilot pressure from the PPC valve pushes pilot piston (2). The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a) and chamber (b). Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops. As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens. As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
10-402
46
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
Safety valve for hydraulic drift prevention valve Operation when abnormally high pressure is generated
q q
If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B) opens check valve (1a) to actuate safety valve for hydraulic drift prevention valve (2). The pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure, whichever has higher pressure, opens check valve (1a) or (1b) to actuate safety valve for hydraulic drift prevention valve (2).
PC200, 200LC, 220, 220LC-8M0
10-402
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Arm quick return valve Function q Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed. q The valve reduces this pressure loss. Operation In arm “OUT” operation
q q q q q
q q q
In arm “OUT” operation, the pilot pressure from the PPC valve pushes pilot piston (1). The pressurized oil in chamber (b) inside the valve is drained through orifice (c). The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a) and chamber (b). Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops. If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2) and the spring force. The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring). Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B). The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
In arm “NEUTRAL” operation
q q q q
When the arm is operated from arm “OUT” to “NEUTRAL, the pilot pressure from PPC valve is shut off. The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1). The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ringshaped surface, whose area is equal to the area of (S2 - S1) of valve (2). The combined force of the force exerted on the ring-shaped surface and the spring force of the spring (3) moves valve (2) to the left and shuts off port (A) and port (B).
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
Variable back pressure valve Function q This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in each actuator circuit (motors, cylinders, etc.). q In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation other than the travel and swing is performed. Operation When engine is stopped q Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1). q No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and valve (6) is pressed to the right by the reaction force of spring (5). q Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
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402 Hydraulic system, Part 2 Functions and operation by valve
When engine is running (during swing or travel operation) q The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid valve (3). q Since drive signal (IS3) of variable back pressure solenoid valve (3) is “OFF”, pressurized oil (PR) is flown to spring chamber (C) of variable back pressure valve (4). q Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6) (surface of fd), and it pushes valve (6) to the right as a combined force with the reaction force of spring (5). q Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1) to push valve (6) to the left. q Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = (Area of surface fd) x Pressure (PR) + Reaction force of spring (5) / Area of surface fd1 q Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words, the set pressure of variable back pressure valve (4) is adjusted.
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
When engine is running (other than swing or travel operation) q The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve (3). q Since drive signal (IS3) of variable back pressure solenoid valve (3) is “ON”, the pressurized oil (PR) from self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained through variable back pressure solenoid valve (3). q Only the reaction force of spring (5) pushes valve (6) to the right. q Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1) to push valve (6) to the left. q Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = Reaction force of spring (5) / Area of surface fd1 q Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words, the set pressure of variable back pressure valve (4) is adjusted.
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
402 Hydraulic system, Part 2 Functions and operation by valve
Main relief valve
1. 2.
Spring Poppet
Function q This valve has two selectable settings for its set pressure. q If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is applied to it from the 2-stage relief solenoid valve. q The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set pressure) q When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set. Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure. Operation When pilot pressure (P) is shut off (low pressure setting) q The set pressure is determined by the load at installed length of spring (1). When pilot pressure (P) is supplied (high pressure setting) The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the area of diameter (d1) of poppet (2), raising the set pressure to higher level.
q
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PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
SEN06120-00
2-stage suction-safety valve [Installed to port (B) of the service valve]
1. 2. 3. 4.
Spring Piston Spring Holder
Function q This valve has two settings for its set pressure. q This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment circuit selector solenoid valve. q ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment (breaker, crusher, etc.). q The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure side) q The set pressure of the low-pressure setting is determined by the travel of the piston.
PC200, 200LC, 220, 220LC-8M0
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SEN06120-00
Operation When pilot pressure (P) is shut off (high pressure setting) q Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed length of spring (1) < Load at installed length of spring (3).] q The load at installed length of spring (1) becomes maximum, inducing high-pressure setting. q Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
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402 Hydraulic system, Part 2 Functions and operation by valve
When pilot pressure (P) is supplied (low pressure setting) q When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B). q The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) — (d2)] of piston (2). q Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder (4). q Since spring (1) is expanded and reducing its load at installed length, the set pressure is lowered. q The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
PC200, 200LC, 220, 220LC-8M0
402 Hydraulic system, Part 2 Functions and operation by valve
PC200, 200LC, 220, 220LC-8M0
SEN06120-00
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SEN06120-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06120-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
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SEN06121-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
403 Hydraulic system, Part 3 Swing motor ......................................................................................................................................... 2 Center swivel joint .............................................................................................................................. 10 Travel motor ....................................................................................................................................... 12 PPC valve .......................................................................................................................................... 22 Valve control....................................................................................................................................... 42 Solenoid valve.................................................................................................................................... 44 PPC accumulator ............................................................................................................................... 46 Return oil filter .................................................................................................................................... 47 Attachment circuit selector valve........................................................................................................ 48 Hydraulic cylinder............................................................................................................................... 50
PC200, 200LC, 220, 220LC-8M0
10-403
1
403 Hydraulic system, Part 3 Swing motor
SEN06121-00
Swing motor
1
Model: KMF125ABE-6
B: From swing holding brake solenoid valve MA: From control valve (swing RIGHT) MB: From control valve (swing LEFT) S: From control valve T: To hydraulic tank 1. Reverse prevention valve 2. Safety valve
Specifications Machine models Item Model
KMF125ABE-6
Theoretical displacement
125 cm3/rev
Safety valve set pressure
28.4 MPa {290 kg/cm 2}
Rated engine speed
1,694 rpm
Brake release pressure
10-403
2
PC200-8M0, PC220-8M0, PC200LC-8M0 PC220LC-8M0
1,879 rpm
1.4 MPa {14 kg/cm2}
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Swing motor
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
10-403
3
403 Hydraulic system, Part 3 Swing motor
SEN06121-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
16
17
Check valve spring
Shuttle valve spring
10-403
4
Repair limit
Installed length
Load at installed length
57.2 x 20.0 16.4 x 8.9
Free length x Outside diameter
Free length
Load at installed length
30.9
3.43 N {0.35 kg}
—
2.74 N {0.27 kg}
11.5
13.7 N {1.4 kg}
—
11.0 N {1.12 kg}
Replace spring if damaged or deformed
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Swing motor
SEN06121-00
Model: KMF125AB-6 (For Asian specification)
B: From swing holding brake solenoid valve MA: From control valve (swing RIGHT) MB: From control valve (swing LEFT) S: From control valve T: To hydraulic tank 1. Safety valve
Specifications Machine models Item Model
KMF125AB-6
Theoretical displacement
125 cm3/rev
Safety valve set pressure
28.4 MPa {290 kg/cm 2}
Rated engine speed Brake release pressure
PC200, 200LC, 220, 220LC-8M0
PC200-8M0, PC220-8M0, PC200LC-8M0 PC220LC-8M0
1,694 rpm
1,879 rpm
1.4 MPa {14 kg/cm 2}
10-403
5
SEN06121-00
10-403
6
403 Hydraulic system, Part 3 Swing motor
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Swing motor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
SEN06121-00
Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
16
17
Check valve spring
Installed length
Load at installed length
57.2 x 20.0 16.4 x 8.9
Free length x Outside diameter
Shuttle valve spring
PC200, 200LC, 220, 220LC-8M0
Repair limit
Free length
Load at installed length
30.9
3.43 N {0.35 kg}
—
2.74 N {0.27 kg}
11.5
13.7 N {1.4 kg}
—
11.0 N {1.12 kg}
Replace spring if damaged or deformed
10-403
7
SEN06121-00
403 Hydraulic system, Part 3 Swing motor
Swing holding brake 1. When solenoid valve is de-energized
2. When solenoid valve is energized
Operation q As the swing holding brake is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit (T). q Brake piston (7) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.
Operation q As the swing holding brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) through port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (7) up. q Disc (5) is separated from plate (6), releasing the brake.
10-403
8
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Swing motor
SEN06121-00
Relief valve portion Outline q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation 1 When starting swing q When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port (MA) through control valve (6). q The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank.
PC200, 200LC, 220, 220LC-8M0
2 When swing is stopped q When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. q The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. q Rotation resistance is generated on the motor and hence the brake starts working. q Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). q The pressure on chamber (C) is increased to the se t pr es sur e of r el ief va lv e ( 1) an d becomes the same as that of port (MB). q A high braking torque works on the motor, thereby stopping the motor. q When relief valve (1) is being actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) through check valve (3). q Above prevents cavitation on port (MA).
10-403
9
403 Hydraulic system, Part 3 Center swivel joint
SEN06121-00
Center swivel joint
A1 A2 B1 B2 C1 C2 D1 D2 E1 E2 DR1 DR2
: To L.H. travel motor port (PB) : From control valve (L.H. travel FORWARD port) : To L.H. travel motor [Port (PA)] : From control valve (L.H. travel REVERSE port) : To R.H. travel motor [Port (PA)] : From control valve (R.H. travel FORWARD port) : To R.H. travel motor [port (PB)] : From control valve (R.H. travel REVERSE port) : To L.H. and R.H. travel motor [port (P)] : From travel speed increase solenoid valve : From L.H. and R.H. travel motor [port (T)] : To hydraulic tank 1.
10-403
10
1
1. 2. 3. 4. 5. 6. 7.
Cover Slipper seal Rotor Dust seal 5. O-ring 6. Cover Shaft
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Center swivel joint
SEN06121-00
Unit: mm No.
Check item
8
Clearance between rotor and shaft
PC200, 200LC, 220, 220LC-8M0
Criteria Standard dimension Standard clearance 80
0.056 to 0.105
Remedy Allowable clearance 0.111
Replace
10-403
11
SEN06121-00
Travel motor
403 Hydraulic system, Part 3 Travel motor
1
L.H. travel motor PA : From control valve (L.H. travel FORWARD port) PB : From control valve (L.H. travel REVERSE port) R.H. travel motor PA : From control valve (R.H. travel REVERSE port) PB : From control valve (R.H. travel FORWARD port) P : From travel speed increase solenoid valve T : To hydraulic tank B : Plug (Brake release pressure port) MA : MA pressure pickup port MB : MB pressure pickup port
10-403
12
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Travel motor
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
10-403
13
403 Hydraulic system, Part 3 Travel motor
SEN06121-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Regulator piston Regulator valve Motor case Suction safety valve Check valve Rocker cam Retainer guide Output shaft Pin Retainer Piston Cylinder block Valve plate Counterbalance valve spool Ring Brake piston Plate Disc Ball retainer
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
20
Check valve spring
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
32.5 x 6.5
24.2
7.16 N {0.73 kg}
—
5.69 N {0.58 kg}
—
2.06 N {0.21 kg}
21
Check valve spring
13.0 x 6.5
8.5
2.55 N {0.26 kg}
22
Spool return spring
58.4 x 30
42.6
411 N {41.9 kg}
—
328 N {33.5 kg}
23
Regulator valve spring
21.5 x 11.1
17.1
54.9 N {5.6 kg}
—
43.9 N {4.48 kg}
Replace spring if damaged or deformed
Specifications Model
HMV120
Theoretical discharge (cm3/rev)
Min.
82
Max.
106.2
2
37.3 {380}
Rated pressure: MPa {kg/cm } Rated speed (rpm) Brake release pressure (MPa {kg/cm2}) Travel speed changeover pressure (MPa {kg/cm })
14
2,689
Max.
1,275 1.18 {12}
2
10-403
Min.
0.78 {8.0}
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Travel motor
SEN06121-00
Operation of motor 1) At slow speed (motor swash plate angle at maximum)
q
q q
q
As the solenoid valve is de-energized, the pilot pressurized oil from the self pressure reducing valve does not flow to port (P). Regulator valve (9) is pushed to the right by spring (10). Pressurized oil being conducted from the control valve to end cover (8) by pressing check valve (22) is shut off by regulator valve (9). Fulcrum (a) of rocker cam (4) is eccentric to the working point (b) of the combined force of the propulsion force of cylinder (6).
PC200, 200LC, 220, 220LC-8M0
q
q
q
The combined force of the piston propulsion forces works as the moment of inclining rocker cam (4) toward the maximum swash plate angle. The pressurized oil at regulator piston (15) passes through orifice (c) of regulator valve (9) and is drained to the motor case. Rocker cam (4) is inclined in the maximum swash plate angle direction. The motor capacity becomes maximum, turning on the low speed travel.
10-403
15
SEN06121-00
403 Hydraulic system, Part 3 Travel motor
2) At high speed (motor swash plate angle at minimum)
q
q q
q q
As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P). Regulator valve (9) is pushed to the left. The pressurized oil from the control valve passes through passage (d) in regulator valve (9) and enters regulator piston (15). Regulator piston (15) is pushed to the right. Rocker cam (4) is inclined in the minimum swash plate angle direction. The motor capacity becomes minimum, turning on the high speed travel.
10-403
16
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Travel motor
SEN06121-00
Operation of parking brake 1) When starting travel
q
q
q
As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (19), opening the parking brake circuit. The pressurized oil is conducted to chamber (e) of brake piston (12) and compresses spring (11), pushing piston (12) toward left. Since the pushing force to plate (13) and disc (14) disappears, plate (13) is separated from disc (14) and the brake is released.
PC200, 200LC, 220, 220LC-8M0
10-403
17
SEN06121-00
403 Hydraulic system, Part 3 Travel motor
2) When travel is stopped
q
q
q q q q
As the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and closing the parking brake circuit. The pressurized oil in chamber (e) of brake piston (12) passes through orifice (f) of brake piston (12) and is drained to the motor case. Brake piston (12) is pushed to the right by spring (11). Plate (13) and disc (14) are pushed together, and the brake is applied. As brake piston (12) returns, flow of pressurized oil is reduced with slow return valve (22). The time delay will be set to activate the brake only after the machine has stopped.
10-403
18
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Travel motor
Brake valve q q
The brake valve consists of suction safety valve (18A) and counterbalance valve (18). Functions and operations of respective components shall conform to the following.
1) Counterbalance valve and check valve Function q When traveling downhill, the machine travel speed tends to get faster than the motor (engine) speed because of the downward force generated from its own weight. q If the machine travels with the engine at low speed, the motor may rotate without load, causing the machine to run away; resulting in a very dangerous situation. q These valves are used to prevent above by controlling the machine to travel according to the engine speed (pump discharge).
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
Operation when pressurized oil is supplied q Operating the travel lever conducts the pressurized oil from the control valve to port (PA). q The pressurized oil push-opens suction safety valve (18A) and then flows to motor outlet port (MB) through motor inlet port (MA). q The motor outlet side is closed by suction safety valve (18B) and spool (19), so the pressure at the supply side rises.
10-403
19
SEN06121-00
q
q
q
The pressurized oil on the supply side flows to chamber (S1) through orifice (E1) and orifice (E2) of the spool (19). As the pressure in chamber (S1) goes above the spool selector pressure, spool (19) is pushed toward right. Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the motor rotating.
10-403
20
403 Hydraulic system, Part 3 Travel motor
Operation of brake during travelling downhill q If indication of the machine runaway is sensed while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. q Pressure in chamber (S1) is released through orifices (E1) and (E2). q As the pressure in chamber (S1) goes below the spool selector pressure, spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. q The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from running away. q The spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. q Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump discharge.
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Travel motor
SEN06121-00
2) Safety valve
q
Function q As long as the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. q Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. q The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment.
q
Operation (1) When travel is stopped (or when travelling downhill) (Right swing) q Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). q When it drops beyond the spool switching pressure, spool (19) is returned to the left by spring (20), reducing the pressure at outlet passage (B1). q The motor tries to continue rotation resorting to inertial force, thus pressure on the outlet port (MB) is increased.
PC200, 200LC, 220, 220LC-8M0
q
When the pressure rises above the set pressure of the suction safety valve, poppet (1) opens. The pressurized oil passes through notch (A1) of spool (19) into chamber (MA) of the circuit at the opposite side. At the time of counterclockwise rotation, it makes reverse operation of clockwise rotation.
(2) When starting travel (or when traveling at a constant speed) q As the travel lever is operated, the pressurized oil from the pump moves spool (19) toward right. q The passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure. q The pump pressure rises, providing a large tractional force to the valve.
10-403
21
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
PPC valve
1
Work equipment and swing PPC valve 1
P: P1: P2: P3: P4: T:
From self pressure reducing valve L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port L.H. PPC valve: Swing LEFT port/R.H. PPC valve: Bucket CURL port L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port To hydraulic tank
10-403
22
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
10-403
23
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Piston Disc Nut (for lever connection) Joint Plate Retainer Body Filter Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
10
Centering spring (for ports P3 and P4)
Free length x Outside diameter
Repair limit
Installed length
Load at installed length
Free length
Load at installed length
42.5 x 15.5
34.0
17.7 N {1.80 kg}
—
14.1 N {1.44 kg}
11
Centering spring (for ports P1 and P2)
44.5 x 15.5
34.0
29.4 N {3.0 kg}
—
23.5 N {2.40 kg}
12
Metering spring
26.5 x 8.15
24.9
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
10-403
24
Replace spring if damaged or deformed
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
Operation
SEN06121-00
q
1. When in neutral q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
2. During fine control (Neutral o fine control) q
q
q
q
q
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
PC200, 200LC, 220, 220LC-8M0
10-403
25
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
3. During fine control (When control lever is returned) q
q
q
q
q
q
When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
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26
4. At full stroke q q
q
q
Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
Travel PPC valve
SEN06121-00
1
PPC: Abbreviation for Proportional Pressure Control
P P1 P2 P3 P4 T
: From self-pressure reducing valve : To control valve (L.H. travel REVERSE port) : To control valve (L.H. travel FORWARD port) : To control valve (R.H. travel REVERSE port) : To control valve (R.H. travel FORWARD port) : To hydraulic tank
PC200, 200LC, 220, 220LC-8M0
10-403
27
SEN06121-00
1. 2. 3. 4. 5. 6.
403 Hydraulic system, Part 3 PPC valve
Plate Case Piston Seal Spool Damper
10-403
28
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
7
8
Centering spring
Metering spring
PC200, 200LC, 220, 220LC-8M0
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
48.6 x 15.5
32.5
108 N {11.0 kg}
—
86.3 N {8.8 kg}
26.5 x 8.15
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
Replace spring if damaged or deformed
10-403
29
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
1. Pressure reducing valve function
q
Operation 1) When in neutral q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
2) During fine control (Neutral o fine control) q When piston (4) is pushed by lever (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. q When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). q Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). q As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1). 10-403
30
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
3) During fine control (When control lever is returned) q
q
q
q
q
q
When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
4) At full stroke q q
q
q
Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).
10-403
31
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
Service PPC valve (with EPC valve)
a
1
For the details of operation, see the paragraph of “Work equipment and swing PPC valve.”
10-403
32
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
P: P1: P2: T:
From self pressure reducing valve To service valve To service valve To hydraulic tank
1. 2. 3. 4. 5. 6. 7.
Spool Piston Lever Plate Retainer Body EPC valve Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
8
9
Centering spring
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
33.9 x 15.3
28.4
125 N {12.7 kg}
—
100 N {10.2 kg}
22.7 x 8.10
22.0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
Metering spring
PC200, 200LC, 220, 220LC-8M0
Free length
Load at installed length
Replace spring if damaged or deformed
10-403
33
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
1. EPC valve
C: P: T:
To control valve From self pressure reducing valve To hydraulic tank
1.
Body
2. 3. 4. 5. 6.
Spool Push pin Coil Plunger Connector Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
7
Return spring
10-403
34
Repair limit
Free length
Installed length
Load at installed length
Free length
Load at installed length
9.5
8.4
3.1 N {0.32 kg}
—
2.5 N {0.26 kg}
Replace PPC valve assembly if spring isdamaged or deformed
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the control valve.
PC200, 200LC, 220, 220LC-8M0
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35
SEN06121-00
403 Hydraulic system, Part 3 PPC valve
Operation
1) When signal current is 0 (coil is de-energized) q q q q
When there is no signal current flowing from the controller to coil (4), coil (4) is de-energized. Spool (2) is pushed to the left by spring (3). Port (C) closes and the pressurized oil from the front pump does not flow to the control valve. The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
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36
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
2) When signal current is very small (coil is energized) q q q q q q
When a very small signal current flows to coil (4), coil (4) is energized, and a propulsion force is generated on the right side of plunger (5). Push pin (6) pushes spool (2) to the right, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (5). Spool (2) is pushed to the left, port (P) is shut off from port (C) and ports (C) and (T) are connected. Spool (2) moves so that the propulsion force of plunger (5) may be balance with pressure of port (C) + spring load of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.
PC200, 200LC, 220, 220LC-8M0
10-403
37
SEN06121-00
403 Hydraulic system, Part 3 PPC valve
3) When signal current is maximum (coil is energized) q q q q q
As the signal current flows to coil (4), coil (4) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (5) is also at its maximum. Spool (2) is pushed to the left by push pin (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and the control valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the hydraulic tank.
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38
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
PC200, 200LC, 220, 220LC-8M0
SEN06121-00
10-403
39
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
Service PPC valve
a
1
For the details of operation, see the paragraph of “Work equipment and swing PPC valve“.
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40
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 PPC valve
SEN06121-00
P: P1: P2: T:
From self pressure reducing valve To service valve To service valve To hydraulic tank
1. 2. 3. 4. 5. 6.
Spool Piston Lever Plate Retainer Body Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
7
8
Centering spring
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
33.9 x 15.3
28.4
125 N {12.7 kg}
—
100 N {10.2 kg}
22.7 x 8.10
22.0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
Metering spring
PC200, 200LC, 220, 220LC-8M0
Replace spring if damaged or deformed
10-403
41
SEN06121-00
Valve control
10-403
42
403 Hydraulic system, Part 3 Valve control
1
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Valve control
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
SEN06121-00
Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment control lever Solenoid block Accumulator Control valve Hydraulic pump Junction box L.H. work equipment control lever L.H. PPC valve
Lever positions A. Neutral B. Boom “RAISE” C. Boom “LOWER” D. Bucket “DUMP” E. Bucket “CURL” F. Neutral G. Arm “IN” H. Arm “OUT” J. Swing “RIGHT” K. Swing “LEFT” L. Neutral M. Travel “REVERSE” N. Travel “FORWARD”
PC200, 200LC, 220, 220LC-8M0
10-403
43
SEN06121-00
Solenoid valve
403 Hydraulic system, Part 3 Solenoid valve
1
PPC lock, travel junction, ATT selector, travel speed, swing brake, and 2-stage relief solenoid valves
10-403
44
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Solenoid valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
PPC lock solenoid valve 2-stage relief solenoid valve Swing brake solenoid valve Travel speed solenoid valve Travel junction solenoid valve ATT selector solenoid valve Connector Moving core Coil Spool Block Spring
T: A1: A2: A3: A4: A5: A6: P1: ACC:
SEN06121-00
When solenoid is energized q As the signal current flows from the controller to solenoid (9), solenoid (9) is energized. Accordingly, spool (10) is pushed to the right. This operation flows the pressurized oil from the main pump, through port (P), via inside spool (10), to port (A), and eventually to the actuator. At the same time, port (T) closes, the oil does not flow to the tank.
To tank To PPC valve To main valve (2-stage relief valve) To swing motor To L.H. and R.H. travel motors To main valve (Travel junction valve) To ATT selector valve From main pump To accumulator
Operation When solenoid is de-energized q Since the signal current does not flow from the controller, solenoid (9) is de-energized. For this reason, spool (10) is pushed to the left by spring (12). Since port (P) is closed to port (A), pressurized oil from the main pump does not flow to the actuator. At this time, the oil from the actuator is drained through ports (A) and (T) into the tank.
PC200, 200LC, 220, 220LC-8M0
10-403
45
SEN06121-00
PPC accumulator
1. 2. 3. 4. 5. 6.
403 Hydraulic system, Part 3 PPC accumulator
1
Gas plug Shell Poppet Holder Bladder Oil port
Specifications Gas capacity: 300 cc (for PPC)
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46
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Return oil filter
SEN06121-00
Return oil filter
1
For breaker
1. 2. 3. 4. 5.
Drain plug Filter Case Head cover Relief valve
PC200, 200LC, 220, 220LC-8M0
Specifications Rated pressure: 6.9 MPa {70 kg/cm2} Flow rate: 200 l/min Relief valve cracking pressure: 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2} Filter mesh size: 6 mm Filtering area: 4,570 cm2
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47
403 Hydraulic system, Part 3 Attachment circuit selector valve
SEN06121-00
Attachment circuit selector valve
ACC: ATT: P1: T: TS: V:
1.
1
To accumulator To attachment From attachment selector solenoid valve To hydraulic tank To hydraulic tank To control valve
Spool Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
2
Spool return spring
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48
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
132 x 29
114.5
834 N {85.0 kg}
—
667 N {68.0 kg}
Replace spring if damaged or deformed
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Attachment circuit selector valve
Function q When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. q When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected.
SEN06121-00
2. When breaker is installed q
q q
Operation
1. When attachment other than breaker is installed q q
Pilot pressure from the attachment circuit selector solenoid valve contracts spring (2), and spool (1) moves to the right to the stroke end. Ports (ATT) and (V) are shut off and ports (ATT) and (T) are interconnected. Pressurized oil returning from the breaker returns directly to the hydraulic tank through port (T) without passing through the control valve.
Spool (1) is pressed to the left by the force of spring (2). Ports (ATT) and (V) are interconnected and ports (ATT) and (T) are shut off. Attachment is thus interconnected to the control valve.
PC200, 200LC, 220, 220LC-8M0
10-403
49
SEN06121-00
Hydraulic cylinder
403 Hydraulic system, Part 3 Hydraulic cylinder
1
PC200-8M0 and PC200LC-8M0 Boom cylinder
Arm cylinder
Bucket cylinder
10-403
50
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Hydraulic cylinder
SEN06121-00
Unit: mm No.
1
Check item
Clearance between piston rod and bushing
Criteria Cylinder
Standard size
Boom
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
85
–0.036 –0.090
+0.222 +0.047
0.083 to 0.312
0.412
Arm
95
–0.036 –0.090
+0.222 +0.047
0.083 to 0.312
0.412
Bucket
80
–0.030 –0.076
+0.258 +0.048
0.078 to 0.334
0.434
Replace bushing
100 hours greasing maintenance specification Unit: mm No.
2
3
Check item
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
Criteria
Remedy
Boom
80
–0.030 –0.060
+0.457 +0.370
0.400 to 0.517
1.0
Arm
80
–0.030 –0.076
+0.457 +0.370
0.400 to 0.533
1.0
Bucket
70
–0.030 –0.060
+0.424 +0.350
0.380 to 0.484
1.0
Boom
70
–0.030 –0.060
+0.424 +0.350
0.380 to 0.484
1.0
Arm
80
–0.030 –0.076
+0.457 +0.370
0.400 to 0.533
1.0
Bucket
70
–0.030 –0.060
+0.424 +0.350
0.380 to 0.484
1.0
Replace pin and bushing
500 hours greasing maintenance specification Unit: mm No.
2
3
Check item
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
Criteria
Remedy
Boom
80
–0.030 –0.060
+0.190 +0.070
0.100 to 0.250
1.0
Arm
80
–0.030 –0.076
+0.190 +0.070
0.100 to 0.266
1.0
Bucket
70
–0.030 –0.060
+0.170 +0.070
0.100 to 0.230
1.0
Boom
70
–0.030 –0.060
+0.165 +0.045
0.075 to 0.225
1.0
Arm
80
–0.030 –0.076
+0.190 +0.070
0.100 to 0.266
1.0
Bucket
70
–0.030 –0.060
+0.165 +0.045
0.075 to 0.225
1.0
PC200, 200LC, 220, 220LC-8M0
Replace pin and bushing
10-403
51
SEN06121-00
403 Hydraulic system, Part 3 Hydraulic cylinder
PC220-8M0 and PC220LC-8M0 Boom cylinder
Arm cylinder
Bucket cylinder
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52
PC200, 200LC, 220, 220LC-8M0
403 Hydraulic system, Part 3 Hydraulic cylinder
SEN06121-00
Unit: mm No.
1
Check item
Clearance between piston rod and bushing
Criteria Cylinder
Standard size
Boom
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
90
–0.036 –0.090
+0.222 +0.047
0.083 to 0.312
0.437
Arm
100
–0.036 –0.090
+0.222 +0.047
0.083 to 0.312
0.447
Bucket
90
–0.030 –0.076
+0.258 +0.048
0.078 to 0.334
0.447
Replace bushing
100 hours greasing maintenance specification Unit: mm No.
2
3
Check item
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
Criteria
Remedy
Boom
80
–0.030 –0.060
+0.457 +0.370
0.400 to 0.517
1.0
Arm
80
–0.030 –0.076
+0.457 +0.370
0.400 to 0.533
1.0
Bucket
80
–0.030 –0.060
+0.457 +0.370
0.400 to 0.517
1.0
Boom
80
–0.030 –0.060
+0.457 +0.370
0.400 to 0.517
1.0
Arm
80
–0.030 –0.076
+0.457 +0.370
0.400 to 0.533
1.0
Bucket
80
–0.030 –0.060
+0.457 +0.370
0.400 to 0.517
1.0
Replace pin and bushing
500 hours greasing maintenance specification Unit: mm No.
2
3
Check item
Clearance between piston rod support shaft and bushing
Clearance between cylinder bottom support shaft and bushing
Criteria
Remedy
Boom
80
–0.030 –0.060
+0.190 +0.070
0.100 to 0.250
1.0
Arm
80
–0.030 –0.076
+0.190 +0.070
0.100 to 0.266
1.0
Bucket
80
–0.030 –0.060
+0.175 +0.075
0.100 to 0.246
1.0
Boom
80
–0.030 –0.060
+0.190 +0.070
0.075 to 0.225
1.0
Arm
80
–0.030 –0.076
+0.190 +0.070
0.100 to 0.266
1.0
Bucket
80
–0.030 –0.060
+0.190 +0.070
0.075 to 0.225
1.0
PC200, 200LC, 220, 220LC-8M0
Replace pin and bushing
10-403
53
SEN06121-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06121-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
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54
SEN06122-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
500 Work equipment Work equipment .............................................................................................................................................. 2 Dimensions of arm ........................................................................................................................................ 10 Dimensions of bucket.................................................................................................................................... 12
PC200, 200LC, 220, 220LC-8M0
10-500
1
500 Work equipment Work equipment
SEN06122-00
Work equipment a
1
The portion B in the figure shows L.H. boom cylinder.
10-500
2
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Work equipment
SEN06122-00
PC200-8M0, PC200LC-8M0 Unit: mm No.
1
Item
Criteria
Clearance between mounting pin and bushing of revolving frame and boom
Standard dimension
Tolerance
Remedy
Shaft
Hole
Standard clearance
Allowable clearance
90
–0.036 –0.071
+0.135 +0.074
0.110 to 0.206
1.0
2
Clearance between mounting pin and bushing of boom and arm
90
–0.036 –0.071
+0.137 +0.077
0.113 to 0.208
1.0
3
Clearance between mounting pin and bushing of arm and link
70
–0.030 –0.076
+0.158 +0.078
0.108 to 0.234
1.0
4
Clearance between mounting pin and bushing of arm and bucket
80
–0.030 –0.076
+0.137 +0.074
0.104 to 0.213
1.0
5
Clearance between mounting pin and bushing of link and bucket
80
–0.030 –0.076
+0.166 +0.086
0.116 to 0.242
1.0
6
Clearance between mounting pin and bushing of link and link
70
–0.030 –0.076
+0.154 +0.074
0.104 to 0.230
1.0
Width of boss
7
Connected part of revolving frame and boom
Standard dimension
Tolerance
Standard dimension
Tolerance
625.5
0 -0.5
632
+1 -2
8
Standard clearance 4.5 to 8.0
(*2)
L7: Adjust with combination of shims 2.0 mm (2), 2.5 mm (1), 3.0 mm (1) and 3.5 mm (1) R7: Insert the shim 2.0 mm (1)
(*3)
L7: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) R7: Insert the shim 1.5 mm (1) 96
(*1) Connected part of revolving frame and boom cylinder
Width of hinge
±1.2
99.3
+1.5 0
2.1 to 6.0
(*2)
L8: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2) R8: Insert the shim 1.0 mm (1)
(*3)
L8: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2) R8: Insert the shim 1.5 mm (1)
PC200, 200LC, 220, 220LC-8M0
Replace pin and bushing
Adjust with shims so that the clearance is 1.0 mm or below
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
10-500
3
500 Work equipment Work equipment
SEN06122-00
Unit: mm No.
Item
Criteria Width of boss
9
Standard dimension 695
+3 -1
2.6 to 11.4
±1.2
99.3
+1.5 0
2.1 to 6.0
L10: Insert the shim 1.5 mm (1) R10: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3)
Connected part of boom (*2) and arm
Connected part of arm cylinder and arm
Connected part of arm 13 and bucket cylinder
(*3)
L12: Insert the shim 1.5 mm (1) R12: –
10-500
4
+0.5 0
±1.2
109.3
+1.5 0
99.3
+1.5 0
2.1 to 6.0
L13: Insert the shim 1.5 mm (1) R13: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2)
–
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
0 to 3.0 –
±1.2
100.2
+0.5
2.5 to 5.9 –
0 -0.5
–
–
–
R15b: – L15b: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (4) 280
(*4)
±1
L15a: – R15a: – 280
(*3)
326.5
L14: – R14: – 96
–
±0.5
Adjust with shims so that the clearance is 1.0 mm or below
Replace shim
(*3)
325
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
2.1 to 6.0
(*2)
(*3)
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
4.5 to 5.5
L13: Insert the shim 1.0 mm (1) R13: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
0 -0.5
–
–
–
L16: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) R16: – 325
Connected part of arm and bucket
±1.2
L12: Insert the shim 1.0 mm (1) R12: Insert the shim 1.0 mm (1)
Connected part of bucket cylinder and link
Connected part of arm 16 and link
310
L11: Insert the shim 1.5 mm (1) R11: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2)
(*2)
Connected part of link and bucket
Connected part of link 15b and link
0 -0.5
L11: Insert the shim 2.0 mm (1) R11: Adjust with either shim 2.0 mm (1) or 2.5 mm (1) or 3.0 mm (1)
96
17
701
(*3)
106
15a
±2.4
Standard clearance
L10: Insert the shim 1.0 mm (1) R10: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3)
14
Tolerance
Connected part of boom (*2) and arm cylinder
305.5
12
Tolerance
L9-1: Insert the shims 0.8 mm (1) and 1.5 mm (2) L9-2: Insert the shim 1.5 mm (1) R9-1: Insert the shim 1.5 mm (1) R9-2: Insert the shim 1.5 mm (1) 96
11
Width of hinge Standard dimension
L9-1: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2) L9-2: Insert the shim 1.0 mm (1) R9-1: Insert the shim 1.0 mm (1) R9-2: Insert the shim 1.0 mm (1)
Connected part of boom and boom cylinder (*2)
(*3)
10
Remedy
0 -0.5
327.5
+2.2 -0.2
2.3 to 5.2
L17: – R17: Adjust with combination of shims 0.5 mm (4) and 1.0 mm (12)
Adjust with shims so that the clearance is 1.0 mm or below Adjust with shims so that the clearance is 1.0 mm or below Adjust with shims so that the clearance is between 0.5 mm and 1.0 mm
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Work equipment
SEN06122-00
*1: The criterion indicates the L.H. boom cylinder. The shim adjustment place for the R.H. boom cylinder is opposite to L.H. *2: Use plastic shim (with flange). *3: Use iron shim (without flange). *4: Use the separated iron shim. a A number written in ( ) after the shim thickness means the number of shims to prepare.
PC200, 200LC, 220, 220LC-8M0
10-500
5
500 Work equipment Work equipment
SEN06122-00
PC220-8M0, PC220LC-8M0 Unit: mm No.
1
Item
Criteria
Clearance between mounting pin and bushing of revolving frame and boom
Standard dimension
Tolerance
Remedy
Shaft
Hole
Standard clearance
Allowable clearance
100
–0.036 –0.071
+0.138 +0.078
0.114 to 0.209
1.0
2
Clearance between mounting pin and bushing of boom and arm
90
–0.036 –0.071
+0.137 +0.077
0.113 to 0.208
1.0
3
Clearance between mounting pin and bushing of arm and link
80
–0.030 –0.076
+0.166 +0.086
0.116 to 0.242
1.0
4
Clearance between mounting pin and bushing of arm and bucket
80
–0.030 –0.076
+0.137 +0.074
0.104 to 0.213
1.0
5
Clearance between mounting pin and bushing of link and bucket
80
–0.030 –0.076
+0.166 +0.086
0.116 to 0.242
1.0
6
Clearance between mounting pin and bushing of link and link
80
–0.030 –0.076
+0.166 +0.066
0.196 to 0.242
1.0
Width of boss
7
Connected part of revolving frame and boom
Standard dimension
Tolerance
Standard dimension
625.5
0 -0.5
632
8
Connected part of boom and boom cylinder
4.5 to 8.0
(*3)
L7: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) R7: Insert the shim 1.5 mm (1) ±1.2
99.3
+1.5 0
2.1 to 6.0
(*2)
L8: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2) R8: Insert the shim 1.0 mm (1)
(*3)
L8: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2) R8: Insert the shim 1.5 mm (1) ±2.9
701
+3 -1
(*2)
(*3)
L9-1: Insert the shims 0.8 mm (1) and 1.5 mm (2) L9-2: Insert the shim 1.5 mm (1) R9-1: Insert the shim 1.5 mm (1) R9-2: Insert the shim 1.5 mm (1) ±1.2
109.3
+1.5 0
2.1 to 6.0
Connected part of boom (*2) and arm cylinder
L10: Insert the shim 1.0 mm (1) R10: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3)
L10: Insert the shim 1.5 mm (1) R10: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) 305.5
Connected part of boom (*2) 11 and arm (*3)
10-500
6
0 -0.5
310
+0.5 0
Adjust with shims so that the clearance is 1.0 mm or below
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
2.1 to 11.9
L9-1: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2) L9-2: Insert the shim 1.0 mm (1) R9-1: Insert the shim 1.0 mm (1) R9-2: Insert the shim 1.0 mm (1)
106
10
+1 -2
Standard clearance
L7: Adjust with combination of shims 2.0 mm (2), 2.5 mm (1), 3.0 mm (1) and 3.5 mm (1) R7: Insert the shim 2.0 mm (1)
695
9
Tolerance
(*2)
96 (*1) Connected part of revolving frame and boom cylinder
Width of hinge
Replace pin and bushing
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
4.5 to 5.5
L11: Insert the shim 2.0 mm (1) R11: Adjust with either shim 2.0 mm (1) or 2.5 mm (1) or 3.0 mm (1) L11: Insert the shim 1.5 mm (1) R11: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2)
Adjust with shims so that the clearance is 1.0 mm or below
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Work equipment
SEN06122-00
Unit: mm No.
Item
Criteria Width of boss
12
Connected part of arm cylinder and arm
Standard dimension 106
13
14
15a
Connected part of arm and bucket cylinder
Connected part of arm and bucket
±1.2
109.3
+1.5 0
2.1 to 6.0
99.3
+1.5 0
2.1 to 6.0
L12: Insert the shim 1.5 mm (1) R12: – ±1.2
(*2)
L13: Insert the shim 1.0 mm (1) R13: Adjust with combination of shims 1.0 mm (1) and 2.0 mm (2)
(*3)
L13: Insert the shim 1.5 mm (1) R13: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (2) 325 –
L14: – R14: –
–
L15a: – R15a: –
96
280 (*3)
280 (*3)
(*4)
±0.5
326.5
±1
Replace shim
Adjust with shims so that the clearance is 1.0 mm (*3), 1.5 mm (*2) or below
0 to 3.0 –
±1.2
100.2
+0.5
2.5 to 5.9 –
0 -0.5
–
–
–
R15b: – L15b: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (4) 0 -0.5
–
–
–
L16: Adjust with combination of shims 0.8 mm (1) and 1.5 mm (3) R16: – 325
17
Tolerance
(*3)
Connected part of bucket cylinder and link
Connected part of arm 16 and link
Standard clearance
Tolerance
(*2)
Connected part of link and bucket
Connected part of link 15b and link
Width of hinge Standard dimension
L12: Insert the shim 1.0 mm (1) R12: Insert the shim 1.0 mm (1)
96
Remedy
0 -0.5
327.5
+2.2 -0.2
2.3 to 5.2
L17: – R17: Adjust with combination of shims 0.5 mm (4) and 1.0 mm (12)
Adjust with shims so that the clearance is 1.5 mm or below Adjust with shims so that the clearance is 1.5 mm or below Adjust with shims so that the clearance is between 0.5 mm and 1.0 mm
*1: The criterion indicates the L.H. boom cylinder. The shim adjustment place for the R.H. boom cylinder is opposite to L.H. *2: Use plastic shim (with flange). *3: Use iron shim (without flange). *4: Use the separated iron shim. a A number written in ( ) after the shim thickness means the number of shims to prepare.
PC200, 200LC, 220, 220LC-8M0
10-500
7
500 Work equipment Work equipment
SEN06122-00
Shims for work equipment Outline q There are two types of shims for work equipment, iron shim and plastic shim. q The shims for work equipment are inserted to adjust the clearance of each connected part of the work equipment so that it will be in the range of standard value.
Plastic shim q The plastic shim is mainly used for the machine which has the 500 hours greasing maintenance specification. q The purpose of using plastic shim is to reduce the lateral play of work equipment and to prevent the squeal or galling caused when iron connected parts are rubbed each other. q
When the plastic shim is used with the bushing which extends the greasing interval, it prevents the squeal caused by grease shortage and then it can extend the greasing interval.
q
The plastic shim is always inserted to every contact face of iron connected part to prevent the iron parts from rubbing each other.
a
Combined use of the plastic shim with the long greasing interval bushing and dust seal enables to extend the greasing interval to 500 hours. There are two types of plastic shim which has different flange shape, type A and type B. Whichever type can be used, however, always use only one type of plastic shim on one connected part and not mix different types.
Function Iron shim The iron shim is mainly used for the machine which has the 100 hours greasing maintenance specification. q The purpose of using iron shim is to reduce the lateral play of work equipment. a There are two types of iron shims, integrated shim and separated shim. q
a a
a
When replacing the plastic shim on one connected part, always use only one type and new plastic shim.
Type A
10-500
8
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Work equipment
Type B
PC200, 200LC, 220, 220LC-8M0
SEN06122-00
Shims to adjust play of bucket Outline q The separated iron shims are used for the connection of arm and bucket. q By adjusting the number of shims, play at connecting part can be adjusted . a Play can be reduced by deleting some shims when the play becomes large.
10-500
9
500 Work equipment Dimensions of arm
SEN06122-00
Dimensions of arm
10-500
10
1
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Dimensions of arm
SEN06122-00
Unit: mm No.
18
19
PC200, 200LC-8M0
PC220, 220LC-8M0
Standard size
Tolerance
Standard size
Tolerance
1
80
+0.1 +0.0
80
+0.1 +0.0
2
109.3
+1.5 +0.0
109.3
+1.5 +0.0
3
305.5
–0.5 –0.5
305.5
–0.5 –0.5
4
90
+0.054 +0.000
90
+0.054 +0.000
5
402.1
±1
423.9
±1
6
187.2
±0.5
206.1
±0.5
7
829.1
±1
918.6
±1
8
2,919
—
3,037
—
9
2,630.5
±1
2,562.6
±1
10
410
±1
465
±1
11
640
±0.2
585
±0.2
12
600
±0.5
600
±0.5
13
458.1
—
446.3
—
14
1,486
—
1,575.5
—
15
80
+0.1 +0.0
80
+0.1 +0.0
16
325
±0.5
325
±0.5
17
80
+0.1 +0.0
80
+0.1 +0.0
Arm itself
311
–0.5 –0.5
311
–0.5 –0.5
When press fitting bushing
325
—
325
—
Min.
1,680
—
1,605
—
Max.
2,800
—
2,625
—
PC200, 200LC, 220, 220LC-8M0
10-500
11
500 Work equipment Dimensions of bucket
SEN06122-00
Dimensions of bucket
10-500
12
1
PC200, 200LC, 220, 220LC-8M0
500 Work equipment Dimensions of bucket
SEN06122-00
Unit: mm No.
PC200, 200LC-8M0
PC220, 220LC-8M0
Standard size
Tolerance
Standard size
Tolerance
457.6
±0.5
442.4
±0.5
2
22
±0.5
59.2
±0.5
3
92° 45’
—
97° 37’
—
4
458.1
—
446.3
—
5
1,477.3
—
1,540.3
—
6
158.6
—
185.6
—
7
—
—
—
—
8
15° 54’
—
7° 48’
—
9
80
+0.1 +0.1
80
+0.1 +0.1
10
326.5
±1
326.5
±1
11
56
—
59
—
12
106
—
104
—
1
13
470
—
470
—
14
23.5
—
23.5
—
15
140
—
140
—
16
190
—
190
—
17
133.2
—
156.3
—
18
131.6
—
133.1
—
19
107
—
107
—
20
85
—
82
—
21
348.5
+2 +0
348.5
+2 +0
22
38
—
37
—
PC200, 200LC, 220, 220LC-8M0
10-500
13
SEN06122-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06122-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-500
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SEN06123-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
10 Structure, function and maintenance standard
1
600 Electrical system Engine control ...................................................................................................................................... 2 Electrical control system .................................................................................................................... 12 Machine monitor system .................................................................................................................... 35 Sensor................................................................................................................................................ 56 KOMTRAX system ............................................................................................................................. 60
PC200, 200LC, 220, 220LC-8M0
10-600
1
600 Electrical system Engine control
SEN06123-00
Engine control
1
Operation of system
1
Starting engine q When the starting switch is turned to the START position, the starting signal flows to the starting motor. Then, the starting motor turns to start the engine. When it happens, the engine controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control The fuel control dial sends a signal voltage corresponding to the rotation angle to the engine controller.
q
The engine controller sends a driving signal to the supply pump depending on the signal voltage to control the fuel injection pump, and eventually controls the engine speed.
Stopping engine When detecting that the starting switch is set to the “STOP” position, the engine controller cuts the signal of the supply pump drive solenoid to stop the engine.
q
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2
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Engine control
Component
SEN06123-00
1
Fuel control dial
1. 2. 3.
Knob Dial Spring
PC200, 200LC, 220, 220LC-8M0
4. 5. 6.
Ball Potentiometer Connector
10-600
3
SEN06123-00
600 Electrical system Engine control
Function q The fuel control dial is installed under the machine monitor. q Turning knob (1) rotates the shaft of potentiometer (5). q The rotation of the shaft changes the resistance of the variable resistor in potentiometer (5), sending any throttle signal to the engine controller. q The hatched area in the graph is the abnormality detection area. When the throttle voltage is within this area, the engine is running at low idle.
10-600
4
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Engine control
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
10-600
5
SEN06123-00
600 Electrical system Engine control
Engine controller
10-600
6
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Engine control
Input and output signals q The following is the list of the symbols used for signal classification in the input/output signal table. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication CN-CE01 Input/ output 1 NC (*) – 2 Electric power supply for IMA D 3 Ambient pressure sensor B 4 NC (*) – 5 NC (*) – 6 CAN (–) E 7 NC (*) – 8 CAN (+) E 9 NC (*) – 10 NC (*) – 11 NC (*) – 12 NC (*) – 13 NC (*) – 14 Water-in-fuel B 15 Coolant temperature sensor B 16 5V electric power supply for sensor A 17 Oil pressure switch B 18 NC (*) – 19 NC (*) – 20 NC (*) – 21 NC (*) – 22 NC (*) – 23 Boost temperature sensor B 24 NC (*) – 25 Common rail pressure sensor B 26 Bkup sensor (+) B 27 NE sensor (+) B 28 NC (*) – 29 NC (*) – 30 NC (*) – 31 NC (*) – 32 IMA return C 33 5V electric power supply for sensor A 34 NC (*) – 35 NC (*) – 36 NC (*) – 37 5V electric power supply for sensor A 38 GND C 39 NC (*) – 40 NC (*) – 41 NC (*) – *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
CN-CE01 Input/ output 42 NC (*) – 43 NC (*) – 44 Boost pressure sensor B 45 Injector #1 (+) D 46 Injector #5 (+) D 47 G sensor (–) C 48 Ne sensor (–) C 49 NC (*) – 50 NC (*) – 51 Injector #2 (–) C 52 Injector #3 (–) C 53 Injector #1 (–) C 54 Injector #2 (+) D 55 Injector #3 (+) D 56 Injector #4 (+) D 57 Injector #6 (+) D 58 Injector #4 (–) C 59 Injector #6 (–) C 60 Injector #5 (–) C *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
CN-CE02 Input/ output 1 NC (*) – 2 NC (*) – 3 NC (*) – 4 NC (*) – 5 NC (*) – 6 NC (*) – 7 NC (*) – 8 NC (*) – 9 Fuel control dial (+) B 10 NC (*) – 11 NC (*) – 12 NC (*) – 13 NC (*) – 14 NC (*) – 15 NC (*) – 16 NC (*) – 17 NC (*) – 18 NC (*) – 19 NC (*) – 20 NC (*) – 21 NC (*) – 22 Fuel control dial (+5V) A 23 Fuel control dial (–) C 24 NC (*) – 25 NC (*) – 26 NC (*) – *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
10-600
7
600 Electrical system Engine control
SEN06123-00
CN-CE02 Pin No.
Signal name
27 28 29 30 31 32 33 34 35 36 37 38 39
Input/ output – – – – – – C – – – – – B
NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) GND NC (*) NC (*) NC (*) NC (*) NC (*) Key switch (ACC) Electrical intake air heater relay 40 D drive 41 NC (*) – Electrical intake air heater relay 42 C return 43 NC (*) – 44 NC (*) – 45 NC (*) – 46 CAN(+) E 47 CAN(–) E 48 NC (*) – 49 PWM OUTPUT D 50 NC (*) – *: Never connect to NC or malfunctions or failures will occur. CN-CE03 Pin No.
Signal name
1 2
Input/ output C –
GND NC (*) Electric power supply (+24V con3 A stantly) 4 NC (*) – *: Never connect to NC or malfunctions or failures will occur.
10-600
8
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Engine control
SEN06123-00
Coolant temperature sensor
1. 2. 3.
Sensor O-ring Connector
Oil pressure switch
1. 2. 3.
Connector Sensor O-ring
PC200, 200LC, 220, 220LC-8M0
10-600
9
SEN06123-00
600 Electrical system Engine control
Rotation sensor
1. 2. 3.
Connector Sensor O-ring
Boost pressure and temperature sensor
1. 2. 3.
Connector Sensor O-ring
10-600
10
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Engine control
SEN06123-00
WIF (water-in-fuel detection) sensor
1. 2. 3. 4.
Connector Tube Sensor O-ring
Engine oil level sensor
1. 2. 3. 4.
Connector Bracket Float Switch
PC200, 200LC, 220, 220LC-8M0
10-600
11
SEN06123-00
Electrical control system
600 Electrical system Electrical control system
1
Machine control system diagram
10-600
12
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
10-600
13
SEN06123-00
600 Electrical system Electrical control system
1. Engine and pump composite control function
10-600
14
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
Function q This function allows the operator to select engine torque (T) and pump absorption torque d ep en d in g o n t he wo r k c o nt en ts o f th e machine. Five modes of P, E, L, ATT, and B (three modes of P, E, and L for machines with “No ATT” specified) are specified as working modes. To select a working mode, use the working mode selector switch of the machine monitor. q The pump controller controls the pump so that it can absorb all the torque at the output points of the engine depending on the pump absorption torque specified for each mode, rotation set by the fuel control dial, and actual engine speed.
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
1) Control method in each mode P mode, E mode, and ATT mode q Matching point:
q
q
Mode
Matching point
P and ATT (Work)
99.2 kW/1,800 rpm {135 HP/1,800 rpm}
E
86.8 kW/1,800 rpm {118 HP/1,800 rpm}
In P, E, or ATT mode, engine speed is always controlled so that it is kept around the matching point specified for each mode. If the pump load increases and the pressure rises, engine speed (N) lowers. If it happens, the engine speed is increased to around the matching point, allowing the pump controller to decrease pump discharge (Q). On the contrary, the pump load decreases and the pressure lowers, the pump controller continues to increase pump discharge until the engine speed reaches around the matching point.
10-600
15
600 Electrical system Electrical control system
SEN06123-00
B mode and L mode
q q
q
Mode
B
L
Partial output point
75%
70%
Mode
Matching point
B
80.9 kW/1,780 rpm {108 HP/1,780 rpm}
L
73.6 kW/1,800 rpm {99 HP/1,800 rpm}
In B or L mode, engine output is controlled to a constant level. The controller controls the pump absorption torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve. The controller controls pump discharge (Q) so that the engine torque can be kept at a constant level along the equal engine horsepower curve.
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16
2) q q
q
Function to control pump during travel Traveling the machine in P or ATT mode increases engine speed (N). Traveling the machine in E or B mode leaves the working mode unchanged, but raises the pump absorption torque and engine speed (N) to values same as those in P mode. If the machine travels in L mode, the working mode and engine speed (N) do not change, but the pump absorption torque is increased.
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
3) q
SEN06123-00
Function to control when emergency pump drive switch is turned on Even if any abnormality occurs in the controller or sensor, setting emergency pump drive switch (1) to the “ON” position activates the machine with an absorption torque approximately equivalent to that in E mode. In this case, a constant current flows from the battery to the EPC valve for PC and therefore, the oil pressure is sensed by only the EPC valve for PC.
PC200, 200LC, 220, 220LC-8M0
10-600
17
SEN06123-00
600 Electrical system Electrical control system
2. Pump and valve control function
Function q The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
10-600
18
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
1) q
q
2) q
LS control function Depending on the operation condition of the actuator, this function changes the pressure output from the LS-EPC valve to LS valve to change the change point (LS set differential pressure (DLS)) of the pump discharge in the LS valve. By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved.
SEN06123-00
3) q
2-stage relief function The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 37.2 MPa {380 kg/cm2}. By this operation, the hydraulic force is increased further.
Operating condition for turning on 2stage relief function • During travel • When swing lock switch is turned to the ON position • When boom is lowered • When power maximizing function is turned on • When L mode is operated
Relief pressure 34.8 MPa {355 kg/cm2} O 37.2 MPa {380 kg/cm2}
Cut-off function This function increases PC-EPC current (J) to reduce the flow rate in the relief state, improving fuel consumption. Operating condition for turning on cut-off function
When the average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2} with the power maximizing function off. The cut-off function does not work, however, while the machine is travelling in A mode, swing lock switch is in the “ON” position.
PC200, 200LC, 220, 220LC-8M0
10-600
19
600 Electrical system Electrical control system
SEN06123-00
3. Power maximizing function
Function The power maximizing function allows the operator to increases power for a certain time by operating the left knob switch. q This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock). q Pressing the L.H. knob switch in P, E, or ATT mode increases a hydraulic force by approximately 7% and horsepower by approximately 3%, increasing a digging force. At this time, each function is automatically set as shown below. q
Function
Matching at rated output point
2-stage relief function
34.8 MPa {355 kg/cm2} O 37.2 MPa {380 kg/cm2}
10-600
20
These settings are automatically reset after 8.5 seconds when the switch is pressed.
Setting
Engine and pump control
Software cut-off function
q
Cancel
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
SEN06123-00
4. Auto-deceleration function
Function q The auto-deceleration function automatically reduces the engine speed to its medium speed range when the all control levers are set in NEUTRAL while waiting for a dump truck or work to reduce the fuel consumption and noise. q If any lever is operated, the engine speed instantly returns to the speed set with the fuel control dial. Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec. during operation at a engine speed above a decelerator operation level (approximately 1,050 rpm), this function lowers the engine speed to the deceleration operation level (approximately 1,050 rpm) and keeps it until you operate any lever. When any control lever is operated q If you operate any control lever while the engine speed is kept at the deceleration operation level, the engine speed instantly rises to the level set with the fuel control dial.
PC200, 200LC, 220, 220LC-8M0
10-600
21
SEN06123-00
600 Electrical system Electrical control system
5. Auto-warm-up and overheat prevention function
Function The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts.
q
The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during operation to protect the engine from overheating.
10-600
22
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
1) q
SEN06123-00
Auto-warm-up function After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All of following conditions)
Coolant temperature: Below 30°C Engine speed: Max. 1,200 rpm
Engine speed: 1,200 rpm
Resetting condition (Any one of following conditions) Auto Manual
2) q
q
Operated
Coolant temperature: Min. 30°C Auto-warm-up operation time: Min. 10 minutes Fuel control dial: Kept at 70% of full level or above for 3 sec. or longer
Reset
Engine speed: Any level
Overheat prevention function This function reduces the pump load and engine speed when coolant or hydraulic oil temperature is too high to protect the engine and hydraulic components from overheating. This function starts when coolant temperature reaches 100°C or hydraulic oil temperature reaches 95°C. Operating condition
Operation/Remedy
Coolant temperature: Min. 105°C or Hydraulic oil temperature: Min. 105°C
Working mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Operating condition
Operation/Remedy
Coolant temperature: Min. 102°C Hydraulic oil temperature: Min. 102°C
Working mode: P, E, B, or L mode Engine speed: Kept as is. Monitor alarm lamp: Lights up Reduce pump discharge.
Operating condition
Operation/Remedy
Coolant temperature: Min. 100°C or Hydraulic oil temperature: Min. 100°C
Working mode: P or E mode Engine speed: Kept as is. Reduce pump discharge.
Operating condition
Operation/Remedy
or
Hydraulic oil temperature: Min. 95°C
Working mode: Travel Engine speed: Kept as is. Lower travel speed.
PC200, 200LC, 220, 220LC-8M0
Resetting condition Coolant temperature, hydraulic oil temperature: Below 105°C Fuel control dial: Return to low idle position once. Under above condition, controller is set to condition before operation of function. (Manual reset)
Resetting condition Coolant temperature, hydraulic oil temperature: Below 102°C Under above condition, controller is set to condition before operation of function. (Automatic reset)
Resetting condition Coolant temperature, hydraulic oil temperature: Below 100°C Under above condition, controller is set to condition before operation of function. (Automatic reset)
Resetting condition Hydraulic oil temperature: Below 95°C Under above condition, controller is set to condition before operation of function. (Automatic reset)
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23
SEN06123-00
600 Electrical system Electrical control system
6. Swing control function
Function The swing lock and swing holding brake function are provided as a swing control function.
10-600
24
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
1) q
q
SEN06123-00
Swing lock and swing holding brake function The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. Operation of swing lock switch and swing lock/ holding brake
Lock switch
OFF
Lock lamp
OFF
ON
ON
Function
2) q
Quick hydraulic oil warm-up function when swing lock switch is turned on If swing lock switch (2) is turned on, the pump cut-off function is cancelled and the relief pressure rises from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380 kg/cm2}. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.
Operation
If swing lever is set in neutral, swing brake operates Swing in about 5 sec. If swing holding lever is operated, brake is brake released and machine can swing freely.
Swing lock
Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.
Swing holding brake cancel switch q If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake cancel switch. Swing ON holding (when controller has brake cancel trouble) switch Swing lock switch
ON
OFF
OFF (when controller is normaly) ON
OFF
Swing Swing Swing Swing holding Swing brake lock is lock is lock is brake is turned on. canceled. turned on. turned on. q
q
Even if the swing holding brake cancel switch is turned on, if the swing lock switch is placed in the ON position, the swing brake is not released. If the swing lock is reset, only the hydraulic brake is applied by the safety valve. Note that if swinging is stopped on a slope, the upper structure may swing by its gravity.
PC200, 200LC, 220, 220LC-8M0
10-600
25
SEN06123-00
600 Electrical system Electrical control system
7. Travel control function
Function The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or allowing operator to change travel speed automatically or manually.
q
10-600
26
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
1) q
2)
a
SEN06123-00
Pump control function during travel For details, see "Engine and pump composite control function". Travel speed change function 1] Manual change with travel speed selector switch Switching the travel speed selector switch from Lo to Mi and Hi causes the pump controller to control the pump capacity and motor capacity at each gear speed as shown below, switching the travel speed. PC200-8M0, PC200LC-8M0
Travel speed switch
Lo (Low speed)
Mi (Medium speed)
Hi (High speed)
Pump capacity (%)
66
89
100
Max.
Max.
Min.
3.0
4.1
5.5
Motor capacity Travel speed (km/h)
a
PC200-8M0, PC200LC-8M0
PC220-8M0, PC220LC-8M0
PC220-8M0, PC220LC-8M0
Travel speed switch
Lo (Low speed)
Mi (Medium speed)
Hi (High speed)
Pump capacity (%)
77
71
100
Max.
Min.
Min.
3.0
4.1
5.5
Motor capacity Travel speed (km/h)
2]
3]
Automatic change by engine speed If you adjust the engine speed to 1,500 rpm or less with the fuel control dial, q The travel speed does not switch to Hi when the machine is traveling in Mi. q The travel speed automatically changes to Mi when the machine is travelling in Hi. Automatic change by pump discharge pressure If the travel pressure is kept to 24.5 MPa {250 kg/cm 2 } at least 0.5 sec. due to increased load during traveling in Hi on an uphill, the travel motor capacity automatically switches to the medium speed (Mi) (the travel speed switch stays at Hi). If the machine starts traveling on level ground or downhill during operation of the above mentioned function and the travel pressure goes below 14.7 MPa {150 kg/cm2} and continues such the condition at least 0.5 sec., the travel motor capacity will automatically change, switching the travel speed switch to Hi again.
PC200, 200LC, 220, 220LC-8M0
3)
Travel junction function q The controller detects the pilot pressure when travel cotrol lever is operated, and j udges the operator ’s intention, the straight travel or turning operation. q For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow rate between the right and left to be equal, to prevent travel deveation and improve straight-travel ability. q For turning operation, the signal to the travel junction solenoid valve is shut off. This separates the pump flow rate to the right and left travel motors from each other and improves the traction while turning.
10-600
27
600 Electrical system Electrical control system
SEN06123-00
8. Attachment flow control circuit selector function (if equipped)
Function This function is available only with attachment specification. q The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully. 2) Attachment operation switches depending on the working mode as shown below. q
10-600
Working mode
Attachment operation
ATT
Double-acting
B
Single-acting
28
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
SEN06123-00
9. System component parts 1) PPC oil pressure switch
1. 2. 3.
Plug Switch Connector
Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) pressure: 0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2} Function q The attachment PPC valve has a PPC oil pressure switch. q This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.
PC200, 200LC, 220, 220LC-8M0
10-600
29
600 Electrical system Electrical control system
SEN06123-00
2)
Oil pressure sensor
1. 2.
Sensor Connector
Function The junction block has 8 PPC oil pressure sensors. The travel PPC valve has 4 PPC oil pressure sensors. q This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.
q
The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below.
q
The amplifier magnifies output voltage (E) and transmits it to the pump controller.
q
Operation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part, the diaphragm is deformed. q The deformation in the diaphragm causes the resistance of the gauge to change. This causes a change in the output voltage, which is transmitted to the amplifier (voltage amplifier).
10-600
30
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
3)
Pump pressure sensor
1. 2.
Sensor Connector
SEN06123-00
Operation q The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below.
PC200, 200LC, 220, 220LC-8M0
10-600
31
SEN06123-00
4)
600 Electrical system Electrical control system
Pump controller
10-600
32
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Electrical control system
SEN06123-00
Input and output signals CN-C01 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Signal name Continuous power supply Continuous power supplyGND Washer motor power Continuous power supply Continuous power supply GND NC (*) NC (*) Power (+5 V) Power (+5 V) NC (*) NC (*) NC (*) NC (*) Boom lower pressure sensor Arm out pressure sensor Swing (L) pressure sensor Arm in pressure sensor Analog GND Swing lock NC (*) Machine select 2 NC (*) NC (*) Key SW (ACC) NC (*) NC (*) NC (*) NC (*) Hydraulic oil temperature NC (*) NC (*) NC (*) NC (*) Bucket dump pressure sensor Back of L.H. travel oil pressure sensor Back of R.H. travel oil pressure sensor NC (*) Swing brake cancel switch Machine select 5 Machine select 1 Knob SW NC (*) Key SW (ACC) NC (*) CAN_H Analog GND NC (*) NC (*) F pump pressure sensor NC (*)
Input/Output Input Input Output Input Input — — Output Output — — — — Input Input Input Input Input Input — Input — — Input — — — — Input — — — — Input
CN-C01 Pin No. Signal name 51 NC (*) 52 NC (*) 53 Boom raise pressure sensor Front of L.H. travel oil pressure 54 sensor Front of R.H. travel oil pressure 55 sensor 56 Wiper (W) 57 Window limit SW 58 Machine select 4 59 NC (*) 60 Key SW (C) 61 NC (*) 62 External drive signal 63 NC (*) 64 CAN_L 65 NC (*) 66 NC (*) 67 NC (*) 68 R pump pressure sensor 69 NC (*) 70 NC (*) 71 NC (*) 72 Swing (R) pressure sensor 73 Bucket digging pressure sensor 74 NC (*) 75 Wiper (P) 76 Service pressure SW 77 Machine select 3 78 NC (*) 79 Key SW (ACC) 80 NC (*) 81 NC (*)
Input/Output — — Input Input Input Input Input Input — Input — Input — Input/Output — — — Input — Input — Input Input — Input Input Input — Input — —
*: Never connect to NC or malfunctions or failures will occur.
Input Input — Input Input Input Input — Input — Input/Output Input — — Input —
*: Never connect to NC or malfunctions or failures will occur.
PC200, 200LC, 220, 220LC-8M0
10-600
33
600 Electrical system Electrical control system
SEN06123-00
CN-C02 Pin No. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121
Signal name NC (*) NC (*) NC (*) Variable back pressure SOL Attachment selector SOL Travel speed SOL LS-EPC Merge-divider LS EPC NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) PC-EPC (F) Service current EPC NC (*) NC (*) NC (*) Swing holding brake SOL NC (*) NC (*) PC-EPC (R) NC (*) NC (*) Travel alarm Battery relay 2-stage relief SOL Travel junction SOL NC (*) Merge-divider main EPC NC (*) Wiper motor (–) Solenoid GND Solenoid power Solenoid GND Solenoid power Wiper motor (+) Solenoid GND Solenoid power
Input/Output — — — Output Output Output Output Output — — — — — — Output Output — — — Output — — Output — — Output Output Output Output — Output — Output Input Input Input Input Output Input Input
*: Never connect to NC or malfunctions or failures will occur.
10-600
34
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Machine monitor system
1. 2. 3. 4. 5. 6. 7. 8. 9.
Machine monitor Battery Pump controller Engine controller
Input and output signals a. Power supply b. CAN signal c. Sensor and switch signals d. Drive signal e. Camera signal
PC200, 200LC, 220, 220LC-8M0
1
Function q The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions by using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The information displayed on the machine monitor falls into the following types: 1. Alarm when the machine has trouble 2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.) 3. Display of camera image q The switches on the machine monitor have an operating function to control the machine.
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35
600 Electrical system Machine monitor system
SEN06123-00
Machine monitor
Function q
The machine monitor has monitor display function, mode selection function and switch function for electrical parts etc. Also it has an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of a display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.
1
q
q
When the engine is started, the battery voltage may drop suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor display may go off for a moment. However, this phenomenon is not a failure. Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. Blue bright spots can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.)
Precautions on the machine monitor display One of the features of liquid crystal display panels is that there may be black spots (spots that do not light up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this is not a failure or a defect. Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal.
q
10-600
36
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Input and output signals 070-18P [CN-CM01] Pin No. 1
Signal name
Input/Output signal
Continuous power supply (24 V)
Input
2
Continuous power supply (24 V)
Input
3
GND (continuous power supply)
—
4
GND (continuous power supply)
5
External start signal
— Input
6
Starting motor cut-off relay (for personal code)
7
NC (*)
Output —
8
System operating lamp
9
Lamp switch
Input/Output
10
Starting switch (ACC)
Input
11
Starting switch (C)
Input
12
Preheating
Input
13
Engine shutdown secondary switch
Input
Input
14
GND (body signal)
15
Fuel level sensor
Input
—
16
Charge level (Alternator R terminal)
Input
17
NC (*)
—
18
NC (*)
—
*: Never connect these pins. Malfunctions or failures may occur. 070-12P [CN-CM02] Pin No.
Signal name
1
NC (*)
2
Engine oil level sensor
Input/Output signal — Input
3
Radiator coolant level sensor
Input
4
Air cleaner clogging sensor
Input Input
5
Swing lock switch
6
NC (*)
7
CAN (C) terminating resistor terminal
8
CAN (C)_H
Input/Output
9
CAN (C)_L
Input/Output
10
NC (*)
—
11
NC (*)
—
12
NC (*)
—
— —
*: Never connect these pins. Malfunctions or failures may occur. 070-20P [CN-CM03] Pin No.
Signal name
Input/Output signal
1
NC (*)
—
2
NC (*)
—
3
NC (*)
—
4
NC (*)
—
5
NC (*)
—
6
NC (*)
—
7
NC (*)
—
8
NC (*)
—
PC200, 200LC, 220, 220LC-8M0
10-600
37
600 Electrical system Machine monitor system
SEN06123-00
070-20P [CN-CM03] Pin No.
Signal name
Input/Output signal
9
NC (*)
—
10
NC (*)
—
11
NC (*)
—
12
NC (*)
—
13
NC (*)
—
14
NC (*)
—
15
NC (*)
—
16
NC (*)
—
17
NC (*)
—
18
NC (*)
—
19
NC (*)
—
20
NC (*)
—
*: Never connect these pins. Malfunctions or failures may occur. 070-8P [CN-CM04] Pin No.
10-600
Signal name
Input/Output signal
1
Camera power supply (8 V)
2
Camera NTSC signal 1
Input
3
Camera NTSC signal 2
Input
4
Camera NTSC signal 3
Input
5
GND (Camera power supply)
6
Switching camera 2 to original/mirror image
Output
7
Switching camera 3 to original/mirror image
Output
8
Shield GND
38
Output
—
—
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
10-600
39
600 Electrical system Machine monitor system
SEN06123-00
Display
A: Standard screen B: Check before starting screen C: Maintenance due time warning screen D: Warning screen E: Guidance screen F: Camera image screen a Camera image screen (F) shown in the figure is when two or more cameras are installed 1. 2. 3. 4. 5. 6.
Message monitor Air conditioner monitor Wiper monitor Swing lock monitor Engine preheating monitor Service meter
10-600
40
1
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Auto-deceleration monitor Working mode monitor Travel speed monitor Fuel level gauge Fuel level monitor Eco gauge Fuel consumption gauge Hydraulic oil temperature monitor Hydraulic oil temperature gauge Engine coolant temperature monitor Engine coolant temperature gauge Radiator coolant level monitor Charge level monitor Engine oil pressure monitor Engine oil level monitor PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
22. 23. 24. 25. 26. 27. 28.
SEN06123-00
Air cleaner clogging monitor Water separator monitor Clock Maintenance due time warning monitor System status monitor Action level monitor ECO guidance
PC200, 200LC, 220, 220LC-8M0
10-600
41
600 Electrical system Machine monitor system
SEN06123-00
Gauge Gauge
Display item
(*1) Engine coolant temperature gauge
(*1) Hydraulic oil temperature gauge
Description Range
Temperature (°C)
Background color
W1
105
Red
W2
102
Red
W3
100
Blue
W4
85
Blue
W5
60
Blue
W6
30
White
Range
Temperature (°C)
Background color
H1
105
Red
H2
102
Red
H3
100
Blue
H4
85
Blue
H5
40
Blue
H6
20
White
Quantity (l)
Background color
Range
(*1) Fuel level gauge
Remarks
F1
289
Blue
F2
244.5
Blue
F3
200
Blue
F4
100
Blue
F5
60
Blue
F6
41 Segment
• Indicates corresponding temperature range. • Alarm buzzer sounds when the temperature is 105°C or higher. • If the monitor background appears white, warm-up the engine.
• Indicates corresponding temperature range. • Alarm buzzer sounds when the temperature is 105°C or higher. • If the monitor background appears white, warm up the hydraulic components.
• Indicates corresponding remaining fuel level.
Red Load level
Green
1 to 8
Light to medium
Orange
9, 10
Heavy
(*2) Eco gauge
• Indicates instantaneous fuel consumption (average of fuel consumption per 3 minutes) in 10 steps. (It is displayed when the user menu’s “ECO guidance” o Display setting o “Eco gauge display” is set.)
Service meter
00000.0 h - 99999.9 h
• Indicates accumulated engine operating hours (the alternator is running). (F4 switch changes it to clock display.)
Clock
• 12-hour display (AM/PM) • 24-hour display
• Displays time. (F4 switch changes it to service meter display.)
• 1 day • Split • Not installed
• Indicates average fuel consumption. (Display is switched when the user menu’s “ECO guidance” o “Display setting” o “Fuel gauge display” are specified.)
(*2) Fuel consumption gauge
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer disappears. *2: Display item is switched when the user menu’s “ECO guidance” o “Display setting” are specified. 10-600
42
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Caution monitor Description Symbol
Display item
(*1) Engine coolant temperature
(*1) Hydraulic oil temperature
(*1) Fuel level
(*1) Radiator coolant level
(*1) Battery charge condition
(*1) Engine oil pressure
Range
Monitor display (Background color)
Action level monitor
Min. 102°C
Lights up (Red)
L02
Min. 30°C or below 102°C
Lights up (Blue)
—
Below 30°C
Lights up (White)
—
Min. 102°C
Lights up (Red)
L02
Min. 20°C or below 102°C
Lights up (Blue)
—
Below 20°C
Lights up (White)
—
Below 41 l
Lights up (Red)
—
Min. 41 l
Lights up (Blue)
—
When abnormal (When below specified level)
Lights up (Yellow)
(*3) L01
When normal
Lights off
—
When charge is defective (Charge voltage < battery voltage)
Lights up (Red)
L03
When normal
Lights off
—
When abnormal Lights up (Red) (When below specified level)
L03
When normal
Lights off
—
(*1) Eng. oil level
When abnormal (When below specified level)
Lights up (Yellow)
(*3) L01
When normal
Lights off
—
(*1) Clogging of air cleaner
When abnormal (When above specified level)
Lights up (Yellow)
(*3) L01
When normal
Lights off
—
PC200, 200LC, 220, 220LC-8M0
Remarks
• Background color changes depending on the temperature detected. • Alarm buzzer sounds when the temperature is 105°C or higher. • If the monitor background appears white, warm-up the engine. • Background color changes depending on the temperature detected. • Alarm buzzer sounds when the temperature is 105°C or higher. • If the monitor background appears white, warm up the hydraulic components. • Background color changes depending on the remaining fuel level.
• When failure is detected with the engine stopped, the monitor lights up on the screen.
• The monitor lights up on the screen and alarm buzzer sounds when failure is detected while the engine running. • The monitor lights up on the screen and alarm buzzer sounds when failure is detected while the engine running. • When failure is detected with the engine stopped, the monitor lights up on the screen. • When failure is detected with the engine running, the monitor lights up on the screen.
10-600
43
600 Electrical system Machine monitor system
SEN06123-00
Description Symbol
Display item
(*1) Water separator
Maintenance interval warning
System status
State of engine system
Range
44
Action level monitor
When abnormal (There is water collected Lights up (Red) above the specified amount.)
—
When normal
—
Lights off
Remarks
• When failure is detected with the engine running, the monitor lights up on the screen.
When exceeding maintenance interval
Lights up (Red)
—
(*2) When exceeding maintenance notifying time
Lights up (Yellow)
—
When action level “L04” or “L03” is detected
Lights up (Red)
L04 and L03
When action level “L01” is detected
Lights up (Yellow)
(*3) L01
When action level “L04” or “L03” is detected
Lights up (Red)
L04 and L03
When action level “L01” is detected
Lights up (Yellow)
(*3) L01
Lights up (Red)
L04 and L03
Lights up (Yellow)
(*3) L01
When action level “L04” or “L03” is State of hydraulic detected system When action level “L01” is detected
10-600
Monitor display (Background color)
• The display changes depending on the time to/ after the maintenance. • After the starting switch is turned to ON position , the monitor turns on if the monitor light-up conditions are met, and then goes out in 30 seconds. • When failure is detected in the machine system, the monitor lights up. • When the background color is red, the alarm buzzer sounds. • When failure is detected in the engine system, the monitor lights up. • When the background color is red, the alarm buzzer sounds. • When failure is detected in the hydraulic system, the monitor lights up. • When the background color is red, the alarm buzzer sounds.
Engine overspeed
Engine overspeed is detected
Lights up (Red)
L02
• The monitor lights up and alarm buzzer sounds when engine overspeed is detected.
Sate of air conditioner system
When air conditioner is abnormal
Lights up (Yellow)
(*3) L01
• When failure is detected in the air conditioner system, the monitor lights up.
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Description Symbol
Display item
Action level
Monitor display (Background color)
Action level monitor
When action level “L04” is detected
Lights up (Red)
L04
When action level “L03” is detected
Lights up (Red)
L03
When action level “L02” is detected
Lights up (Red)
L02
When action level “L01” is detected
Lights up (Yellow)
(*3) L01
Range
Remarks
• When failure is detected on the machine, the monitor lights up. When the background color is red, the alarm buzzer sounds.
*1: It is included in the check before starting items. After the staring switch is turned to “ON” position, the monitor turns on for two seconds, and changes to the standard screen if no failure is found. *2: The notifying time is changeable from the items in “Maintenance mode display setting” of the service mode. *3: Monitor goes out after lighting up for 2 seconds.
PC200, 200LC, 220, 220LC-8M0
10-600
45
600 Electrical system Machine monitor system
SEN06123-00
Pilot monitor Symbol
Display item
Description
Automatic preheating
Preheating Manual preheating
One-touch power max. switch One-touch power max.
10-600
46
Elapsed time after turning the starting switch to “HEAT (Preheating)”
Monitor display
0 to 30 sec.
Lights up
30 to 40 sec.
Flashes
After 40 sec. or longer
Lights off
• Indicates preheat operating status.
Monitor display
ON
Lights up (Goes out if pressed for 8.5 seconds)
OFF
Lights out
Swing lock switch Swing lock
Remarks
• It operates automatically at a low temperature. (Symbol lights up as long as for approx. 30 seconds) • It goes off after the engine is started.
Swing brake cancel switch
• Indicates the operating status of one-touch power maximizing function.
Monitor display
OFF
OFF
Lights off
ON
OFF
Lights up
OFF
ON
Flashes
ON
ON
Flashes
• Indicates swing lock operating status.
Wiper
INT: Intermittent operation ON: Continuous operation Lights off: Holds in position
• Indicates front glass wiper operating condition.
Air conditioner
Lights up: ON Lights off: OFF
• Indicates air conditioner and air blower operating status.
Message (Unread)
Lights up: There is unread message. Lights off: No message
• State of the message is displayed.
Message (No return message, already-read message)
Lights up: There is an already-read message but return message for it is not sent yet. Lights off: No message
• State of the message is displayed.
Auto-deceleration
Lights up: ON Lights off: OFF
• Indicates auto-decelerator operating status.
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
Symbol
SEN06123-00
Display item
Description
Remarks
Working mode
P: Heavy-duty operation E: Low-fuel consumption operation L: Fine operation B: Breaker operation • Displays working mode. ATT-P: Double-acting attachment operation ATT-E: Double-acting attachment and low-fuel consumption operation
Travel speed
Lo: Low speed Mi: Middle speed Hi: High speed
• Displays travel speed setting.
ECO guidance
Idle stop guidance Guidance on deterrence of hydraulic relief E-mode recommendation guidance Travel partial recommendation guidance Low oil level guidance
• Guidance for supporting the machine operation and control are displayed.
PC200, 200LC, 220, 220LC-8M0
10-600
47
600 Electrical system Machine monitor system
SEN06123-00
Switches
No.
1
1
Name Auto-deceleration switch [Numeric keypad: 1]
Function
Operation
Switches the auto-deceleration function ON/OFF. Lights up: ON Lights off: OFF
• When working mode is “L”, this switch is always “OFF” after engine started. OFF io ON
Displays the working mode selector screen.
P: Heavy-duty operation E: Low-fuel operation L: Fine operation B: Breaker operation ATT-P: Double-acting attachment operation ATT-E: Double-acting attachment and low-fuel operation
2
(*1) Working mode selector switch [Numeric keypad: 2]
3
Changes the travel speed. Travel speed selector Lo lights up: Low speed switch Mi lights up: Medium speed [Numeric keypad: 3] Hi lights up: High speed
4
Stops the alarm buzzer. • The alarm buzzer stops sounding. Buzzer cancel switch (Some alarm buzzer does not • The alarm buzzer sounds again if another error [Numeric keypad: 4] stop sounding even if the switch is worth alarming is detected. pressed.)
5
(*2) Wiper switch [Numeric keypad: 5]
10-600
48
Operates the front glass wiper. INT: Intermittent operation ON: Continuous operation Lights off: Holds in position
• Speed is sequentially changed as shown below. • Lo (Low speed) o Mi (Medium speed) o Hi (High speed) o Lo (Low speed)
• Pressing the switch sequentially changes the wiper operation. OFF (Stop) o INT (Intermittent) o ON (Continuous) o OFF (Stop)
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
No.
6
Name
(*2) Window washer switch [Numeric keypad: 6]
SEN06123-00
Function
Operation
ON: Washer fluid is sprayed and windshield wiper works continuously. [When wiper stops] OFF: Windshield wiper works twice continuously Sprays washer fluid onto the front and stops after the switch is released. window glass. [When wiper operates intermittently] OFF: Windshield wiper works twice continuously and returns to intermittent operation after the switch is released.
Fan switch (increase) Controls the air flow of the air [Numeric keypad: 7] conditioner in 6 levels. (Low, Medium 1, Medium 2, Fan switch (decrease) Medium 3, Medium 4 and High)
• The air flow increases immediately after the air conditioner adjustment screen appears.
8a
Temperature control switch (raise) [Numeric keypad: 8]
• The preset temperature increases immediately after the air conditioner adjustment screen appears.
8b
Temperature control switch (lower) [Numeric keypad: 0]
9
(*3) Auto switch [Numeric keypad: 9]
10
Selects the air conditioner ON/ OFF. (*4) A/C ON lights up: Manual Air conditioner switch operation Lights off: Stop
• Switches to the air conditioner adjustment screen, and pressing it again switches ON/OFF. OFF io ON
11
FRESH/RECIRC air changeover switch
Changes the FRESH/RECIRC.
• Switches to the air conditioner adjustment screen, and pressing it again switches FRESH/ RECIRC. RECIRC io FRESH
12
Vent selector switch
Selects the air vent mode from 6 modes. 1. Front vent 2. Front and rear vents 3. Front, rear and foot vents 4. Foot vent 5. Foot and defroster vents 6. Defroster vent
• Switches to the air conditioner adjustment screen, and pressing it again switches air vent mode. 1o2o3o4o5o6o1
13
OFF switch
Stops the fan and air conditioner. • The fan and air conditioner stop. Lights off: OFF
14a
Guidance icon
14b
Function switch
7a 7b
Controls the temperature inside the cab. (18.0°C to 32.0°C: Setting is available in 0.5°C steps)
Operates the air conditioner and air flow with automatic operation. AUTO lights up: Automatic operation
• The air flow decreases immediately after the air conditioner adjustment screen appears.
• The preset temperature decreases immediately after the air conditioner adjustment screen appears. • The air flow, combination of vents, and selection of FRESH/RECIRC air are automatically selected according to the set temperature immediately after the air conditioner adjustment screen appears.
a See Guidance icon and function switch
*1: When the working mode is changed, the auto-deceleration function is turned ON. But, when L mode is selected, it is turned OFF. *2: When the front window is open, the wiper and washer do not operate even if the switch is pressed. *3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to “High” and does not change even if the set temperature is reached. *4: Air conditioner cannot be operated while the fan stops.“
PC200, 200LC, 220, 220LC-8M0
10-600
49
600 Electrical system Machine monitor system
SEN06123-00
Guidance icon and function switch q Functions available with the function switch vary depending on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches. Guidance icon
Item
Function
Selection of user mode screen
Selects user menu screen. Background colors allow confirming the type of information transmitted. • Gray: When the condition is normal • Red: When exceeding maintenance interval warning • Yellow: When exceeding maintenance interval warning • Green: When there is unread KOMTRAX message
Switching clock/service meter
Switches clock/service meter display.
Switching to camera screen Switches to camera image display screen.
10-600
50
Enter
Enters selected/setting item. Background colors allow confirming the type of information transmitted. • Gray: When the condition is normal • Green: When energy saving guidance is displayed
Return
Returns to the previous screen or status.
Switching the select item
Selects the item right above the current item (To the bottom item from the top item.)
Switching the select item
Selects the item right below the current item (To the top item from the bottom item.)
Switching the select item
Green arrow: Selects the item on the right side of the tab. White arrow: Selects the item on the right side of the current item. (To the leftmost item from the rightmost item.)
Switching the select item
Green arrow: Selects the item on the left side of the tab. White arrow: Selects the item on the left side of the current item. (To the rightmost item from the leftmost item.)
Switching the select item
Selects the page right above the current page. (To the bottom page from the top page.)
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Item
Guidance icon
Function
Switching the select item
Selects the page right below the current page. (To the top page from the bottom page.)
Clear
Clears selected/displayed item.
Restores default value
Sets selected item back to default. (Used for screen adjustment.)
Set
Performs setting.
Start
Starts function. (Used for starting measurement of split fuel consumption on the fuel consumption display screen.)
Stop
Stops operation. (Used for stopping measurement of split fuel consumption on fuel consumption display screen.)
Saving
Saves setting
Switching to the name setting screen
Switches the current screen to the name setting screen
Switching to ATT1 oil flow setting screen
Switching the current screen to attachment 1 oil flow setting screen. (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow setting screen
Switching the current screen to attachment 2 oil flow setting screen. (Enabled only when attachments 1 and 2 are equipped)
HOLD
Holds the value of the target item of monitoring. (Used when monitoring is turned on)
Resetting the hold
Resets the currently held value of the target item of monitoring. (Used when monitoring is turned on)
PC200, 200LC, 220, 220LC-8M0
10-600
51
600 Electrical system Machine monitor system
SEN06123-00
Guidance icon
Item
Function
Switching the fuel Switches the graphs on the fuel consumption record screen. consumption record screen
Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen. screen
Switches to the currently occurring failures list screen. Switching to the currently Background colors allow confirming the type of information transmitted. occurring failures list screen • Red: When an action level of L2, L3 or L4 is displayed • Yellow: When the action level of L1 is displayed
10-600
52
Display No. 1 camera screen
Selects No. 1 camera image display screen.
Display No. 2 camera screen
Selects No. 2 camera image display screen.
Display No. 1 and No. 2 camera screens
Display both images of No. 1 and No. 2 cameras simultaneously.
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Operator mode function q The operator can select the information to be displayed usually on the screen and the function to be used by operating the switches. Display and setting of some functions require special operation of the switch. q Items available in the operator mode are as follows: Category (*1)
Item
V
W
X
Y
Z
1
1
1
1
1
Password input screen
2
—
—
—
—
Breaker mode check screen
—
—
2
—
—
Checks before starting screen
3
2
3
2
2
Warning screen after check before starting
—
—
—
3
—
Overdue maintenance time item screen
—
—
—
—
3
Working mode and travel speed check screen
4
3
4
4
4
Standard screen
5
4
5
5
5
KOMATSU logo screen
A
Display order (*2)
End screen Selecting auto-deceleration function Selecting working mode Selecting travel speed Stopping alarm buzzer Operating windshield wiper Operating window washer Operating air conditioner B
Operating camera mode display Switching between clock display and service meter display Checking maintenance information Setting and displaying user menu • ECO Guidance • Machine Setting • Maintenance • Monitor Setting • Message display (including KOMTRAX messages for user) Displaying ECO guidance
C
Displaying caution monitor Displaying action level and failure code LCD (Liquid Crystal Display) display condition checking function
D
Service meter reading checking function Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below. A: Displays that appear since starting switch is turned to “ON” position until the standard screen appears, and the displays that appear after starting switch is turned to “OFF” position . B: Displays that appear when the switch on the machine monitor is operated. C: Displays when a certain condition is satisfied D: Displays that require special switch operations. *2: Display sequence from “ON” of starting switch to the standard screen varies depending on the settings and conditions of the machine as follows: V: When engine start lock is set effective W: When engine start lock is disabled X: When working mode at start is set to “Breaker Mode (B)”.
PC200, 200LC, 220, 220LC-8M0
10-600
53
SEN06123-00
600 Electrical system Machine monitor system
Y: When a failure is detected during check before starting. Z: When a maintenance time overdue is detected for an item. a For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Operator mode (Outline)” section in Testing and adjusting. a For how to set the engine start lock on/off, see “Password setting/cancel manual”.
10-600
54
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Machine monitor system
SEN06123-00
Service mode function q The functions in this mode are not displayed usually on the screen. Information display and various settings can be made only by the technician through the special operation of the switches. This mode is used for special setting, testing, adjusting, or troubleshooting. q Items available in the service mode are as follows: Monitoring / Pre-defined Monitoring / Custom Abnormality Record
Mechanical Systems Electrical Systems
Maintenance Record Maintenance Mode Setting Phone Number Entry Key-on Mode Default
Unit With/Without Attachment Camera
Diagnostic Tests
Cylinder Cut-out Pump Absorption Torque (F)
Adjustment
Pump Absorption Torque (R) Low Speed Attachment Flow Adjustment
No Injection Terminal Status KOMTRAX Settings
GPS & Communication Status Modem Status
Service Message
a
For how to operate the service mode functions, see “section in Testing and adjusting”.
PC200, 200LC, 220, 220LC-8M0
10-600
55
600 Electrical system Sensor
SEN06123-00
Sensor q q
1
The signals from the sensors are input to the monitor panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Type of sensor
When normal
When abnormal
Hydraulic oil level
Contact
ON (Closed)
OFF (Open)
Fuel level
Resistance
—
—
Air cleaner clogging
Contact
OFF (Closed)
ON (Open)
Coolant level
Contact
ON (Closed)
OFF (Open)
Sensor name
Hydraulic oil level sensor
1. 2. 3. 4.
1
Connector Bracket Float Switch
10-600
56
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Sensor
SEN06123-00
Fuel level sensor
1
1. 2. 3. 4.
Float Connector Cover Variable resistor
Air cleaner clogging sensor
1. 2.
Adapter Hood
PC200, 200LC, 220, 220LC-8M0
1
3. 4.
Indicator Connector
10-600
57
SEN06123-00
Coolant level sensor
1. 2. 3. 4.
600 Electrical system Sensor
1
Reserve tank Float Sensor Connector
10-600
58
PC200, 200LC, 220, 220LC-8M0
600 Electrical system Sensor
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
10-600
59
600 Electrical system KOMTRAX system
SEN06123-00
KOMTRAX system
q q q
a
1
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna. This system transmits various machine information by use of the radio communication. This system allows the KOMTRAX operator to refer the information and provide various services to the customers. Information transmittable from the KOMTRAX system are as follows. 1. Operation map 2. Service meter reading 3. Location information 4. Abnormality record To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
KOMTRAX terminal Model: TC330
1. 2.
GPS antenna connection Machine harness connection (070-18P)
10-600
60
3. 4.
Machine harness connection (070-12P) Communication antenna connection
PC200, 200LC, 220, 220LC-8M0
600 Electrical system KOMTRAX system
SEN06123-00
Input and output signals 070-18P[CN-CK01] Pin No.
Signal name
Input/Output signal
1
(*1)
—
2
(*1)
—
3
(*1)
—
4
(*1)
—
5
(*1)
—
6
(*1)
—
7
(*1)
—
8
(*1)
—
9
(*1)
—
10
CAN (C)_H
Input/Output Input/Output
11
CAN (C)_L
12
(*1)
—
13
(*1)
—
14
External start signal
15
(*1)
—
16
(*1)
—
17
(*1)
—
18
(*1)
—
Input/Output
*1: Never connect these pins. Malfunctions or failures may occur. 070-12P [CN-CK02] Pin No.
Signal name
Input/Output signal
1
GND
—
2
GND
—
3
Starting switch (ACC)
Input
4
Alternator (R)
Input
5
(*1)
6
Power supply
Input
7
Power supply
Input
8
(*1)
—
9
(*1)
—
10
(*1)
—
11
Starting switch (C)
12
(*1)
—
Input —
*1: Never connect these pins. Malfunctions or failures may occur.
PC200, 200LC, 220, 220LC-8M0
10-600
61
SEN06123-00
600 Electrical system KOMTRAX system
Function q This terminal uses the satellite communications technology. q The terminal is an equipment which transmits various machine information obtained through network signals and input signals, as well as GPS positioning data. The terminal can transmit data via the communication antenna. q The status of the terminal can be checked by using the menu of “KOMTRAX setting” in the service mode of the machine monitor . q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed. q This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its display section. a
When changing the country where the system is used, you must give notice to Komatsu Ltd. the information which country the system is used in advance.
10-600
62
PC200, 200LC, 220, 220LC-8M0
600 Electrical system KOMTRAX system
PC200, 200LC, 220, 220LC-8M0
SEN06123-00
10-600
63
SEN06123-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06123-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
10-600
64
SEN06125-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
20 Standard value table
1
100 Standard service value table Standard value table for engine related parts ................................................................................................. 2 Standard value table for chassis related parts ................................................................................................ 4
PC200, 200LC, 220, 220LC-8M0
20-100
1
100 Standard service value table Standard value table for engine related parts
SEN06125-00
Standard value table for engine related parts
1
PC200, 200LC-8M0
Category
Item
Engine speed
Applicable model
PC200, 200LC-8M0
Engine
SAA6D107E-1 Unit
Standard value for new machine
Judgement criteria
High idle
rpm
2,060 ± 70
2,060 ± 70
• Coolant temperature: Within Low idle operating range
rpm
1,050 ± 50
1,050 ± 50
rpm
2,000
2,000
kPa {mmHg}
Min. 133 {Min. 1,000}
103 {775}
Opacity %
Max. 25
35
Opacity %
—
—
Intake valve
mm
0.25
0.152 to 0.381
Exhaust valve
mm
0.51
0.381 to 0.762
Compression pressure
MPa {kg/cm2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Engine speed
rpm
250 to 280
250 to 280
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
MPa {kg/cm2}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
Measurement condition
Rated speed Intake pressure (boost pressure)
• Coolant temperature: Within operating range • Arm IN relief + Power Max.
Exhaust gas color
At sudden • Coolant acceleration temperature: Within operating range At high idle
Engine
Valve clearance
• Normal temperature
Compression pressure
• Oil temperature: 40 to 60°C
Blow-by pressure
• Coolant temperature: Within operating range • Arm IN relief + power max.
Oil pressure
• SAE0W30E0S, SAE5W40E0S, High idle SAE10W30DH, SAE15W40DH, SAE30DH engine oil • Coolant temperature: Within Low idle operating range
Oil temperature
• Whole speed range (inside oil pan)
°C
80 to 110
120
Fan belt tension
• Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx. 98 N{10 kg}
mm
8
6 to 10
Air conditioner compressor belt tension
• Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx. 60 N{6.2 kg}
mm
6.3 to 8.7
6.3 to 8.7
20-100
2
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for engine related parts
SEN06125-00
PC220, 220LC-8M0
Category
Item
Engine speed
Applicable model
PC220, 220LC-8M0
Engine
SAA6D107E-1 Unit
Standard value for new machine
Judgement criteria
High idle
rpm
2,100 ± 70
2,100 ± 70
• Coolant temperature: Within Low idle operating range
rpm
1,050 ± 50
1,050 ± 50
rpm
2,000
2,000
kPa {mmHg}
Min. 133 {Min. 1,000}
103 {775}
Opacity %
Max. 25
35
Opacity %
—
—
Intake valve
mm
0.25
0.152 to 0.381
Exhaust valve
mm
0.51
0.381 to 0.762
Compression pressure
MPa {kg/cm2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Engine speed
rpm
250 to 280
250 to 280
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
MPa {kg/cm2}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
Measurement condition
Rated speed Intake pressure (boost pressure)
• Coolant temperature: operating range • Arm IN relief + Power Max.
Exhaust gas color
At sudden • Coolant acceleration temperature: Within operating range At high idle
Engine
Valve clearance
• Normal temperature
Compression pressure
• Oil temperature: 40 to 60°C
Blow-by pressure
• Coolant temperature: Within operating range • Arm IN relief + power max.
Oil pressure
• SAE0W30E0S, SAE5W40E0S, High idle SAE10W30DH, SAE15W40DH, SAE30DH engine oil • Coolant temperature: Within Low idle operating range
Oil temperature
• Whole speed range (inside oil pan)
°C
80 to 110
120
Fan belt tension
• Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx. 98 N{10 kg}
mm
8
6 to 10
Air conditioner compressor belt tension
• Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx. 60 N{6.2 kg}
mm
6.3 to 8.7
6.3 to 8.7
PC200, 200LC, 220, 220LC-8M0
20-100
3
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Standard value table for chassis related parts
1
PC200, 200LC-8M0 Applicable model Measurement condition
Unit
Standard value for new machine
Judgement criteria
2 pumps at relief
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Power mode (P) • Arm IN relief condition
rpm
1,800 ± 100
1,800 ± 100
At 2-pump relief + power max.
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Arm IN relief + Left knob switch ON
rpm
1,950 ± 100
1,950 ± 100
Speed when autodeceleration is operated
• Engine at high idle • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition
rpm
1,050 ± 100
1,050 ± 100
Raise
mm
11.5 ± 0.5
11.5 ± 0.5
Lower
mm
9.5 ± 0.5
9.5 ± 0.5
IN
mm
11.5 ± 0.5
11.5 ± 0.5
OUT
mm
9.5 ± 0.5
9.5 ± 0.5
Bucket control valve
CURL, DUMP
mm
9.5 ± 0.5
9.5 ± 0.5
Swing control valve
LH, RH swing
mm
9.5 ± 0.5
9.5 ± 0.5
Travel control valve
Forward, Reverse
mm
9.5 ± 0.5
9.5 ± 0.5
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
115 ± 12
115 ± 12
Work equipment
mm
Max. 15
Max. 20
Travel
mm
Max. 20
Max. 25
Category
Engine speed
PC200, 200LC-8M0
Item
Spool stroke
Boom control valve
Arm control valve
• Engine stopped • For measuring point, see Control valve.
Boom control lever
Travel of control levers
Arm control lever Bucket control lever Swing control lever
• Engine stopped • Control lever grip at center • Max. reading up to stroke end (except lever play in NEUTRAL position)
Travel control lever
Play of control lever
20-100
4
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model
Operating force of control levers and pedal
Category
Unit
Standard value for new machine
Judgement criteria
Boom control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
Travel control lever
N {kg}
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
Travel control pedal
N {kg}
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all control levers in NEUTRAL position
MPa {kg/cm2}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
MPa {kg/cm2}
30.3 ± 1.5 {310 ± 15}
28.4 to 32.3 {290 to 330}
MPa {kg/cm2}
38.7(+1.0/–2.0) {395(+10/–20)}
36.8 to 40.2 {375 to 410}
MPa {kg/cm2}
3.23(+0.2/–0.3) {33(+2/–3)}
2.75 to 3.43 {28 to 35}
When all control levers in NEUTRAL position
MPa {kg/cm2}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
When traveling at half stroke
MPa {kg/cm2}
1.8 ± 0.1 {18 ± 1}
1.8 ± 0.1 {18 ± 1}
Item
Bucket control lever Swing control lever
Unload pressure
Boom relief
Arm relief
Bucket relief Hydraulic pressure
PC200, 200LC-8M0
Swing relief
Travel relief
Measurement condition
• Hydraulic oil temperature: Within operating range • Engine at high idle • Control lever grip at center • Pedal at tip • Max. reading up to stroke end
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved
• Hydraulic oil temperature: Within operating range Control circuit source • Engine running at high idle pressure • Self pressure reducing valve output pressure with all control levers in NEUTRAL position
LS differential pressure
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Traveling speed: Hi • Run either track with no load • Hydraulic oil pump pressure – LS pressure
PC200, 200LC, 220, 220LC-8M0
20-100
5
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Measurement condition
Unit
Standard value for new machine
Judgement criteria
Overswing
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Swing circle misalignment amount when stopping after one turn • For measuring posture, see Swing 1
deg. (mm)
Max. 100 (—)
Max. 130 (—)
90°
sec.
3.1 ± 0.3
Max. 3.7
Time required for starting swing
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for passing points 90° and 180° from starting point • For measuring posture, see Swing 1
180°
sec.
4.4 ± 0.4
Max. 5.5
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for 5 more turns after making initial one turn • For measuring posture, see Swing 1
sec.
24.2 ± 2.5
Max. 30
• Hydraulic oil temperature: Within operating range • Engine stopped • Keeping upper structure transverse on slope of 15° Swing drift on a slope • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes • For measuring posture, see Swing 2
mm
0
0
l/min
Max. 5
Max. 10
[PC200-8M0] 51.3 (+3.6/-6.7)
[PC200-8M0] 44.6 to 58.8
[PC200LC-8M0] 55.9 (+3.9/-7.3)
[PC200LC-8M0] 48.6 to 63.8
[PC200-8M0] 37.5 ± 3.8
[PC200-8M0] 33.7 to 45.3
[PC200LC-8M0] 40.8 ± 4.1
[PC200LC-8M0] 36.7 to 48.9
[PC200-8M0] 26.5 ± 1.3
[PC200-8M0] 25.2 to 29.8
[PC200LC-8M0] 28.8 ± 1.5
[PC200LC-8M0] 27.3 to 32.3
Category
Swing
Item
Time required to complete turns
Travel
PC200, 200LC-8M0
Leakage from swing motor
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Swing lock switch: ON • Leakage amount for one minute during swing relief
Travel speed (idle running)
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required to make five idle turns of track off ground after one idle turn • For measuring posture, see Travel 1
20-100
6
Lo
Mi
Hi
sec.
sec.
sec.
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Unit
Standard value for new machine
Judgement criteria
Lo
sec.
24 (+1.7/-3.1)
20.9 to 26.9
Mi
sec.
17 ± 2.5
14.5 to 20.5
Hi
sec.
13 ± 1.0
12.0 to 15.0
Travel deviation
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Travel speed: Lo • Solid and flat ground • Travel deviation (x) in travel of 20 m after running up 10 m • For measuring posture, see Travel 2 and 3
mm
Max. 150
Max. 250
Machine drift on a slope
• Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope of 12° with sprocket facing upslope • Sliding distance for 5 minutes • For measuring posture, see Travel 4
mm
0
0
Leakage from travel motor
• Hydraulic oil temperature: Within operating range • Engine at high idle • Traveling with sprocket locked • Leakage in 1 minute during travel relief
l/min
13.6
27.2
mm
Max. 644
Max. 966
mm
Max. 19
Max. 29
mm
Max. 184
Max. 276
mm
Max. 42
Max. 63
Category
Item
Hydraulic drift of work equipment
Travel
Travel speed (actual running)
Work equipment
PC200, 200LC-8M0
Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Flat ground • Time required to travel 20 m after running up 10 m • For measuring posture, see Travel 2
• Hydraulic oil temperature: Within operating range • Flat and level ground • Fill bucket with dirt or rated load (0.8m 3: 1,440kg) • Boom horizontal, arm fully retracted, Boom cylinder bucket cylinder fully extended • Engine stopped • Work equipment control lever in Arm cylinder NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting Bucket cylinder • For measuring posture, see Work equipment 1
Whole work equipment
PC200, 200LC, 220, 220LC-8M0
20-100
7
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Category
Item
Work equipment speed
Work equipment
Boom
Arm
Bucket
20-100
8
PC200, 200LC-8M0 Unit
Standard value for new machine
Judgement criteria
RAISE
sec.
3.3 ± 0.4
Max. 4.8
LOWER
sec.
2.4 ± 0.3
Max. 3.7
IN
sec.
3.5 ± 0.4
Max. 4.5
OUT
sec.
2.7 ± 0.3
Max. 3.5
CURL
sec.
2.4 ± 0.3
Max. 3.3
DUMP
sec.
1.8 ± 0.2
Max. 2.7
Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from RAISE stroke end till bucket touches ground • For measuring posture, see Work equipment 2 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from OUT stroke end to IN stroke end • For measuring posture, see Work equipment 3 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from DUMP stroke end to CURL stroke end • For measuring posture, see Work equipment 4
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Measurement condition
Unit
Standard value for new machine
Judgement criteria
Boom
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Lower boom from RAISE stroke end and measure time from when work equipment touches the ground until front side of machine rises • For measuring posture, see Work equipment 5
sec.
Max. 1.0
Max. 1.2
Arm
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Move arm to IN from OUT stroke end and measure time from when arm stops momentarily until it starts moving again • For measuring posture, see Work equipment 6
sec.
Max. 2.0
Max. 2.8
Bucket
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Move bucket to CURL from DUMP stroke end and measure time from when bucket stops momentarily until it starts moving again • For measuring posture, see Work equipment 7
sec.
Max. 1.0
Max. 3.6
cc/min
4.5
20
cc/min
10
50
Performance in compound operation
PC200, 200LC-8M0
• Hydraulic oil temperature: Within operating range • Engine at high idle Travel deviation in • Working mode: P mode simultaneous • Traveling speed: Lo operation of work • Travel deviation (x) in travel of 20 m equipment and travel after running up 10 m on hard and flat ground • For measuring posture, see Travel 2 and 3
mm
Max.200
Max.220
Characteristics of PC flow control valve
Applicable model
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Rated load applied to bucket (0.8m 3: 1,440kg) Time required for • On hard and flat ground, set arm turning from 0 to 90° vertically and lower back of bucket with boom raised to ground • Time required till passing spot of 90° starting from illustrated posture and with boom raised • For measuring posture, see Work equipment 8
sec.
Time lag
Item
Internal leakage
Work equipment
Category
—
Cylinders
Center swivel joint
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Leakage amount for one minute with cylinder or travel to be measured in relief condition
Discharge amount of hydraulic pump
PC200, 200LC, 220, 220LC-8M0
4.2 ± 0.4 (Reference value)
See performance of hydraulic pump (next page)
20-100
9
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model
Hydraulic pump
Category
a a
Item
Performance of hydraulic pump
PC200, 200LC-8M0
Measurement condition
Unit
Standard value
Standard lower limit of discharge
• Pump speed (rpm): 2,000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump (MPa {kg/cm2}): P1 • Discharge pressure of another pump (MPa {kg/cm2}): P2 • Average discharge pressure (MPa {kg/cm2}): Pp=(P1+P2)÷2
l/min
Q (See graph)
Q (See graph)
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-100
10
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
PC220, 220LC-8M0 Applicable model
Engine speed
Category
PC220, 220LC-8M0
Measurement condition
Unit
Standard value for new machine
Judgement criteria
2 pumps at relief
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Power mode (P) • Arm IN relief condition
rpm
1,900 ± 100
1,940 ± 100
At 2-pump relief + power max.
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Arm IN relief + Left knob switch ON
rpm
1,950 ± 100
1,950 ± 100
Speed when autodeceleration is operated
• Engine at high idle • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition
rpm
1,050 ± 100
1,050 ± 100
Raise
mm
11.5 ± 0.5
11.5 ± 0.5
Lower
mm
9.5 ± 0.5
9.5 ± 0.5
IN
mm
11.5 ± 0.5
11.5 ± 0.5
OUT
mm
9.5 ± 0.5
9.5 ± 0.5
Bucket control valve
CURL, DUMP
mm
9.5 ± 0.5
9.5 ± 0.5
Swing control valve
LH, RH swing
mm
9.5 ± 0.5
9.5 ± 0.5
Travel control valve
Forward, Reverse
mm
9.5 ± 0.5
9.5 ± 0.5
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
115 ± 12
115 ± 12
Work equipment
mm
Max. 15
Max. 20
Travel
mm
Max. 20
Max. 25
Item
Spool stroke
Boom control valve
Arm control valve
• Engine stopped • For measuring point, see Control valve.
Boom control lever
Travel of control levers
Arm control lever Bucket control lever Swing control lever
• Engine stopped • Control lever grip at center • Max. reading up to stroke end (except lever play in NEUTRAL position)
Travel control lever
Play of control lever
PC200, 200LC, 220, 220LC-8M0
20-100
11
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Unit
Standard value for new machine
Judgement criteria
Boom control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
Travel control lever
N {kg}
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
Travel control pedal
N {kg}
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all control levers in NEUTRAL position
MPa {kg/cm2}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
Normal relief
MPa {kg/cm2}
34.8 (+1.5/-1.2) {355 (+15/-12)}
33.1 to 37.2 {338 to 380}
Power max.
MPa {kg/cm2}
37.3 (+1.5/-1.2) {380 (+15/-12)}
36.1 to 39.7 {368 to 405}
MPa {kg/cm2}
30.3 ± 1.5 {310 ± 15}
28.4 to 32.3 {290 to 330}
MPa {kg/cm2}
38.7(+1.0/–2.0) {395(+10/–20)}
36.8 to 40.2 {375 to 410}
MPa {kg/cm2}
3.23(+0.2/–0.3) {33(+2/–3)}
2.75 to 3.43 {28 to 35}
When all control levers in NEUTRAL position
MPa {kg/cm2}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
When traveling at half stroke
MPa {kg/cm2}
1.8 ± 0.1 {18 ± 1}
1.8 ± 0.1 {18 ± 1}
Operating force of control levers and pedal
Category
Item
Bucket control lever Swing control lever
Unload pressure
Boom relief
Arm relief
Bucket relief Hydraulic pressure
PC220, 220LC-8M0
Swing relief
Travel relief
Measurement condition
• Hydraulic oil temperature: Within operating range • Engine at high idle • Control lever grip at center • Pedal at tip • Max. reading up to stroke end
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved
• Hydraulic oil temperature: Within operating range Control circuit source • Engine running at high idle pressure • Self pressure reducing valve output pressure with all control levers in NEUTRAL position
LS differential pressure
20-100
12
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Traveling speed: Hi • Run either track with no load • Hydraulic oil pump pressure – LS pressure
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Measurement condition
Unit
Standard value for new machine
Judgement criteria
Overswing
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Swing circle misalignment amount when stopping after one turn • For measuring posture, see Swing 1
deg. (mm)
Max. 165 (—)
Max. 200 (—)
90°
sec.
3.0 ± 0.3
Max. 3.5
Time required for starting swing
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for passing points 90° and 180° from starting point • For measuring posture, see Swing 1
180°
sec.
4.5 ± 0.4
Max. 5.4
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for 5 more turns after making initial one turn • For measuring posture, see Swing 1
sec.
25.7 ± 2.8
Max. 31
• Hydraulic oil temperature: Within operating range • Engine stopped • Keeping upper structure transverse on slope of 15° Swing drift on a slope • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes • For measuring posture, see Swing 2
mm
0
0
l/min
Max. 5
Max. 10
[PC220-8M0] 53.6 (+3.8/-7.0)
[PC220-8M0] 46.6 to 61.5
[PC220LC-8M0] 58.1 (+4.1/-7.6)
[PC220LC-8M0] 50.5 to 66.3
[PC220-8M0] 39.2 (+4.4/-3.6)
[PC220-8M0] 35.6 to 47.6
[PC220LC-8M0] 42.5 (+4.7/-3.9)
[PC220LC-8M0] 38.6 to 51.2
[PC220-8M0] 28.0 (+1.5/-1.3)
[PC220-8M0] 26.7 to 31.5
[PC220LC-8M0] 30.3 (+1.6/-1.4)
[PC220LC-8M0] 28.9 to 33.9
Item
Swing
Category
Time required to complete turns
Travel
PC220, 220LC-8M0
Leakage from swing motor
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Swing lock switch: ON • Leakage amount for one minute during swing relief
Travel speed (idle running)
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required to make five idle turns of track off ground after one idle turn • For measuring posture, see Travel 1
PC200, 200LC, 220, 220LC-8M0
Lo
Mi
Hi
sec.
sec.
sec.
20-100
13
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Unit
Standard value for new machine
Judgement criteria
Lo
sec.
24 (+1.7/-3.1)
20.9 to 26.9
Mi
sec.
17 ± 2.5
14.5 to 20.5
Hi
sec.
13 ± 1.0
12.0 to 15.0
Travel deviation
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Travel speed: Lo • Solid and flat ground • Travel deviation (x) in travel of 20 m after running up 10 m • For measuring posture, see Travel 2 and 3
mm
Max. 150
Max. 250
Machine drift on a slopel
• Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope of 12° with sprocket facing upslope • Sliding distance for 5 minutes • For measuring posture, see Travel 4
mm
0
0
Leakage from travel motor
• Hydraulic oil temperature: Within operating range • Engine at high idle • Traveling with sprocket locked • Leakage in 1 minute during travel relief
l/min
13.6
27.2
mm
Max. 600
Max. 900
mm
Max. 18
Max. 27
mm
Max. 160
Max. 240
mm
Max. 40
Max. 58
Category
Item
Hydraulic drift of work equipment
Travel
Travel speed (actual running)
Work equipment
PC220, 220LC-8M0
20-100
Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Flat ground • Time required to travel 20 m after running up 10 m • For measuring posture, see Travel 2
• Hydraulic oil temperature: Within operating range • Flat and level ground • Fill bucket with dirt or rated load (0.8m 3: 1,440kg) • Boom horizontal, arm fully retracted, Boom cylinder bucket cylinder fully extended • Engine stopped • Work equipment control lever in Arm cylinder NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting Bucket cylinder • For measuring posture, see Work equipment 1 Whole work equipment
14
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model Category
Item
Work equipment speed
Work equipment
Boom
Arm
Bucket
PC220, 220LC-8M0 Unit
Standard value for new machine
Judgement criteria
RAISE
sec.
3.4 (+0.5/-0.3)
Max. 4.7
LOWER
sec.
2.7 ± 0.3
Max. 4.4
IN
sec.
4.1 ± 0.4
Max. 4.6
OUT
sec.
3.0 (+0.4/-0.2)
Max. 3.5
CURL
sec.
2.7 ± 0.3
Max. 3.3
DUMP
sec.
2.1 ± 0.2
Max. 2.7
Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from RAISE stroke end till bucket touches ground • For measuring posture, see Work equipment 2 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from OUT stroke end to IN stroke end • For measuring posture, see Work equipment 3 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from DUMP stroke end to CURL stroke end • For measuring posture, see Work equipment 4
PC200, 200LC, 220, 220LC-8M0
20-100
15
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Measurement condition
Unit
Standard value for new machine
Judgement criteria
Boom
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Lower boom from RAISE stroke end and measure time from when work equipment touches the ground until front side of machine rises • For measuring posture, see Work equipment 5
sec.
Max. 1.0
Max. 1.2
Arm
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Move arm to IN from OUT stroke end and measure time from when arm stops momentarily until it starts moving again • For measuring posture, see Work equipment 6
sec.
Max. 2.0
Max. 2.8
Bucket
• Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Move bucket to CURL from DUMP stroke end and measure time from when bucket stops momentarily until it starts moving again • For measuring posture, see Work equipment 7
sec.
Max. 1.0
Max. 3.6
cc/min
4.5
20
cc/min
10
50
Performance in compound operation
PC220, 220LC-8M0
• Hydraulic oil temperature: Within operating range • Engine at high idle Travel deviation in • Working mode: P mode simultaneous • Traveling speed: Lo operation of work • Travel deviation (x) in travel of 20 m equipment and travel after running up 10 m on hard and flat ground • For measuring posture, see Travel 2 and 3
mm
Max.200
Max.220
Characteristics of PC flow control valve
Applicable model
• Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Rated load applied to bucket (0.8m 3: 1,440kg) Time required for • On hard and flat ground, set arm turning from 0 to 90° vertically and lower back of bucket with boom raised to ground • Time required till passing spot of 90° starting from illustrated posture and with boom raised • For measuring posture, see Work equipment 8
sec.
Time lag
Item
Internal leakage
Work equipment
Category
—
Cylinders
Center swivel joint
Discharge amount of hydraulic pump
20-100
16
• Hydraulic oil temperature: Within operating range • Engine running at high idle • Leakage amount for one minute with cylinder or travel to be measured in relief condition
4.3 ± 0.4 (Reference value)
See performance of hydraulic pump (next page)
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Applicable model
Hydraulic pump
Category
a a
Item
Performance of hydraulic pump
PC220, 220LC-8M0
Measurement condition
Unit
Standard value
Standard lower limit of discharge
• Pump speed (rpm): 2,000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump (MPa {kg/cm2}): P1 • Discharge pressure of another pump (MPa {kg/cm2}): P2 • Average discharge pressure (MPa {kg/cm2}): Pp=(P1+P2)÷2
l/min
Q (See graph)
Q (See graph)
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC200, 200LC, 220, 220LC-8M0
20-100
17
SEN06125-00
For all models (Posture of machine for measuring performance and measurement procedure)
100 Standard service value table Standard value table for chassis related parts
Travel 1: Travel speed (idle running)
Control valve: spool stroke
Travel 2: Travel speed (actual running), travel deviation Swing 1: Overswing, time required for starting swing, time required to complete turns
Travel 3: Travel deviation
Swing 2: Swing drift on a slope
20-100
18
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
SEN06125-00
Travel 4: Machine drift on a slope
Work equipment 3: Arm speed
Work equipment 1: Hydraulic drift of work equipment
Work equipment 4: Bucket speed
Work equipment 5: Boom time lag Work equipment 2: Boom speed
PC200, 200LC, 220, 220LC-8M0
20-100
19
SEN06125-00
100 Standard service value table Standard value table for chassis related parts
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
Work equipment 8: Characteristics of PC flow control valve
20-100
20
PC200, 200LC, 220, 220LC-8M0
100 Standard service value table Standard value table for chassis related parts
PC200, 200LC, 220, 220LC-8M0
SEN06125-00
20-100
21
SEN06125-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06125-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
20-100
22
SEN06127-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
30 Testing and adjusting
1
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 3 Sketch of special tool ...................................................................................................................................... 7 Testing engine speed ...................................................................................................................................... 8 Testing intake air pressure (boost pressure) ................................................................................................... 9 Testing exhaust gas color ............................................................................................................................. 10 Adjusting valve clearance ..............................................................................................................................11 Testing compression pressure ...................................................................................................................... 13 Testing blowby pressure ............................................................................................................................... 16 Testing engine oil pressure ........................................................................................................................... 17 Handling fuel system parts............................................................................................................................ 18 Releasing residual pressure from fuel system .............................................................................................. 18 Testing fuel pressure..................................................................................................................................... 19 Handling reduced cylinder mode operation .................................................................................................. 22 Handling no-injection cranking operation...................................................................................................... 22 Testing fuel discharge, return and leak amount ............................................................................................ 23 Bleeding air from fuel circuit.......................................................................................................................... 26 PC200, 200LC, 220, 220LC-8M0
30-101
1
101 Testing and adjusting, Part 1 SEN06127-00
Testing fuel circuit for leakage....................................................................................................................... 27 Handling controller high voltage circuit ......................................................................................................... 28 Testing and adjusting air conditioner compressor belt tension...................................................................... 29 Replacing alternator belt ............................................................................................................................... 30 Testing swing circle bearing clearance.......................................................................................................... 31 Testing and adjusting track tension ............................................................................................................... 32 Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 34 Testing control circuit source pressure.......................................................................................................... 37 Testing and adjusting oil pressure in pump PC control circuit....................................................................... 38 Testing and adjusting oil pressure in pump LS control circuit ....................................................................... 41 Testing solenoid valve output pressure ......................................................................................................... 46 Testing PPC valve output pressure ............................................................................................................... 49 Adjusting play of work equipment and swing PPC valves............................................................................. 51 Testing parts which cause hydraulic drift of work equipment ........................................................................ 52 Releasing remaining pressure from hydraulic circuit .................................................................................... 54 Testing oil leakage......................................................................................................................................... 55 Bleeding air from each part ........................................................................................................................... 58 Testing cab tipping stopper ........................................................................................................................... 60 Adjusting mirrors ........................................................................................................................................... 61 Installation and adjustment of mirrors ........................................................................................................... 62 Angle adjustment of rear view camera.......................................................................................................... 65
30-101
2
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
SEN06127-00
Testing/Adjusting item
Symbol
Testing intake air pressure (boost pressure)
R 1
Testing exhaust gas color
A
2 1
Adjusting valve clearance B
Testing compression pressure
D
Testing engine oil pressure
E
1
Bosch index: 0 to 9
1 0 to 7.0 MPa {0 to 70 kg/cm2} 1 For 107E-1 engine
4
1 For 107E-1 engine
1
6754-11-3130 Gasket Commercially Hose available 799-201-1504 Blowby checker
2
795-790-3300 Blowby tool
1
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester 799-101-5002 Hydraulic tester
1
1
1 Inside diameter: Approx. 15 mm 1 0 to 5 kPa {0 to 500 mmH2O} 1 For 107E-1 engine Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} 1 Pressure gauge: 60 MPa {600 kg/cm2} 1 Pressure gauge: 1 MPa {10 kg/cm2} Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2}
3
6215-81-9710 O-ring 799-401-2320 Gauge
1 Pressure gauge: 60 MPa {600 kg/cm2} 1 10 × 1.0 mm o R1/8 1 1 Pressure gauge: 1 MPa {10 kg/cm2}
4 5
795-790-5110 Screw 799-201-2202 Boost gauge kit
1 1
6 1
07005-01212 Gasket 795-790-4700 Tester kit
1 1
2
6164-81-5790 Joint 07005-01212 Washer
1 2
3
6754-71-5340 Connector 6754-71-5350 Washer
1 1
4
Commercially Measuring cylinder available
1
5
Commercially Stopwatch available
1
2
G
6 7 8
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
1
795-502-1590 Compression gauge 795-790-4410 Adapter
F
Testing swing circle bearing clearance
799-201-9001 Handy smoke checker Commercially Smoke meter available
–101 to 200 kPa {–760 to 1,500 mmHg}
2 3
1
Testing fuel return rate and leakage
1
1
2
Testing fuel pressure
799-201-2202 Boost gauge kit
Remarks
1 Intake: 0.25 mm, Exhaust: 0.51 mm
5 Testing blow-by pressure
Part name
1
795-799-1131 Gear Commercially Thickness gauge available 795-799-6700 Puller
2
C
Part No.
Q'ty
Tools for testing, adjusting, and troubleshooting
H 1 J 2
790-261-1204 Digital hydraulic tester 795-790-4430 Adapter
Commercially available Commercially available Commercially available Commercially available
Hose
1 Inside diameter: f14 mm
Hose
1 Inside diameter: f7 mm
Hose
1 Inside diameter: f12 mm
Dial gauge
1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester 799-101-5220 Nipple
1 Pressure gauge: 60 MPa {600 kg/cm2} 2 Size: 10 × 1.25 mm 2
07002-11023
PC200, 200LC, 220, 220LC-8M0
O-ring
30-101
3
Testing/Adjusting item
Testing basic pressure of control circuit
Symbol 1 K 2
1 Testing and adjusting oil pressure in pump PC con- L trol circuit 2 1 Testing and adjusting oil pressure in pump LS con- M 2 trol circuit 3
Testing solenoid valve output pressure
1
N
2
Testing PPC valve output pressure
Testing oil leakage
Troubleshooting for engine Controller/sensors/actuators
30-101
4
1 P 2 3 Q
S
Part No.
Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester Differential pressure 799-401-2701 gauge
Q'ty
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
SEN06127-00
Remarks
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} 1 Pressure gauge: 60 MPa {600 kg/cm2} 1 Size: 10 × 1.25 mm 1 Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} 1 Pressure gauge: 60 MPa {600 kg/cm2} 4 Size: 10 × 1.25 mm 4 Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} 1 Pressure gauge: 60 MPa {600 kg/cm2} 1
1 49 MPa {500 kg/cm2}
799-101-5220 Nipple 07002-11023 O-ring
4 Size: 10 × 1.25 mm 4
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester 799-401-3100 Adapter
1 1
799-101-5002 Hydraulic tester
1
790-261-1204 799-401-3100 799-401-3200 Commercially available 799-601-4101 or 799-601-4201
Digital hydraulic tester Adapter Adapter
1 1 1
Measuring cylinder
1
T-adapter assembly
1
799-601-4350 • Measurement box
1
799-601-4211 799-601-4220 799-601-4260 799-601-9020
1 1 1 1
• • • •
T-adapter T-adapter T-adapter T-adapter
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Size: 02 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Size: 02 Size: 03
For DRC60, ECONO (Does not include 799-601-4201) Engine controller Engine controller Engine controller For injector
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
Symbol
Part No.
Part name
799-601-4101 or 799-601-4201 or T-adapter assembly 799-601-9000 or 799-601-9200
Troubleshooting for chassis Sensors/wiring harnesses
T
Testing coolant temperature and oil temperature
—
Testing operating effort and depressing force
—
Testing stroke and hydraulic drift Testing work equipment speed Testing voltage and resistance Removal and installation of boost pressure and temperature sensors
— —
Q'ty
Testing/Adjusting item
SEN06127-00
1
799-601-4350 or • Measurement box 799-601-9320
1
799-601-9020 • Adapter for DT
1
799-601-9030 • Adapter for DT
1
799-601-4260 • Adapter for DT
1
799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000
1
799-601-2600 • Measurement box
1
799-601-7090 799-601-7110 799-601-7120 799-601-7140
1 1 1 1
• • • •
Adapter for M Adapter for M Adapter for M Adapter for S
799-601-7050 • Adapter for SWP
1
799-601-7060 • Adapter for SWP
1
799-601-7010 • Adapter for X
1
799-601-7020 799-601-7360 799-601-7310 799-601-9890 799-601-4280
1 1 1 1 1
• Adapter for X Adapter for relay Adapter for SWP Adapter for multiple Measurement box
Remarks
For ECONO (Does not include 799-601-4201/ 799-601-9000 and 799-601-9200) For ECONO (Does not include 799-601-4101/ 799-601-4201 and 799-601-9200) For DT2P For DT3P (Does not include 799-601-4101 and 799-601-4201) For DT4P (Does not include 799-601-9000 and 799-601-9200)
For ECONO (Does not include 799-601-7000) For M2P For M3P For M4P For S8P For SW6P (Does not include 799-601-8000) For SW8P (Does not include 799-601-8000) For X1P (Does not include 799-601-7000 and 799-601-7100) For X2P For REL-5P For SW12P For DT-2, 3, 4/DTM-2 For pump controller
799-101-1502 Digital thermometer
1 –99.9 to 1,299°C
79A-264-0021 Push-pull scale 79A-264-0091 Push-pull scale Commercially Ruler available Commercially Stopwatch available
1 0 to 294 N {0 to 30 kg} 1 0 to 490 N {0 to 50 kg} 1 1
—
Commercially Circuit tester available
—
Commercially 3.26 mm torque wrench Hexlobe (TORX) wrench 1 available (KTC Q4T15 or equivalent)
PC200, 200LC, 220, 220LC-8M0
1
30-101
5
Testing/Adjusting item Removal and installation of engine oil pressure sensor Removal and installation of engine coolant temperature sensor (6261-81-6900) Engine serial No.: 26500006 – 26530192 Removal and installation of engine coolant temperature sensor (6261-81-6901) Engine serial No.: 26530193 and up
a
Symbol
Part No.
Part name
Q'ty
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
SEN06127-00
Remarks
—
795-799-6210 Deep socket
1 27 mm deep socket
—
Commercially Deep socket available
1
—
795T-981-1010 Deep socket
21 mm deep socket (MITOLOY 4ML-21 or equivalent)
1 19 mm deep socket
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see “Troubleshooting (General information on troubleshooting), List of T-boxes and T-adapters”.
30-101
6
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Sketch of special tool
SEN06127-00
Sketch of special tool
1
—: Socket
PC200, 200LC, 220, 220LC-8M0
30-101
7
101 Testing and adjusting, Part 1 Testing engine speed
SEN06127-00
Testing engine speed a a
1.
2.
1
3.
Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the working mode in the power mode (P) and turn the auto-decelerator OFF. 3) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and measure the engine speed.
4.
Measuring 2-pump relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). 3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and measure the engine speed.
5.
Measuring 2-pump relief and power maximizing speed (near rated speed) 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). 3) While operating the left work equipment control lever to relieve the arm circuit at the IN stroke end and depressing the power maximizing switch, measure the engine speed. a The power maximizing function is reset automatically in approximately 8.5 seconds even if the switch is kept depressed. Accordingly, measure the engine speed in that period. a You may check with the swing lock switch ON (In this case, you do not need to operate the power maximizing switch.)
6.
Measuring auto-deceleration speed 1) Start the engine, set the fuel control dial in the high idle position (MAX), and turn the auto-decelerator ON. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and measure the engine speed when the auto-decelerator operates. a The engine speed lowers to a certain level approximately 5 seconds after all the levers and pedals are set in neutral. This level is the auto-deceleration speed.
Measure the engine speed with the monitoring function of the machine monitor. Measure the engine speed under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range Preparation work Operate the machine monitor so that the engine speed can be monitored. a For the operating method of the machine monitor, see Special functions of machine monitor. a Monitoring code: 01002 Engine speed
Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set all the levers and pedals for work equipment control, swing control, and travel in neutral and measure the engine speed.
30-101
8
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing intake air pressure (boost pressure)
Testing intake air pressure (boost pressure) 1 a
3.
Run the engine at middle or higher speed and bleed oil from the hose. a Install the connecting parts of the gauge and hose approximately a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you use the airbleeding coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.
4.
Set the working mode in the power mode (P) and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief.
5.
While running the engine with full throttle, relieve the arm circuit and measure the intake air pressure.
6.
After finishing measurement, remove the measuring tools and return the removed parts.
Measuring tools for intake air pressure (boost pressure)
Symbol
Part No.
R
799-201-2202
k
a
SEN06127-00
Part name Boost gauge kit
Stop the machine on a level ground and lower the work equipment to the ground. Measure the intake air pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Open the engine hood and remove intake air pressure pickup plug (1) from the intake air connector.
2.
Install nipple [1] of boost gauge kit R and connect it to gauge [2].
PC200, 200LC, 220, 220LC-8M0
30-101
9
101 Testing and adjusting, Part 1 Testing exhaust gas color
SEN06127-00
Testing exhaust gas color a
Checking tools for exhaust gas color
Symbol A k k
a
a
1.
1
Part No.
Part name
1
799-201-9001
Handy smoke checker
2
Commercially available
Smoke meter
Stop the machine on a level ground and lower the work equipment to the ground. Be careful not to touch any hot part when removing or installing the checking tools. Check the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. Testing with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine and accelerate it suddenly or run it at high idle and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas. a Absorbing time: 1.4 ± 0.2 sec
2)
3)
4)
5)
6) 4) 5)
2.
Remove the filter paper and compare it with the attached scale. After finishing measurement, remove the measuring tools and return the removed parts.
Checking with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
30-101
10
7)
8)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. Connect the power cable to an AC receptacle. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter A2.
Start the engine and accelerate it suddenly or run it at high idle and depress the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring tools and return the removed parts.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Adjusting valve clearance
SEN06127-00
Adjusting valve clearance a
k
a
5.
Loosen injector terminal nut (6), and remove 12 terminals from the injectors.
6.
Remove gasket (7). a Take care not to allow any foreign matter to get into the engine. a If defects, such as crack, deterioration and/or wear, are found on gasket (7), replace the gasket with a new one.
7.
Remove plate (8) and cap (10) from the flywheel housing, and install gear B1.
Measuring tools for valve clearance
Symbol B
1
Part No.
Part name
1
795-799-1131
Gear
2
Commercially available
Thickness gauge
Stop the machine on a level ground and lower the work equipment to the ground. Measure the valve clearance under the following condition. q Engine coolant temperature: Normal temperature
1.
Open the engine hood and remove the belt guard at the top of the air conditioner compressor.
2.
Disconnect three connectors (2) and two bands (3) from wiring harness (1), and separate wiring harness (1) from the head cover. a Since the connector has a lock stopper, press down the stopper with your finger and pull the connectors apart. At that time, support the gasket with your hand not to move.
3.
Remove five head cover mounting bolts (6). a After loosening the bolts, hold the head cover and blow off the sludge and foreign matters attached around with air so that they do not get into the head cover mounting section.
4.
Remove head cover (5). a Take care not to hit the cover against nearby parts. a Since the breather connector on the rear side of the cylinder head cover is connected to the flywheel housing through the O-ring, pull it together with the cylinder head cover.
PC200, 200LC, 220, 220LC-8M0
30-101
11
SEN06127-00
8.
Rotate the crankshaft forward with gear B1, and align wide slit (b) of the rotation sensor ring with the top surface of projection (a) of the front cover. a When seen from the air conditioner compressor side, the top surface of projection (a) must be in the range of wide slit (b). a If you can find the yellow marks of projection top (a) and wide slit (b), you may match them each other. k No. 1 or No. 6 piston is not set to the compression top dead center (TDC) if the crankshaft is set as described above.
9.
Check the movement of the rocker arm of the No. 1 cylinder to determine which valve should be adjusted. a If you can manually move the rocker arms of intake air valves (IN) the same distance as the valve clearance, adjust the valves marked with Q in the valve arrangement figure. a If you can manually move the rocker arms of exhaust valves (EX) the same distance as the valve clearance, adjust the valves marked with q in the valve arrangement figure. a Valve arrangement figure
101 Testing and adjusting, Part 1 Adjusting valve clearance
10. Adjust the valve clearance according to the following procedure: 1) Insert clearance gauge B2 into the clearance between rocker arm (12) and crosshead (13). 2) Loosen locknut (14), and adjust the valve clearance by using adjustment screw (15). a With the clearance gauge inserted, turn the adjustment screw to the degree that you can move the clearance gauge lightly. 3) With adjustment screw (15) fixed, tighten locknut (14). 3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening the locknut, check the valve clearance again.
11. Turn the crankshaft one rotation forward according to step 10 and align wide slit (b) with the top surface of projection (a). 12. Adjust the remaining valve clearances according to steps 11 and 12. a If you adjust the valves marked with Q of the valve arrangement figure in steps 11 and 12, adjust the remaining valves marked with q. a If you adjust the valves marked with q of the valve arrangement figure in steps 11 and 12, adjust the remaining valves marked with Q. 13. After finishing the adjustment, remove the tools and restore the machine . k Make sure not to forget removal of gear B1. 3 Cylinder head cover mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Injector terminal nut (8): 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm} a Check that the injector wiring harness does not interfere with the rocker arm.
30-101
12
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing compression pressure
Testing compression pressure a
k
k
a
1
Measuring tools for compression pressure
Symbol
C
SEN06127-00
Part No.
Part Name
1
795-799-6700
Puller
2
795-502-1590
Gauge assembly
3
795-790-4410
Adapter
4
6754-11-3130
Gasket
5
Commercially available
Hose inside diameter: approx. 15 mm
Be careful not to touch the exhaust manifold or muffler, which may get you burnt, or get caught in a rotating part when checking compression pressure. Keep the cable disconnected from the negative (-) battery terminal. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 to 60°C)
1.
Open the engine hood and remove the belt guard at the top of the air conditioner compressor.
2.
Disconnect three connectors (2) and two bands (3) from wiring harness (1), and separate wiring harness (1) from the head cover. a Since the connector has a lock stopper, press down the stopper with your finger and pull the connectors apart. At that time, support the gasket with your hand not to move.
3.
Remove five head cover mounting bolts (4). a After loosening the bolts, hold the head cover and blow off the sludge and foreign matters attached around with air so that they do not get into the head cover mounting section.
4.
Remove head cover (5). a Take care not to hit the cover against nearby parts. a Since the breather connector on the rear side of the cylinder head cover is connected to the flywheel housing through the O-ring, pull it together with the cylinder head cover.
PC200, 200LC, 220, 220LC-8M0
5.
Disconnect fuel high-pressure tube (6). a When measuring compression pressure, fuel spurts from the disconnected portion on the common rail side. Therefore, connect hose C5 and drain the fuel into a container. k Do not make bending modification of the high-pressure pipes to be used.
6.
Loosen injector terminal nut (7), and remove the terminal from the injector.
7.
Set the piston in the cylinder to be checked to the compression top dead center. a See "Adjusting valve clearance".
8.
Remove rocker arm assembly (8).
30-101
13
SEN06127-00
9.
Remove retainer (12) and fuel inlet connector (10). a In advance, remove the mud and dirt attached around so that they do not get into the mounting section of the inlet connector.
10. Remove holder (11). 11. Remove injector (12). a Use tool C1 to remove the injector. Remove the injector with impacts of a slide hammer. a Do not remove the injector by prying its top up. a Take care not to allow any dirt or foreign matter to get into the mounting section of the injector.
101 Testing and adjusting, Part 1 Testing compression pressure
14. Connect gauge assembly C2 to adapter C3. a Engine oil if applied thinly to the portion connecting the adapter and gauge offers resistance to air leak. 15. Install rocker arm assembly (8). 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm} 16. Adjust the valve clearance. a See "Adjusting valve clearance".
17. By referring to "Special functions of Equipment Management Monitoring System (EMMS)", set the engine in the no-injection cranking mode. k Engine may start during a check and incur a great danger to human body unless it is set in the no-injection cranking mode. Make sure not to forget setting the engine in the no-injection cranking mode. 18. Check the compression pressure when cranking the engine with the starting motor. a Read the gauge when its pointer stops movement.
12. Fit gasket C4 to the top end of adapter C3, and insert them in the injector (12) mounting portion. 13. Fix adapter C3 by using the injector holder (11). a Tighten the holder mounting bolts alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
30-101
14
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing compression pressure
SEN06127-00
19. After finishing the measurement, remove the tools. Be sure to restore the machine . For details, see Disassembly and assembly, "Removal and installation of cylinder head assembly". a Install the injector and fuel high-pressure tube according to the following procedure: 1) Match injector’s projection (a) to holder’s notch (b), and set the injector in the cylinder head. a When setting the injector, face the above matching point toward the fuel inlet connector insertion side.
2) 3)
4)
5)
6)
Tighten injector holder mounting bolts (13) by approximately three to four turns. Set fuel inlet connector (10). a Push the fuel inlet connector until the O-ring fits in firmly and produces a click. Lightly tighten retainer (9) of fuel inlet connector (10). 3 Retainer: 15 ± 5 Nm {1.5 ± 0.5 kgm} a Tighten above retainer (11) to the specified torque in step 6). Tighten injector holder mounting bolts (13) alternately. 3 Holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} ighten retainer (9) of the fuel inlet connector. 3 Retainer: 50 ± 5 Nm {5.1 ± 0.5 kgm}
PC200, 200LC, 220, 220LC-8M0
7)
Tighten the sleeve nuts of fuel high pressure tube (6) on the head side and then on the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
8) a
Connect injector harness connectors (12). After installing the rocker arm assembly (8), adjust the valve clearance by referring to " Adjusting valve clearance ". 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm}
a
Tighten the injector terminal nut (7) with the following torque 3 Terminal nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
a
Check that the injector harness (1) does not interfere with the rocker arm.
a
Tighten the head cover with the following torque. 3 Head cover mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
30-101
15
101 Testing and adjusting, Part 1 Testing blowby pressure
SEN06127-00
Testing blowby pressure a
Measuring tools for blowby pressure
Symbol D k
a
1
Part No.
Part name
1
799-201-1504
Blowby checker
2
799-790-3300
Blowby tool
Stop the machine on a level ground and lower the work equipment to the ground. Measure the blowby pressure under the following condition. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Remove the undercover of the hydraulic pump.
2.
Install tool and adapter [1] of blowby checker D1 or blowby tool D2 to breather hose (1) and connect gauge [2].
3.
Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief.
4.
While running the engine at high idle, relieve the arm circuit and measure the blowby pressure. a Read the gauge when the pointer is stabilized.
30-101
16
5.
After finishing measurement, remove the measuring tools and return the removed parts.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing engine oil pressure
SEN06127-00
Testing engine oil pressure a
Measuring tools for engine oil pressure
Symbol E
1 2
k
a
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
Stop the machine on a level ground and lower the work equipment to the ground. Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range
1.
Open the side cover of the pump room and remove oil pressure pickup plug (1) from the engine oil filter.
2.
Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2.
3.
Start the engine and turn the auto-decelerator OFF.
4.
Run the engine and measure the engine oil pressure at high idle and low idle.
PC200, 200LC, 220, 220LC-8M0
5.
After finishing measurement, remove the measuring tools and return the removed parts.
30-101
17
101 Testing and adjusting, Part 1 Handling fuel system parts
SEN06127-00
Handling fuel system parts a
a
1
Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When checking and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
30-101
18
Releasing residual pressure from fuel system 1 a
a
a
k
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel main filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is checked and its parts are removed, the remaining pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before checking the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing fuel pressure
SEN06127-00
Testing fuel pressure a
Measuring tools for fuel pressure
Symbol
790-261-1204
Digital hydraulic tester
795-790-4430
Adapter (10 × 1.0 mm o R1/8)
6215-81-9710
O-ring
3
799-401-2320
Gauge
4
795-790-5110
Screw
5
799-201-2202
Boost gauge kit
6
07005-01212
Gasket
F
k
1.
Part name Hydraulic tester
2
a
Part No. 799-101-5002
1
k
1
3)
Stop the machine on a level ground and lower the work equipment to the ground. Measure only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/injector to fuel tank. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot be measured.
k
Measuring pressure in fuel low-pressure circuit 1) Open the engine hood and remove fuel pressure pickup plug (1) from the fuel main filter.
2)
Install adapter F2 and nipple [1] of hydraulic tester F1 and connect them to oil pressure gauge [2] a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
PC200, 200LC, 220, 220LC-8M0
Run the engine at low idle and measure the pressure in the fuel low-pressure circuit. a If the pressure in the fuel low-pressure circuit is in the following range, it is normal.
4)
At low idle
0.5 to 1.3 MPa {5.1 to 13.3 kg/cm2}
During cranking
0.3 to 1.1 MPa {3.1 to 11.3 kg/cm2}
If the engine cannot be started, you may measure the fuel return rate while rotating the engine with the starting motor. Do not rotate for more than 30 seconds continuously, however, for protection of the starting motor.
After finishing measurement, remove the measuring tools and return the removed parts. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.2 kgm}
30-101
19
101 Testing and adjusting, Part 1 Testing fuel pressure
SEN06127-00
2.
Measuring pressure in fuel return circuit 1) Remove joint bolt (2) from the fuel return circuit.
5) 2)
3)
4)
Connect fuel return hose (3) again by using tool F4. a When installing tool F4, fit gaskets F6 to both sides of the fuel return hose eye-joint. 3 Tool F4: 19.6 to 29.4 Nm {2.0 to 3.0 kgm} Install nipple [1] of hydraulic tester F1, and connect them to hydraulic tester F3. a Nipple [1]: 799-101-5160
Measuring fuel negative-pressure circuit pressure 1) Remove joint bolt (2) of fuel hose (1) between the prefilter and supply pump.
Run the engine at low idle and measure the pressure in the fuel return circuit. a If the pressure in the fuel return circuit is in the following range, it is normal. At low idle During cranking k
30-101
3.
After finishing measurement, remove the measuring tools and return the removed parts. 3 Joint bolt (2): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
20
Max. 0.02 MPa {Max. 0.19 kg/cm2}
If the engine cannot be started, you may measure the fuel return rate while rotating the engine with the starting motor. Do not rotate for more than 30 seconds continuously, however, for protection of the starting motor.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing fuel pressure
2) a
3)
4)
5)
6)
SEN06127-00
Connect fuel hose (1) to supply pump (3) by tool F4 instead of joint bolt (2). When installing tool F4, fit the gaskets to both sides of the fuel hose joint. 3 Tool F4: 19.6 to 29.4 Nm {2.0 to 3.0 kgm} Connect tool F4 to tool F5.
Run the engine and measure the circuit negative pressure at high idle. Circuit standard negative pressure: Max. –50.7 kPa {–380 mmHg} If the negative pressure is higher than the standard pressure, the fuel prefilter may be clogged. In this case, replace the fuel prefilter and measure again. After finishing measurement, remove the measuring instruments and return the removed parts. 3 Joint bolt (2): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC200, 200LC, 220, 220LC-8M0
30-101
21
101 Testing and adjusting, Part 1 Handling reduced cylinder mode operation
SEN06127-00
Handling reduced cylinder mode operation 1
Handling no-injection cranking operation 1
a
a
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows.
1.
This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal).
2.
When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage through cylinder head gasket q Defective injection q Defective piston, piston ring q Defective valve mechanism (Moving valve system) q Defect in electrical system
3.
Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a The reduced cylinder mode operation is set from the service mode of the machine monitor. For details, see "Special functions of machine monitor (EMMS)", "5. Reduced cylinder mode operation function".
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22
q
a
No-injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. When a machine or engine has been stored for a long time, implementing the no-injection cranking before starting the engine lubricates the engine parts and thus prevents its seizure. The no-injection cranking operation is set from the service mode of the machine monitor. For details, see "Special functions of machine monitor (EMMS)", “6. No-injection cranking function”.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing fuel discharge, return and leak amount
SEN06127-00
Testing fuel discharge, return and leak amount 1 a
Testing tools for fuel discharge, return and leak amount.
Symbol 1
Joint Washer
6754-71-5340
Connector
6754-71-5350
Washer
4
Commercially available
Measuring cylinder
5
Commercially available
Stopwatch
6
Commercially available
Hose (Inside diameter: 14 mm)
7
Commercially available
Hose (Inside diameter: 7 mm)
8
Commercially available
Hose (Inside diameter: 12 mm)
G
1.
Tester kit
07005-01212
3
k
795-790-4700
Part name
6164-81-5790
2
a
Part No.
3)
Since some fuel flows out during check, prepare an oil (receiving) pan of approximately 20 l. Stop the machine on a level ground and lower the work equipment to the ground.
Crank the engine for 30 seconds and measure the discharge with measuring cylinder G4. a Adjust the route of the test hose so that it will not slacken and put its end in an oil receiving pan. a Do not crank the engine for more than 30 seconds to protect the starting motor in any case other than this measurement. a If the supply pump discharge is in the following standard range, it is normal. At cranking speed (125 rpm)
Min. 75 cc
At cranking speed (150 rpm)
Min. 90 cc
Measuring supply pump discharge 1) Loosen clamp (2) of discharge tube (1) of the supply pump and disconnect tube (1).
4)
2)
Install test hose G6 to the nipple on the discharge side of the supply pump. a Fix the hose with a wire etc. a Adjust the route of the test hose so that it will not slacken and put its end in an oil receiving pan.
PC200, 200LC, 220, 220LC-8M0
After finishing measurement, remove the measuring tools and return the removed parts. 3 Tube sleeve nut: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm}
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23
101 Testing and adjusting, Part 1 Testing fuel discharge, return and leak amount
SEN06127-00
2.
Measuring return rate from supply pump 1) Open the right side cover of the engine, and remove joint bolt (1) of the supply pump (4). Then, disconnect return hoses (2) and (3).
At low idle During cranking
6) 2) 3)
4)
5)
30-101
To prevent the fuel from flowing out, install joint bolt [1], cap nut [2] and seal washer [3] of tester kit G1 to the return hose (2). Install joint G2 to supply pump (4) by using joint bolt (1). a Fit seal washer G2 to both sides. 3 Joint bolt: 19.6 to 29.4 Nm {2.0 to 3.0 kgm} Connect test hose [4] of tester kit G1 to joint G2. a Arrange the hose run so that slack be eliminated from the test hose. Put the hose’s top end in the oil receiving container.
3.
Max. 1,000 cc/min. Max. 140 cc/min.
Remove the tools after finishing measuring. Be sure to restore the machine. a If you are going to measure the leakage from the pressure limiter or finish the measurement: Restore the machine. a If you are going to measure the leakage from the injector: Leave the machine as it is, and keep the top end of the test hose put in the container.
Measuring leakage from pressure limiter 1) Open the right side cover of the engine, and disconnect return hose (1) of the pressure limiter. a Disconnect hose clamp (2), and disconnect the hose at quick coupler (a).
Start the engine. By using measuring cylinder G4, measure the return rate for 1 minute with the engine speed at low idle. a You may make the measurement for 20 seconds and multiply the measured result by 3. a If the return rate from the supply pump is within the following standard range, it is normal.
24
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing fuel discharge, return and leak amount
2) 3)
Insert connector G6 on the drain side of the hose, and install cap nut [2] of tester kit G1 to prevent fuel from flowing out. Connect test hose G7 on the pressure limiter side. a Arrange the hose run so that slack be eliminated from the test hose. Put the hose’s top end in the oil receiving container.
SEN06127-00
4.
Measuring return rate from injector 1) Open the right engine side cover. Remove joint bolt (1) from the supply pump (4). Disconnect return hoses (2) and (3). 2) Disconnect the return hose (2) at quick coupler (a).
3)
4)
Start the engine. By using measuring cylinder G4, measure the leakage for 1 minute with the engine speed at low idling. a If the leakage from the pressure limiter is within the following standard value, it is normal. At low idle
5)
0 cc (No leakage)
4)
5) 6)
To prevent the fuel from flowing out, install joint bolt [1], cap nut [2] and seal washer [3] of tester kit G1 on the drain side of return hose (2). Connect return hose (3) to supply pump (4). 3 Joint bolt: 19.6 to 29.4 Nm {2.0 to 3.0 kgm} Connect hose G7 to return hose (2-1). Install connector G6 to return hose (2), and connect test hose G8. a Arrange the hose run so that slack be eliminated from the test hose. Put the hose’s top end in the oil receiving container.
Remove the tool used after measurement. Be sure to restore the machine. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
PC200, 200LC, 220, 220LC-8M0
30-101
25
101 Testing and adjusting, Part 1 Bleeding air from fuel circuit
SEN06127-00
7)
Start the engine. By using measuring cylinder G4, measure the return rate from the injector for 1 minute with the engine speed at low idle. a You may make the measurement for 20 seconds and multiply the measured result by 3. a If the return rate from the supply pump is within the following standard range, it is normal.
k
8)
30-101
Low idle
Max. 180 cc
Cranking
Max. 90 cc
Bleeding air from fuel circuit a k
1
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground.
1.
Fill up fuel tank with fuel. a Add fuel until the float of the sight gauge reaches the maximum position.
2.
Open the side cover of the pump room.
3.
Loosen knob (1) of the feed pump and pull it out, and then operate it forward and backward. a Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed. a After bleeding air, some air may be left in the water separator. If the feed pump is operated until it becomes heavy, however, the engine can be started. The remaining air is bled naturally while the engine is running for a while. This phenomenon occurs when the fuel in the fuel prefilter is drained too much and does not indicate an abnormality or a trouble.
4.
After bleeding air, push in and tighten knob (1).
If you cannot start the engine, you may measure the return rate with the engine cranked with the starting motor. However, for protection of the starting motor, do not keep cranking continuously for 20 seconds or longer.
Remove the tools after finishing measuring. Be sure to restore the machine. 3 Joint bolt: 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
26
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing fuel circuit for leakage
Testing fuel circuit for leakage k
k
a
SEN06127-00
1
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
4.
Run the engine at low idle.
5.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
6.
Run the engine at high idle.
7.
Check the fuel piping and devices for fuel leakage. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2.
8.
Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end.
PC200, 200LC, 220, 220LC-8M0
9.
Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 2. a If no fuel leakage is detected, check is completed.
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27
SEN06127-00
101 Testing and adjusting, Part 1 Handling controller high voltage circuit
Handling controller high voltage circuit 1 1.
Disconnection or connection of the connector between the engine controller and engine must be done after turning off the starting switch.
2.
It is prohibited to start the engine when Tadapter is inserted or connected, for troubleshooting purpose, to the connector between the engine controller and engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-101
28
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting air conditioner compressor belt ten-
Testing and adjusting air conditioner compressor belt tension k
1
Stop the machine on a level ground and lower the work equipment to the ground.
Testing 1. Open the engine hood and remove the belt guard from the top of the air conditioner compressor. 2.
Adjusting a If the belt deflection is abnormal, adjust it according to the following procedure. 1.
Loosen bolts (1) and (2).
2.
Move compressor (3) and bracket (4) together to adjust the belt tension.
3.
After positioning compressor (3), tighten bolts (1) and (2). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack, replace it. a If the belt is replaced, adjust their tension again after operating the machine for 1 hour. a After tightening the bolts, check the belt tension again according the above procedure.
4.
After finishing measurement, return the removed parts.
Press the intermediate point of the belt between fan pulley and compressor pulley with a finger and measure deflection (a) of the belt. q Belt pressing force: 60 N {6.2 kg}
PC200, 200LC, 220, 220LC-8M0
SEN06127-00
30-101
29
101 Testing and adjusting, Part 1 Replacing alternator belt
SEN06127-00
Replacing alternator belt a a k
1
The auto-tensioner is provided for the fan belt. Thus, testing and adjustment of the belt is usually not necessary. Disconnect air conditioner compressor belt before replacing the fan belt.
3.
Replace the fan belt (3). Check each pulley for breakage and crack.
q
Stop the machine on a level ground and lower the work equipment to the ground.
1.
Open engine hood and remove fan belt cover (1).
2.
Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (2), and rotate it to the opposite to the winding-up direction to decrease the fan belt (3) tension. k Make sure that the wrench is secured at the portion (A) of the tensioner assembly (2) before rotating it. (The spring of the tensioner assembly (2) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing the fan belt (3), return the tensioner assembly (2) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (3) during work.
30-101
30
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing swing circle bearing clearance
Testing swing circle bearing clearance a
4.
Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. a At this time the front of the upper structure rises and the rear lowers.
5.
Under this condition, read dial gauge H. a The value indicated by dial gauge H is the clearance of the bearing. a For the standard value, see Structure, function and maintenance standard, “Swing circle”.
6.
Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If the dial gauge does not indicate 0, repeat steps 2 through 5.
1
Measuring tools for swing circle bearing clearance
Symbol
Part No.
H
Commercially available
a k k
1.
SEN06127-00
Part name Dial gauge
When testing the swing circle bearing clearance installed to the machine, perform the following procedure. Stop the machine on a level ground and lower the work equipment to the ground. Do not put your hands or feet under the undercarriage during test. Fix dial gauge H to the track frame and apply the probe to the lower end of the outer race.
2.
Set the work equipment to the maximum reach position and set the bucket tip to the height of the under side of the revolving frame. a At this time the front of the upper structure lowers and the rear rises.
3.
Set dial gauge H to the 0 point.
PC200, 200LC, 220, 220LC-8M0
30-101
31
101 Testing and adjusting, Part 1 Testing and adjusting track tension
SEN06127-00
Testing and adjusting track tension
1
Testing 1. Run the engine at low idle and drive the machine forward by the length of track on ground, and then stop slowly. 2.
Place straight bar [1] on the track shoe between the idler and the 1st carrier roller. a As the straight bar, use an angle steel, etc. which will be deflected less.
3.
Measure maximum clearance (a) between steel bar [1] and track shoe. q Standard maximum clearance (a): 10 to 30 mm
Adjusting a If the track tension is abnormal, adjust it according to the following procedure. 1.
Increasing tension 1) Add grease through grease fitting (1) with a grease gun. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track tension again according to the above procedure.
a
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32
You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn much. In this case, reverse or replace the pins and bushings.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting track tension
2.
SEN06127-00
Decreasing tension 1) Loosen valve (2) to discharge grease, and then tighten it. k Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the highpressure grease in it. 2) To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track tension again according to the above procedure.
PC200, 200LC, 220, 220LC-8M0
30-101
33
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in work equipment,
SEN06127-00
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Symbol 1 J 2 k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see “Releasing residual pressure from hydraulic circuit”.
Measuring a The oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor, too (For details, see “Special functions of machine monitor”). q Monitoring code: 01100 F pump pressure q Monitoring code: 01101 R pump pressure a Measure the oil pressure in the work equipment, swing, and travel circuits under the following condition. q Hydraulic oil temperature: Within operating range 1.
Install nipples J2 and connect oil pressure gauges [1] of hydraulic tester J1. a Use the oil pressure gauge with capacity 60 MPa {600 kg/cm2}.
Measuring and adjusting tools for oil pressure in work equipment, swing, and travel circuits
Preparation work 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug
2.
Combination of pump, actuator, and valve a When the oil from the pumps is divided, the front pump and rear pump act independently on each actuator. Note that different actuators relieve different valves. a When the work equipment circuit or swing circuit is relieved singly, the oils of the pumps are merged. When the travel circuit is relieved singly, the oils of the pumps are divided. a The actuators in the table are arranged in the order when the control valve is seen from the front of the machine (and an attachment is installed to the service valve). Actuator
Valve relieved
(R unload valve) (R main relief valve) Rear pump
a
2)
Service
Safety-suction valve
Bucket
R main relief valve
Left travel R main relief valve Boom
Raise: R main relief valve Lower: Safety-suction valve
(Pump merge-divider valve) (Travel junction valve)
Front pump
(Self pressure reducing valve) Swing
Swing motor safety valve
Right travel
F main relief valve
Arm
F main relief valve
(F unload valve) (F main relief valve) (Centralized safety valve) (Back pressure valve)
30-101
34
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in work equipment,
3.
SEN06127-00
Measuring unload pressure 1) Start the engine, set the working mode in the power mode (P), and turn the autodecelerator OFF. 2) Run the engine at high idle, set all the levers and pedals for work equipment control and travel in neutral, and test the oil pressure. a The pressure measured when the unload valve is unloaded is indicated.
2)
6.
4.
5.
Measuring work equipment relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Set the working mode in the power mode (P). 3) Run the engine at full speed, operate the right and left work equipment control levers to relieve the cylinder, and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated (If the boom is lowered singly, the safety-suction valve of the control valve for lowering the boom is relieved). a If the power maximizing switch is released, the main relief valve is relieved at low pressure. If the former is pressed, the latter is relieved at high pressure. a If the swing lock switch is set in turned ON, the 2-stage relief solenoid valve is kept turned ON and the relief valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF. Measuring swing relief pressure 1) Start the engine, set the working mode in the power mode (P), and turn the swing lock switch ON.
PC200, 200LC, 220, 220LC-8M0
Measuring travel relief pressure 1) Run the engine and lock the travel mechanism. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
2) 3)
7.
Run the engine at high idle, operate the left work equipment control lever to relieve the swing motor, and measure the oil pressure. a The pressure measured when the swing motor relief valve is relieved is indicated. a The swing relief pressure is lower than the main relief pressure.
Set the working mode in the power mode (P). Run the engine at high idle, operate the travel lever and pedal to relieve the travel motor, and measure the oil pressure. k Before operating the travel lever and pedal, check the position and locking direction of the locked sprocket again. a The pressure measured when the main relief valve of the control valve is relieved is indicated. The travel circuit is always relieved at high pressure.
Work after finishing measurement After finishing measurement, remove the measuring tools and return the removed parts. 3 Oil pressure pickup plug: 20 to 27 Nm {2.0 to 2.8 kgm}
Adjusting a The unload valve and suction safety valve for lowering the boom cannot be adjusted.
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35
SEN06127-00
1.
Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valves (3) and (4) according to the following procedure. q (3): Front (F) main relief valve q (4): Rear (R) main relief valve a When adjusting the main relief valves, remove the top cover of the control valve. a Adjust only the low relief pressure of the main relief valve. If the low repair procedure is adjusted, the high repair procedure is set automatically. a The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port.
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in work equipment,
5) 6)
2.
Adjusting swing relief pressure a If the swing relief pressure is abnormal, adjust safety valve (8) of the swing motor according to the following procedure.
1) 2)
1) 2) 3)
4)
Disconnect pilot hose (5). While fixing holder (6), loosen locknut (7). Turn holder (6) to adjust the set pressure. a If the holder is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} While fixing holder (6), tighten locknut (7). 3 Locknut: 49 to 58.8 Nm {5 to 6 kgm}
3)
4)
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36
Connect pilot hose (5). After finishing adjustment, check again that the oil pressure is normal according to the above described measurement procedure.
While fixing adjustment screw (9), loosen locknut (10). Turn adjustment screw (9) to adjust the pressure. a If the adjustment screw is q Turned to the right, the set pressure is increased. q Turned to the left, the set pressure is decreased. a Quantity of adjustment per turn of adjustment screw: Approx. 6.7 MPa {Approx. 68.4 kg/cm2} While fixing adjustment screw (9), tighten locknut (10). 3 Locknut: 78 to 103 Nm {8 to 10.5 kgm}
After finishing adjustment, check again that the oil pressure is normal according to the above described measurement procedure.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing control circuit source pressure
Testing control circuit source pressure a
1 K 2
a
1.
2.
Part No. 799-101-5002
3.
Start the engine, set the working mode in the power mode (P), and turn the auto-decelerator OFF.
4.
Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel to the neutral, and measure the oil pressure.
5.
After finishing measurement, remove the measuring tools and return the removed parts.
a
The control circuit basic pressure may be measured with oil pressure pickup plug (2) on the hydraulic pump side.
a
Do not adjust the relief valve for control circuit source pressure.
1
Measuring tools for control circuit basic pressure
Symbol
k
SEN06127-00
Part name Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the remaining pressure from the hydraulic circuit. For details, see “Releasing remaining pressure from hydraulic circuit”. Measure the control circuit source pressure under the following condition. q Hydraulic oil temperature: Within operating range Remove the control valve top cover and oil pressure pickup plug (1).
Install nipple K2 and connect oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauge with capacity 6 MPa {60 kg/cm2}.
PC200, 200LC, 220, 220LC-8M0
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37
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump PC control cir-
SEN06127-00
Testing and adjusting oil pressure in pump PC control circuit 1 a
Measuring and adjusting tools for oil pressure in pump PC control circuit
Symbol 1 L 2 k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the remaining pressure from the hydraulic circuit. For details, see “Releasing remaining pressure from hydraulic circuit”.
2)
Install nipples L2 and nipples [1] of hydraulic tester L1 and connect them to oil pressure gauges [2]. a Connect the measuring part of plug (3) by using joint (790-301-1271) and elbow (790-301-1530) of hydraulic tester L1 and nipple [1] so that it will not interfere with the drain piping. a Use the oil pressure gauge of 60 MPa {600 kg/cm2}.
3)
Start the engine and operate the arm cylinder to the IN stroke end. Set the working mode in the power mode (P) and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for highpressure relief.
Measuring a Before measuring the oil pressure in the PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the control circuit source pressure are normal. a Measure the oil pressure in the pump PC control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1.
Measuring of PC valve output pressure (servo piston inlet pressure) a Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously to compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1), (2), (3), and (4). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug q (3): Front PC valve output pressure pickup plug q (4): Rear PC valve output pressure pickup plug
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38
4)
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump PC control cir-
5)
SEN06127-00
Run the engine at high idle, operate the left work equipment control lever to relieve the arm circuit at the IN stroke end, and measure the oil pressure.
a
2)
Install nipples L2 and connect them to oil pressure gauges [2]. a Use the oil pressure gauge of 6 MPa {60 kg/cm2}.
3)
Start the engine and set the working mode in the power mode (P). Run the engine at high idle and low idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and measure the oil pressure at each speed.
Measuring condition and method of judgment: If the pressures are in the following ratio, the PC valve is normal. Tested oil pressure
Pump discharge pressure PC valve output pressure
Operation of lever
Ratio of oil pressures 1
Arm IN relief
Approx. 0.6 (Approx. 3/5)
a
6)
2.
If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0". After finishing measurement, remove the measuring tools and return the removed parts.
Measuring PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plugs (5) and (6). (5): Front PC-EPC valve output pressure pickup plug (6): Rear PC-EPC valve output pressure pickup plug
PC200, 200LC, 220, 220LC-8M0
4)
30-101
39
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump PC control cir-
SEN06127-00 a
Measuring condition and method of judgment: If the output pressures are the following values, the PC-EPC valve is normal.
Engine Low idle High idle
5)
Operation of lever All control levers and pedals in neutral
Loosen locknut (9). a Before loosening the locknut, make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
2.
Turn adjustment screw (10) clockwise or counterclockwise to adjust. a Turn the adjustment screw q Clockwise when the work equipment speed is low (to in crease pu mp absorption torque) and q Counterclockwise when the engine speed lowers (to decrease pump absorption torque).
3.
Tighten locknut (9). 3 Locknut: 27 to 34 Nm {2.8 to 3.5 kgm}
4.
After finishing adjustment, check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described measurement procedure.
Output pressure Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa {0 kg/cm2}
After finishing measurement, remove the measuring tools and return the removed parts.
Adjusting Adjusting pump PC valve a If either of the following phenomena occurs and the PC valve seems to be defective, adjust PC valves (7) and (8) according to the procedure shown below. q As the working load increases, the engine speed lowers remarkably. q The engine speed is normal but the work equipment speed is low. q (7): Front pump PC valve q (8): Rear pump PC valve a The width across flats of the PC valve locknut is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance.
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1.
40
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump LS control cir-
SEN06127-00
Testing and adjusting oil pressure in pump LS control circuit 1 a
Measuring and adjusting tools for oil pressure in pump LS control circuit
Symbol 1 M
2 3
k
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2701
Differential pressure gauge
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see “Releasing residual pressure from hydraulic circuit”.
2)
Install nipples M3 and nipples [1] of hydraulic tester M1 and connect them to oil pressure gauges [2]. a Connect the measuring part of plug (3) by using joint (790-301-1271) and elbow (790-301-1530) of hydraulic tester M1 and nipple [1] so that it will not interfere with the drain piping. a Use the oil pressure gauge of 60 MPa {600 kg/cm2}.
3)
Start the engine and push up the track shoe on the side to be measured with the work equipment and prepare for running the track shoe idle. q When measuring front circuit: Right track shoe q When measuring rear circuit: Left track shoe k Since the raised track will be run in the air during measurement, secure a sufficient working area. Set the working mode in the power mode (P) and set the travel speed in the High position.
Measuring a Before measuring the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the control circuit source pressure are normal. a Measure the oil pressure in the pump LS control circuit under the following condition. q Hydraulic oil temperature: Within operating range 1.
Measurement of LS valve output pressure (servo piston inlet pressure) a Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously to compare them. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1), (2), (3), and (4). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug q (3): Front LS valve output pressure pickup plug q (4): Rear LS valve output pressure pickup plug
4)
PC200, 200LC, 220, 220LC-8M0
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41
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump LS control cir-
SEN06127-00
5)
Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel control in neutral, and measure the oil pressure. Then, operate the travel lever to run the track in the air and measure the oil pressure. k While taking extreme care for safety, run the raised track shoe. a Do not operate the travel lever to its stroke end (but stop it halfway).
a
Testing condition and judgment method: When the hydraulic pressures are within ratio in the table, LS valve is normal.
2.
Measurement of LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them, to obtain the LS differential pressure. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1), (2), (5), and (6). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug
q q
(5): Front LS pressure pickup plug (6): Rear LS pressure pickup plug
Hydraulic pressure to be measured
Position of levers and pedals Travel lever All levers and move halfpedals are at way (Travel neutral without load)
6)
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Pump discharge pressure LS valve output pressure
Almost same pressure
1 (Actual value is set as 1) Approx. 3/5 of pressure above
After finishing measurement, remove the measuring tools and return the removed parts.
42
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump LS control cir-
2)
Install nipples M3 and connect it to differential pressure gauge M2 or the oil pressure gauge of hydraulic tester M1. a When using differential pressure gauge M2: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12V power source, connect it to a battery. a When using oil pressure gauge (in M1): Use the oil pressure gauge of 60 MPa {600 kg/cm 2 } having the unit of 1.0 MPa {10 kg/cm2}. Since the differential pressure is approximately 4.0 MPa {40 kg/cm2} at maximum, measure it by installing the same gauge to the pickup plugs alternately. q The figure shows the pump discharge pressure side.
q
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3)
4) 5)
Run the engine, push up the track shoe on the side to be measured with the work equipment, and prepare for running track shoe idle. q When measuring front circuit: Right track shoe q When measuring rear circuit: Left track shoe k Since the raised track shoe will be run idle during measurement, secure a sufficient working area. Set the working mode in the power mode (P) and set the travel speed in the High position. Run the engine at high idle, set all the levers and pedals for work equipment control, swing control, and travel in neutral, and measure the oil pressure at each speed. Then, operate the travel lever to run the track shoe idle and measure the oil pressure. k While taking extreme care for safety, run the raised track shoe. a Do not operate the travel lever to its stroke end (but stop it halfway).
The figure shows the LS pressure side. a
Measuring condition and method of judgment: If the pressures are in the following value, the LS valve is normal. Operation of levers
LS differential pressure
All control levers and pedals Specified LS difin neutral ferential pressure Travel lever moved halfway (See standard values table) (Track running in the air)
6)
PC200, 200LC, 220, 220LC-8M0
After finishing measurement, remove the measuring tools and return the removed parts.
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43
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump LS control cir-
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3.
Measurement of LS-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plug (7).
5)
2)
Install nipple M3 and connect them to oil pressure gauge [2]. a Use the oil pressure gauge of 6 MPa {60 kg/cm2}.
3) 4)
Start the engine. Run the engine at high idle, operate the travel speed selector switch and travel lever, and measure the output pressure in each case. a Measuring condition and method of judgment: If the output pressures are the following value, the LS-EPC valve is normal. Travel speed
Operation of lever
After finishing measurement, remove the measuring tools and return the removed parts.
Output pressure
Lo
Travel lever Approx. 2.9 MPa in neutral {Approx. 30 kg/cm2}
Hi
Travel lever operated a little (Note)
0 MPa {0 kg/cm2}
Note: Move the travel lever to a degree that the PPC oil pressure switch is turned ON (before the track starts moving).
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44
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing and adjusting oil pressure in pump LS control cir-
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Adjusting Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. q (8): Front pump LS valve q (9): Rear pump LS valve
1.
While fixing adjustment screw (10), loosen locknut (11).
2.
Turn adjustment screw (10) to adjust the differential pressure. a If the adjustment screw is q Turned to the right, the differential pressure is increased. q Turned to the left, the differential pressure is decreased. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.1 MPa {Approx. 10.8 kg/cm2}
3.
While fixing adjustment screw (10), tighten locknut (11). 3 Locknut: 49 to 68.6 Nm {5 to 7 kgm}
4.
After finishing adjustment, check again that the LS differential pressure is normal according to the above described measurement procedure.
PC200, 200LC, 220, 220LC-8M0
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45
101 Testing and adjusting, Part 1 Testing solenoid valve output pressure
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Testing solenoid valve output pressure a
Part No.
1 2
k
a a
1.
1
Measuring tools for solenoid valve output pressure
Symbol N
a
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3100
Adapter (Size 02)
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the remaining pressure from the hydraulic circuit. For details, see “Releasing remaining pressure from hydraulic circuit”. Before measuring the solenoid valve output pressure, check that the control circuit source pressure is normal. Measure the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
2.
Install adapter N2 and connect the disconnected hose again.
3.
Fit nipple [1] of hydraulic tester N1 and then connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 6 MPa {60 kg/ cm2}. a The figure shows the measuring tools connected to outlet hose (1) of the PPC lock solenoid valve.
4.
Start the engine.
5.
Run the engine at high idle, operate the control levers and switches to turn the solenoid valve ON or OFF, and measure the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operation table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the machine monitor (For details, see “Special functions of machine monitor”). q Monitoring code: 02300 Solenoid 1 q Monitoring code: 02301 Solenoid 2
Disconnect outlet hoses (1) – (6) of the solenoid valves to be measured. No.
Solenoid valve to be measured
1
PPC lock solenoid valve
2
2-stage relief solenoid valve
3
Swing holding brake solenoid valve
4
Travel speed selector solenoid valve
5
Travel junction solenoid valve
6
ATT return selector solenoid valve (Attachment installation specification)
a
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When measuring with hoses (2) – (6), remove the undercover of the control valve.
When measuring with hose (1), remove the undercover (rear side) of the operator's cab.
46
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing solenoid valve output pressure
a
6.
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If the output pressure is as follows, the solenoid valve is normal. Solenoid valve
Output pressure
OFF (Demagnetization)
0 MPa {0 kg/cm2}
ON (Excitation)
2.9 MPa {30 kg/cm2}
After finishing measurement, remove the measuring tools and return the removed parts.
PC200, 200LC, 220, 220LC-8M0
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47
101 Testing and adjusting, Part 1 Testing solenoid valve output pressure
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Operation table of PPC lock solenoid valve Operating condition Lock lever
Operation
Lock
OFF
Free
ON
Operation table of 2-stage relief solenoid valve Operating condition
Operation
Overheat 1st setting is ON Overheat 2nd setting is ON
OFF
All of work equipment, swing, and travel signals are OFF Swing lock switch is ON Travel signal is ON L mode is selected
ON
Boom LOWER signal is ON P/E mode is selected
Left knob switch is ON
Signals other than swing single signal are ON Swing single signal is ON
Other than above condition
OFF
Operation table of swing holding brake solenoid valve Operating condition Work equipment, swing, and travel signals
Operation
All are OFF
OFF
Any one is ON
ON
Operation table of travel speed selector solenoid valve Operating condition
Operation
Overheat 2nd setting signal is ON Fuel control dial is at 1,500 rpm or below Travel speed switch is at Lo/Mi (PC200-8M0) Travel speed switch is at Lo (PC220-8M0)
OFF
Travel speed switch is at Hi (PC200Travel signal is OFF 8M0) F or R pump pressure is 24.5 MPa {250 kg/cm2} Travel speed switch is at Mi/Hi (PC220- Travel signal is ON F or R pump pressure is 15.3 MPa {150 kg/cm2} 8M0)
ON
Other than above condition
Operation table of travel junction solenoid valve Operating condition
Operation
Travel steering signal is ON Travel steering signal is OFF
Travel lever is operated independently
F or R pump pressure is 24.5 MPa {250 kg/cm2}
Other than above condition
ON OFF
Operation table of ATT return selector solenoid valve (Machine with provision for attachment) Operating condition
Operation
Working mode: Other than B
OFF
Working mode: B
ON
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48
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing PPC valve output pressure
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Testing PPC valve output pressure
1
Connecting points of PPC piping
a
The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. The colors in ( ) are the colors of the bands installed for distinction of the pipes.
PC200, 200LC, 220, 220LC-8M0
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49
101 Testing and adjusting, Part 1 Testing PPC valve output pressure
SEN06127-00 a
Measuring tools for PPC valve output pressure
Symbol
k
a a
1.
Part name Hydraulic tester
790-261-1204
Digital hydraulic tester
2
799-401-3100
Adapter (Size 02)
3
799-401-3200
Adapter (Size 03)
1 P
Part No. 799-101-5002
Stop the machine on a level ground and lower the work equipment to the ground. Then, release the remaining pressure from the hydraulic circuit. For details, see “Releasing remaining pressure from hydraulic circuit”. Before measuring the PPC valve output pressure, check that the control circuit source pressure is normal. Measure the solenoid valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range Disconnect the hose of the PPC circuit to be measured. a For the hose to be disconnected, see “Connecting points of PPC piping”.
2.
Install adapter P2 and connect the disconnected hoses again.
3.
Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. a Use the oil pressure gauge of 6 MPa {60 kg/ cm2}. a The figure shows the measuring tools connected to the hose of the bucket dump PPC circuit.
4.
Start the engine and set the working mode in the power mode (P).
5.
Run the engine at high idle and measure the oil pressure with the control lever in neutral and moved to its stroke end.
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50
a
6.
If the output pressure is as follows, the PPC valve is normal. Operation of lever
Output pressure
Neutral
0 MPa {0 kg/cm2}
Stroke end
Almost same as control circuit basic pressure (See standard values table)
After finishing measurement, remove the measuring tools and return the removed parts.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Adjusting play of work equipment and swing PPC valves
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Adjusting play of work equipment and swing PPC valves 1 a a
If the right and left work equipment levers have large play, adjust them according to the following procedure. The play of the lever terminal must be 0.5 – 3 mm at a position of 200 mm from the center of lever rotation.
1.
Remove the work equipment and swing PPC valve assembly.
2.
Remove bellows (1).
3.
Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). a Do not move the piston at this time.
4.
Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 69 to 88 Nm {7 to 9 kgm}
5.
Install bellows (1).
6.
Install the work equipment and swing PPC valve assembly.
PC200, 200LC, 220, 220LC-8M0
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51
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101 Testing and adjusting, Part 1 Testing parts which cause hydraulic drift of work equipment
Testing parts which cause hydraulic drift of work equipment a
If the work equipment (cylinder) drifts hydraulically, check to see if the causal part is the cylinder packing or control valve side according to the following procedure.
1.
Measurement of boom and bucket cylinders 1) Set the machine in the posture for measuring hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.
2.
Inspection of arm cylinder 1) Stop the arm cylinder approximately 100 mm before the IN stroke end and stop the engine.
2)
2)
30-101
When checking the boom cylinder, set the boom control lever to the RAISE position. When checking the bucket cylinder, set the bucket control lever to the CURL position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for approximately 5 seconds to increase the pressure in the accumulator.
52
Operate the arm control lever in the IN position. q If the lowering speed is increased at this time, the cylinder packing is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for approximately 5 seconds to increase the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above posture (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing parts which cause hydraulic drift of work equipment
3.
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Checking PPC valve While the pressure in the accumulator is high, set the lock lever to the LOCK/FREE position and measure the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for approximately 5 seconds to increase the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
PC200, 200LC, 220, 220LC-8M0
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53
101 Testing and adjusting, Part 1 Releasing remaining pressure from hydraulic circuit
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Releasing remaining pressure from hydraulic circuit 1.
2.
4)
1
Releasing remaining pressure from hydraulic tank k Since the hydraulic tank is enclosed and pressurized, release the residual pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released completely.
3.
Release of remaining pressure from swing motor circuit The remaining pressure in the swing motor circuit can be released by performing the operation for “Releasing remaining pressure from hydraulic cylinder circuit” (Operate the lever to SWING only, however).
4.
Release of remaining pressure from travel motor circuit Since the control valve spool of the travel motor circuit is connected to the drain circuit, the pressure in this circuit can be released by performing “Releasing remaining pressure from hydraulic tank”.
Release of remaining pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure from the piping according to the following procedure. 1) Lower the work equipment to the ground and release the residual pressure from the hydraulic tank. For details, see “Releasing remaining pressure from hydraulic tank”. a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch to ON position and set the lock lever to the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 – 3 times. 3) Run the engine at low idle for 5 seconds to increase the pressure in the accumulator. a The engine does not start until the lock lever is set to the LOCK position once.
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54
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing oil leakage
SEN06127-00
Testing oil leakage a
1
Measuring tools for oil leakage
Symbol
Part No.
Q
Commercially available
Part name Measuring cylinder
a
Measure the oil leakage under the following condition. q Hydraulic oil temperature: Within operating range
1.
Measuring oil leakage from boom cylinder 1) Move the boom cylinder to the RAISE stroke end and stop the engine. k Release the residual pressure from the piping on the boom cylinder head side. For details, see “Releasing residual pressure from hydraulic circuit” (Operate the lever in the boom RAISE direction only, however). 2) Disconnect hose (1) on the cylinder head side and block the hose side with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-00640 (Flange #06)
2.
Measuring oil leakage from arm cylinder 1) Move the arm cylinder to the IN stroke end and stop the engine. k Release the residual pressure from the piping on the arm cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever to arm IN only, however). 2) Disconnect hose (2) on the cylinder head side and block the hose side with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-00640 (Flange #06)
3)
4) 5)
3) 4) 5)
Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. After finishing measurement, return the removed parts.
Run the engine at high idle and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. After finishing measurement, return the removed parts.
PC200, 200LC, 220, 220LC-8M0
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55
101 Testing and adjusting, Part 1 Testing oil leakage
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3.
Measuring oil leakage from bucket cylinder 1) Move the bucket cylinder to the CURL stroke end and stop the engine. k Release the residual pressure from the piping on the bucket cylinder head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the bucket CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block the hose side with a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-00640 (Flange #06)
4.
Measuring oil leakage from swing motor 1) Disconnect 2 drain hoses (4) and block the hose side with plugs. a Use the following part to block the hose side. 07376-70522 (Plug #05)
2) 3)
4) 3) 4) 5)
30-101
Turn the swing lock switch ON. Run the engine at high idle and relieve the swing circuit by swinging. a Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. a After measuring 1 time, swing 180°, and then measure again. After finishing measurement, return the removed parts.
Run the engine at high idle and relieve the bucket circuit by curling the bucket. k Take care not to “dump the bucket”. Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. After finishing measurement, return the removed parts.
56
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Testing oil leakage
5.
Measuring oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine, lock the sprocket, and stop the engine. k Put pin [1] between the sprocket and track frame to lock the travel mechanism securely.
3)
Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70422 (Plug #04)
4)
Run the engine at high idle, relieve the travel circuit, and measure the oil leakage. k Before operating the travel lever, check the position and locking direction of the locked sprocket again. k Wrong operation of the lever can cause an accident. Accordingly, make signals and checks securely. a Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. a Measure several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time.
PC200, 200LC, 220, 220LC-8M0
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5)
After finishing measurement, return the removed parts.
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57
101 Testing and adjusting, Part 1 Bleeding air from each part
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Bleeding air from each part
1 q: Execution of work o: Go to next procedure Air bleeding procedure
Air bleeding item 1
2
3
Bleeding air from hydraulic pump
Starting engine
q
q
4
5
6
Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor
Checking oil level and starting operation
q
q (See note)
q (See note)
q
q
o
o
o
q
q
q
o
o
q
• Replacing and repairing control valve • Removing control valve piping
q
q
o
o
q
• Replacing and repairing cylinder • Removing cylinder piping
q
q
o
o
q
• Replacing and repairing swing motor • Removing swing motor piping
q
o
q
o
q
• Replacing and repairing travel motor • Removing travel motor piping
q
o
o
q
q
• Replacing and repairing swivel joint • Removing swivel joint piping
q
o
o
o
q
Contents of work • Replacing hydraulic oil • Cleaning strainer • Replacing return filter element • Replacing and repairing hydraulic pump • Removing suction piping
q
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1.
Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 2) After the oil oozes out, tighten air bleeder (1). 3 Air bleeder: 7.8 to 9.8 Nm {0.8 to 1.0 kgm} a Do not use an impact wrench to tighten the air bleeder.
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58
2.
Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch to the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
3.
Bleeding air from cylinder a If a cylinder is replaced, bleed air from it before installing it to the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for approximately 5 minutes. 2) While running the engine at low idle, raise and lower the boom 4 to 5 times. a Stop the piston rod approximately 100 mm before each stroke end. Do not relieve the oil.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Bleeding air from each part
3) 4)
5)
While running the engine at high idle, perform step 2). While running the engine at low idle, move the piston rod to the stroke end and relieve the oil. Bleed air from the arm cylinder and bucket cylinder according to steps 2) to 4).
4.
Bleeding air from swing motor 1) Run the engine at low idle. 2) Swing slowly to bleed air.
5.
Bleeding air from travel motor 1) Run the engine at low idle. 2) Loosen air bleeder (2) and check that oil oozes out through the air bleeder. 3) After the oil oozes out, tighten air bleeder (2). 3 Air bleeder: 27.5 to 35.3 Nm {2.8 to 3.6 kgm}
6.
Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder fully, lower the work equipment to the ground, and stop the engine.
PC200, 200LC, 220, 220LC-8M0
SEN06127-00
2)
Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. a If the oil level is below line L, it is insufficient. Add oil. a The oil level changes according to the oil temperature. Add oil when the oil level is out of the following standard ranges. q When oil temperature is 10 to 30°C: Between line H and line L q When oil temperature is 50 to 80°C: Near line H
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59
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Testing cab tipping stopper
a
Check the cab tipping stopper according to the following procedure.
1.
Remove the additional under cover at the rear of the operator's cab. (Only for the machine equipped with the reinforced type under cover)
2.
Check the tightening torque of the mounting bolt (2) of the lock plate (1). 3 Bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
101 Testing and adjusting, Part 1 Testing cab tipping stopper
1
[Reference] The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. Take care. 3 Bolt (4): 245 to 309 Nm {25 to 31.5 kgm}
q
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101 Testing and adjusting, Part 1 Adjusting mirrors
Adjusting mirrors
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101 Testing and adjusting, Part 1 Installation and adjustment of mirrors
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Installation and adjustment of mirrors 1.
4)
Retract the mirror into position (C) when transporting the machine.
5)
Retractable mirror (b1): Install at 15 mm (from the top of the stay). Install mirror stay (4) so that the mirror will be fixed at (A) of the 3 stopping positions where the mirror is extracted most and fixed angle (f) to be at an angle of approximately 26 deg. to the side of the machine body. If the mirrors are not installed to the correct positions, they may interfere with the exterior parts.
1
Installation of retractable mirrors Install retractable mirrors (a1) and (b1) as shown in the figure. 1) Retractable mirror (a1): Install at 20 mm (from the bottom of the intermediate stay). Install mirror stay (1) so that the mirror will be fixed at (A) of the 3 stopping positions where the mirror is extracted most and fixed angle (e) to be at an angle of approximately 94 deg. to the intermediate stay. a If the mirrors are not installed to the correct positions, they may interfere with the exterior parts.
a
6)
Tighten bolts (5) of mirror. Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm} 7) Tightening torque of mirror stay bolt (6). 3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm} a If the tightening torque is low, the bolts may be dragged. If the former is too high, the body may be broken. 3
2)
Tighten bolts (2) of mirror. Bolt: 6.0 to 7.0 Nm {0.61 to 0.71 kgm} 3) Tightening torque of mirror stay bolt (3). 3 Bolt: 15 to 19.6 Nm {1.5 to 2 kgm} a If the tightening torque is low, the bolts may be dragged. If the former is too high, the body may be broken. 3
8)
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Retract the mirror into position (C) when transporting the machine.
PC200, 200LC, 220, 220LC-8M0
101 Testing and adjusting, Part 1 Installation and adjustment of mirrors
2.
SEN06127-00
Adjustment of retractable mirrors 1) Adjust the retractable mirrors at position (A). 2) With retractable mirrors (a1) and (b1) open, loosen mirror bolts (1) and (2) and stay mounting bolts (3) and (4) and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator’s seat. a Adjust the mirror so that the operator can see persons (or things 1 m high and approximately 30 cm in diameter) at the right and left rear ends of the machine. a Take care not to tighten stay mounting bolts (3) and (4) (If they are tightened too strongly, the stay may be broken since it is made by die-casting).
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3)
3.
101 Testing and adjusting, Part 1 Installation and adjustment of mirrors
Tighten the stay mounting bolts so that the clearance to the stay mating face will be even.
Adjustment of unretractableble mirrors 1) See the "Adjusting mirrors" page, adjust mirrors (c1) and (d1) so that the operator can see persons at 1 m arou nd the machine (hatched area) from the operators seat. a If the mirror is hard to adjust, loosen mirror screw (1). 2) Tighten screw (1) of mirror. 3 Screw: 3.0 to 3.5 Nm {0.31 to 0.35 kgm} a When adjusting mirror, secure clearance (g) so that mirror stay does not interfere with mirror.
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101 Testing and adjusting, Part 1 Angle adjustment of rear view camera
Angle adjustment of rear view camera
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1.
1
Adjust the camera so that persons in area (w) at 1 meter around the machine is displayed on the machine monitor in the operator cab.
Remove cover (2) by inserting flat-head screwdriver [1] in the hole in cover (3) and pressing the internal pawl.
a If the image displayed on the monitor is out of position, remove cover (2) of camera (1) and adjust the installation angle (A) of the rear view camera.
PC200, 200LC, 220, 220LC-8M0
Claw of cover (2) is made of plastic, it is easily damaged while removing, therefore take special care at work.
2.
Remove two bolts (4).
3.
Remove cover (2).
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4.
101 Testing and adjusting, Part 1 Angle adjustment of rear view camera
Loosen mounting bolts (5) of camera (1) and adjust installation (A) of camera so that the side line of camera is matched with the corner (B) of the bracket. Angle (A): 48°(+2°/0)
a
A part of the machine is displayed on the monitor screen. Adjust the camera so that the image of the counterweight occupy approximately 10 to 15% of the monitor screen.
5.
After adjusting, tighten bolts (5). 3 Camera mounting bolt: 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6.
Install covers (2) and (3).
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101 Testing and adjusting, Part 1 Angle adjustment of rear view camera
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PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06127-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
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HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
30 Testing and adjusting
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102 Testing and adjusting, Part 2 Special functions of machine monitor ............................................................................................................. 2
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Special functions of machine monitor
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Upper part of machine monitor (display portion) (a): Multi-information display a When the engine is started, the battery voltage may drop suddenly, depending on the ambient temperature and the condition of the battery. In this case, the screen display of the machine monitor may go off for a moment. This phenomenon is not a failure, however. Upper part of machine monitor (switch portion) [F1]: F1 Function switch [F2]: F2 Function switch [F3]: F3 Function switch [F4]: F4 Function switch [F5]: F5 Function switch [F6]: F6 Function switch a The function of each function switch is indicated by the icon which is displayed just above the function switch on the screen of the multi-information display panel (a). a If the icon for a function switch is not displayed, that function switch is not working. Lower part of machine monitor (switch portion) [1]: Numeral 1 input switch/Auto-deceleration switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed selector switch [4]: Numeral 4 input switch/Alarm buzzer stop switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Window washer switch [7]: Numeral 7 input switch/Air conditioner switch [8]: Numeral 8 input switch/Air conditioner switch [9]: Numeral 9 input switch/Air conditioner switch [0]: Numeral 0 input switch/Air conditioner switch Switch having no numerals : Air conditioner switch a Each switch has the function indicated by the icon on it and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently enabled according to the screen display of the multi-information display panel (a).
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102 Testing and adjusting, Part 2 Special functions of machine monitor
Ordinary functions and special functions of machine monitor The machine monitor has the ordinary functions and special functions and displays information of various types on the multi-information display panel. Some information are displayed automatically according to the configuration of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special function: Service mode The information items in this mode are not displayed ordinarily. Each technician can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Operator mode (outline)
Service mode Monitoring / Pre-defined
A Display of inputting password
Monitoring / Custom
A Display of check of breaker mode
Abnormality Record (Mechanical Systems)
A Display of check before starting
Abnormality Record (Electrical Systems)
A Display of warning after check before starting
Maintenance record
A Display of ending of maintenance interval
Maintenance Mode Setting
A Display of check of working mode and travel speed
Phone Number Entry
A Display of standard screen
Default (Key-On Mode)
A Display of end screen
Default (Unit)
B Selection of auto-deceleration B Selection of working mode B Selection of travel speed B Operation to stop alarm buzzer B Operation of windshield wiper B Operation of window washer
O (Special operation)
A Display of KOMATSU logo
Default (With/Without Attachment) Default (Camera) Diagnostic Tests (Cylinder Cut-out) Adjustment (Pump Absorption Torque (F)) Adjustment (Pump Absorption Torque (R)) Adjustment (Low Speed)
B Operation of air conditioner/heater
Adjustment (Attachment Flow Adjustment)
Operation to display camera mode B (if camera is installed)
No Injection
B Operation to display clock and service meter B Check of maintenance information B
Setting and display of user mode (including KOMTRAX messages for user)
KOMTRAX Settings (Terminal Status) KOMTRAX Settings (GPS and Communication Status) KOMTRAX Settings (Modem Information) Service Message
C Display of ECO guidance C Display of caution monitor C Display of action level and failure code O (Special operation) Function of checking display of LCD D (Liquid Crystal Display) D Function of checking service meter D
a
Function of usage limitation setting/maintenance password
Group of screens or functions in operator mode A: Display or function from turning ON of starting switch to switching to the standard screen is over, and display after starting switch is turned OFF B: Display or function when the machine monitor switches are operated C: Display or function when certain conditions are met D: Display or function when operation of special switches is required
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Operator mode (Outline) a
a
Only outline of the operator mode is described in this section. For details of contents and operations of each function and display, see “Structure and function”, or the “Operation and Maintenance Manual”. The following are the screens or functions of the operator mode explained in this section (including some items which need special operations). Display pattern
Display sequence in operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to standard screen depends on the setting and condition of the machine. A : When the engine start lock is set effective B : When the engine start lock is set ineffective C : When working mode at start is set to breaker mode (B) D : When there is abnormal item in checkbefore-starting items E : When an overdue maintenance item is discovered
A B C D E Display of KOMATSU logo
1 1 1 1 1
Display of inputting password
2 — — — —
Display of check of breaker mode
— — 2 — —
Display of check before starting
3 2 3 2 2
Display of warning after check before starting
— — — 3 —
Display of ending of maintenance interval
— — — — 3
Display of check of working mode and travel speed
4 3 4 4 4
Display of standard screen
5 4 5 5 5
Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of window washer Operation of air conditioner/heater Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user) Display of ECO guidance Display of caution monitor Display of action level and failure code O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of usage limitation setting/maintenance password
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Display of KOMATSU logo When starting switch is turned to ON position, KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo screen is displayed for 2 seconds, the screen changes to “Password input” screen, or “Check before starting” screen.
Display of inputting password After the KOMATSU logo screen is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is enabled. a If correct password is input, the screen changes to “Check before starting” screen. a The machine monitor has some password protect functions other than the engine start lock. Those functions are independent from one another.
a a
Display of check of breaker mode When the starting switch is turned ON, if the working mode is set to the breaker mode [B], a message to inform the operator of starting in the breaker mode is displayed on the screen. k If an attachment other than the breaker is used while the working mode is set to the breaker mode [B], the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. a After operation to check of the breaker mode is finished, the screen changes to “Display of check before starting”. If [No] is selected: Working mode is set to economy mode [E] If [Yes] is selected: Working mode is set to breaker mode [B]
The following screen may be displayed instead of the above “Password input” screen. If this screen is displayed, call the person responsible for the operation of KOMTRAX in your Komatsu distributor and ask for remedy.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
Display of check before starting When the screen changes to the check before starting screen, the check before starting is performed for 2 seconds. a If any abnormalities are detected in the check before starting, the screen changes to “Warning after the check before starting” screen or “Overdue Maintenance” screen. a If no abnormalities were detected in the check before starting, display changes to “Working Mode and Travel Speed Check” screen. a The monitors (6 monitors) on the screen shows the items currently subjected to the check before starting.
Display of maintenance due time over If the check before starting detected a maintenance item that is near or overdue the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to perform maintenance. a This screen is displayed only when the maintenance reminder function is enabled. If the remaining time of any item is set time hours or less, the yellow icon is displayed. If the remaining time of any item is 0 hour or less, the red icon is displayed. a The maintenance reminder function is enabled or disabled by using the machine monitor in the service mode.
Display of warning after check before starting If any abnormalities are detected in the check before starting, the alarm monitor is displayed on the screen. a The figure shows how air cleaner clogging monitor (a) warns of clogging on air cleaner.
Display of check of working mode and travel speed If the check before starting is finished normally, the screen for checking the working mode and travel speed is displayed for 2 seconds. a After the “Working mode and travel speed check” screen is finished, the screen changes to the “Standard” screen.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
Display of standard screen If the machine monitor starts normally, the standard screen is displayed. a Service meter (a) or clock is displayed in the top center area of the screen (use [F4] to switch the display of the service meter and clock). a Right end of the screen displays ECO gauge (b) (turn on or off the display in the operator mode).
Display of end screen When starting switch is turned to OFF position, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen due to the message display function of KOMTRAX.
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Selection of working mode Select desired working mode according to the following procedure. 1. While the standard screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed. a Following figure shows the working mode selection screen when “with attachment” is set. (If “with attachment” is not set in service mode, attachment mode “ATT/P”, “ATT/E” are not displayed.)
2.
Selection of auto-deceleration While the ordinary screen is displayed, if the autodeceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is changed in the order of [ON] o [OFF] o [ON]. a If the auto-deceleration is set to ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously.
PC200, 200LC, 220, 220LC-8M0
If the auto-deceleration is set to OFF, autodeceleration monitor (b) goes off.
Operate the function switches or working mode selector switch to select the desired working mode and enter the selection. Function switch q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels selection and returns to standard screen q [F6]: Enters selection and returns to standard screen Working mode selector switch q Pressed : Moves to lower item q Kept pressed : Enters selection and returns to standard screen
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3.
If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is determined and the screen changes to the standard screen.
When the ordinary screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed to the selected mode. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too.
q If breaker mode [B] is selected, both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. q If an attachment other than the breaker is used, the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. q After the breaker mode is selected, the screen to confirm the selection of the breaker mode is displayed (The buzzer sounds intermittently while this screen is displayed). q If the setting is confirmed on this screen, the screen changes to the standard screen.
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If “No” is selected: Screen returns to working mode selecting screen If [Yes] is selected: Working mode is set to breaker mode [B]
Selection of travel speed While the standard screen is displayed, if the travel speed selector switch is pressed, large travel speed monitor (a) is displayed for two seconds and the setting of the travel speed is changed. a Travel speed setting sequentially changes between [Lo] o [Mi] o [Hi] o [Lo] in this order every time the switch is pressed. a When large monitor (a) is displayed, the display of travel speed monitor (b) is changed, too.
Operation to stop alarm buzzer While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen display does not change.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
Operation of windshield wiper While the ordinary screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the wiper starts or stops. a The window washer does not operate if the window limit switch is “ON”. a The wiper setting changes sequentially between [INT] o [ON] o [OFF] o [INT] every time you press the switch. a When the wiper is set to INT or ON, large monitor (a) is displayed and the display of wiper monitor (b) is changed at the same time. a If the wiper is set to OFF, large monitor (a) is not displayed and the wiper monitor disappears.
SEN06128-00
Operation to display camera mode (if camera is installed) If [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).
a
Up to two cameras can be connected. When the camera mode is selected, however, only the image of camera 1 is always displayed at first.
a
If any caution is issued with the display panel in the camera mode, the corresponding caution monitor is displayed at the left top of the screen (excluding the low hydraulic oil temperature caution monitor).
Operation of window washer While the ordinary screen is displayed, if the window washer switch is pressed, the washer fluid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen display does not change. Operation of air conditioner/heater While the standard screen is displayed, if the air conditioner switch is pressed, “Air-conditioner Setting” screen is displayed. a While “Air-conditioner Setting” screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the standard screen.
PC200, 200LC, 220, 220LC-8M0
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a a
If no control lever is operated for 10 seconds while a failure enough to display an action level is occurring with the display panel in the camera mode, the screen returns to the standard screen and displays information about that failure. When two or more cameras are connected, the image of one of them or the images of two of them can be displayed. When 2-camera image display [F4] is selected, images of cameras 1 and 2 are displayed on the right and left side of the screen. You can specify which of image of cameras 1 and 2 to appear on the right side and which on the left side from “Camera” in the service mode.
Operation to display clock and service meter While the standard screen is displayed, if [F4] is pressed, the service meter and the clock are displayed alternately in section (a). a When selecting the clock display, perform the time adjustment, 12-hour or 24-hour display setting, and summer time setting by using the user mode functions.
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Check of maintenance information You can check the maintenance information on the maintenance screen by pressing [F6] while the maintenance monitor is displayed. When the maintenance monitor does not appear, press [F6] and then press [F1] or [F2]. Then make sure the display is switched to the maintenance screen.
a
To reset the remaining time after finishing maintenance, more operations are necessary.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
Setting and display of user mode (including KOMTRAX messages for user) To enter the user mode, press [F6] to display the “User Menu” screen while the standard screen is displayed.
a
The User Menu has following menus.
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Display of ECO guidance When the machine is set in a certain operating condition, the ECO Guidance screen is displayed automatically to urge the operator to perform the energy-saving operation. a “ECO Guidance” screen is displayed when the following conditions are met while this display function is set to enabled in operator mode. a Conditions for display: q Idle stop guidance If no lever is operated for a period of at least 5 minutes and the engine keeps running at idle speed during this period, the guidance on idle stop is displayed on the monitor. This function helps reduce unnecessary fuel consumption by alerting the operator to stop the engine while waiting for the next operation, or during a break. a The lamp for the idle stop guidance goes out automatically when the lever operation is resumed, or if the function switch [F5] is pressed.
ECO Guidance Machine setting Maintenance Monitor setting Check mail
[KOMTRAX message] q There are two types of KOMTRAX message; one is for the user and the other is for the technician. q For user: It denotes the messages transmitted from the KOMTRAX base station to users. Upon receiving a message, the message monitor is displayed on the standard screen. Operate this “Check mail” when viewing contents of a message. q For technician: It refers to the messages transmitted to the technicians from the KOMTRAX base station. When a message is received, the standard screen does not display any information relevant to the message received. To view contents of a message, operate “Display service message” of the service menu in the service mode.
PC200, 200LC, 220, 220LC-8M0
Guidance on deterrence of hydraulic relief If relieving lasts for 3 or more seconds during operation, guidance on deterrence of hydraulic relief is displayed on the monitor. a The lamp for the guidance on deterrence of hydraulic relief goes out automatically after 10 seconds has passed since it appeared, or if the function switch [F5] is pressed.
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q
E-mode recommendation guidance If light-load work continues for 10 or more minutes in P- or ATT/P-mode, E-mode recommendation guidance is displayed. This function helps reduce unnecessary fuel consumption by alerting the operator to turn on E-mode. a The lamp for the E-mode recommendation guidance goes out automatically after 10 seconds has passed since it appeared, or if the function switch [F5] is pressed.
q
q
Travel partial recommendation guidance If machine travel in the travel mode Hi and the fuel control dial at MAX continues for 2 or more minutes, the travel partial recommendation guidance is displayed. When traveling the machine for a long period of time, moving the fuel control dial from MAX to a lower position helps reduce fuel consumption. a The lamp for the travel partial recommendation guidance goes out automatically after 10 seconds has passed since it appeared, or if the function switch [F5] is pressed.
Display of caution monitor If an error that is serious enough to display Action Level “L01” alarm monitor on the standard screen or camera mode screen occurs, a large alarm monitor is displayed on the screen once and is continuously shown in window (a). a On the camera mode screen, the alarm monitor flashes at the left upper of the screen when a caution is issued.
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Low fuel level guidance If the amount of time the machine can be operated that is projected from the remaining fuel level and the latest average fuel consumption drops to less than 8 hours, the low oil level guidance is displayed. a The lamp for the low oil level guidance goes out automatically after 10 seconds has passed since it appeared, or if the function switch [F5] is pressed.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
If an error serious enough to display a alarm monitor of Action Level [L02], [L03] or [L04] occurs, the alarm monitor is displayed at the center of the monitor screen until the error is eliminated.
SEN06128-00 a a a
a a
The telephone No. is displayed only when the telephone number is registered in the service mode. If multiple problems occur simultaneously, all the codes are displayed repeatedly in order. Because the information of the displayed failure code is logged in the abnormality record in the service mode, check the details in the service mode. The “Error list” automatically returns to the standard screen after 30 seconds. Since “Error list” cannot be displayed from the screen on which the camera mode is displayed, move to “Error list” from the standard screen side.
Display of action level and failure code If an abnormality that displays an action level and a failure code occurs on the standard screen or camera mode screen, the alarm monitor lights up.
If the alarm monitor lights up, press function switch [F5] to display the “Error list”. q [F1]: Moves to next page (screen) (if displayed) q [F2]: Moves to previous page (screen) (if displayed) q [F5]: To return to standard screen On the “Error list” screen, the following information is displayed. (a): Alarm monitor (b): Action level (3 digits) (c): Failure code (5 or 6 digits) (d): Failure code name (e): Message (f): Telephone No. (if registered) a This screen display appears only when a problem (failure code) for which an action level is set occurs.
PC200, 200LC, 220, 220LC-8M0
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Actions to take given by action levels to operator (Excerpt from the Operation and Maintenance Manual)
Degree of emergency
Action level
High
L04
L03
Buzzer
Q (Continuous)
Q (Intermittent)
Alarm monitor
Remedy
Q
Stop immediately and perform checking and maintenance. Ask your Komatsu distributor for testing and repair services.
Q
Stop work, move machine to safe place, stop it, and perform checking and maintenance. Ask your Komatsu distributor for testing and repair services.
Q
Stop work, and then run the engine at medium speed with no load, or stop it. If the condition does not improve, ask your Komatsu distributor for testing and repair services.
Q
Some functions are restricted, but the machine can work. After finishing work, perform checking and maintenance. Ask your Komatsu distributor to perform testing or repairs as necessary.
I
L02
Low
L01 (For 2 seconds only)
Q (Intermittent)
—
a
To return to the former screen, press any one of the function switches. Reference: An LCD panel, as one of its characteristics, sometimes shows black spots (spots that remain unlit) and bright spots (spots that do not go off). If the number of the bright points and black points does not exceed 10, the LCD panel is not faulty or defective.
Function of checking service meter When checking the service meter with the starting switch in the OFF position, operate the numeral input switches as follows to display only the service meter section. q Switch operations (simultaneous): [4] + [1] a There is some time lag in start of the LCD, so hold down the switches until the service meter is displayed. a If you release one of the switches, the monitor goes off. Reference: After the machine monitor is used continuously over a long period of time, blue points (points that remain lit) may appear on this screen. It does not indicate that the LCD panel is faulty or defective.
Function of checking display of LCD (Liquid Crystal Display) While the standard screen is displayed, if the numeral input switches or function switches are operated in the following manner, the entire LCD screen turns white. q Switch operations (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. 30-102
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Function of usage limitation setting/maintenance password Selecting the Usage Limitation Setting displays the password input screen when you proceed to setting of the breaker or attachment, or maintenance resetting Observe the following procedure when using the Usage Limitation Setting. 1. While the standard screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], press the switches in order): [4]+[5]o[5]o[5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned to ON position.
2.
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3.
Selection of “Usage limitation ON/OFF” After the “Usage Limitation ON/OFF” screen is displayed, select a desired one using the function switch. q Disable Password input screen is not displayed q Enable: The password input screen for setting of the breaker or attachment, or maintenance resetting appears. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the selection and return the display to the preceding screen q [F6]: Validates the selection
After the “Usage Limitation password screen is displayed, input the current password using the numeral input switches and validate it using the function switch. q q
a a a
[F5]: Deletes the entered numbers/ Restores the standard screen [F6]: Validates the entered password Default password: [000000] If the input password is correct, the screen changes to the next screen. If the input password is incorrect, the message to request inputting the password again is displayed.
a
PC200, 200LC, 220, 220LC-8M0
After the “Usage Limitation Setting” screen is displayed, select a setting using the function switch. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the selection and return the display to the preceding screen q [F6]: Validates the selection
The password for the Usage Limitation and the engine start lock password are not identical.
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4.
Changing a password After the “Usage Limitation New Password Input” screen is displayed, input a new password with the numeral input switches and validate it with the function switch. q [F5]: Deletes the entered numbers/ Returns the display to the preceding screen q [F6]: Validates the entered password a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to request inputting the password again is displayed. a Set a new password in 4 to 6 digits (a password of 3 or less digits or 7 or more digits is not accepted).
102 Testing and adjusting, Part 2 Special functions of machine monitor
If the screen to notify completion of setting is displayed and then the standard screen is displayed, the password has been changed successfully
After the “Usage Limitation New Password Input” screen is displayed again, input the new pa ssword again with the numeral inpu t switches and validate it with the function switch. q [F5]: Deletes the entered numbers/ Restores the standard screen q [F6]: Validates the entered password a If the input password is different from the entered in the first time, the message to request reentry is displayed.
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PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
SEN06128-00
Service mode To change the mode of the machine monitor to the service mode from the operator mode, perform the following operation. This operation is always required when you use the service mode. 1.
Check of screen display and operation of switches While the standard screen is displayed, perform the following operation by using the numeral input switches. q Operation of switches (While pressing [4], press the switches in order): [4] + [1] o [ 2 ] o [ 3 ] a This operation of the switches is accepted only while the standard screen is displayed.
a
The menu items which can be selected in the service menu are as follows (including some items which need special operations).
01 Monitoring / Pre-defined 02 Monitoring / Custom 03
Abnormality Record (Mechanical Systems) Abnormality Record (Electrical Systems)
04 Maintenance record 05 Maintenance Mode Setting 06 Phone Number Entry Default (Key-On Mode) 07
Default (Unit) Default (With/Without Attachment) Default (Camera)
2.
Selection of service menu When the “Service Menu” screen is displayed, the service mode is selected. Select the desired service menu by using the function switches or numeral input switches. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns the display to the standard screen (operator mode) q [F6]: Validates the selection a If you input a 2-digit code by using the numeral input switches, the corresponding menu is directly selected. This will allow you to validate the selection using [F6].
PC200, 200LC, 220, 220LC-8M0
08 Diagnostic Tests (Cylinder Cut-out) Adjustment (Pump Absorption Torque (F)) 09
Adjustment (Pump Absorption Torque (R)) Adjustment (Low Speed) Adjustment (Attachment Flow Adjustment)
10 No Injection KOMTRAX Settings (Terminal Status) 11
KOMTRAX Settings (GPS and Communication Status) KOMTRAX Settings (Modem Information)
12 Service Message
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Monitoring / Pre-defined The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which control them. In the monitoring / pre-defined, monitoring items that are used frequently in daily work are selected beforehand. 1.
Selecting the menu Select “Monitoring / Pre-defined” on the “Service Menu” screen.
2.
Check of monitoring / pre-defined information After the “Monitoring / Pre-defined” screen is displayed, you can check the items displayed in the troubleshooting support by using the function switches. q [F1]: Moves to the next page (screen) q [F2]: Moves to the previous page (screen) q [F4]: Selects hold or its releasing (If hold is selected, a diagonal line is displayed on the HOLD portion) q [F5]: Returns to service menu screen a You can select and check any items not displayed in “Monitoring / Pre-defined” from the “Monitoring items”.
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a
If the working mode is changed to breaker mode [B], the screen to confirm the change of the setting is displayed as in changing the working mode on the standard screen.
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
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List of monitoring / pre-defined items (SI unit indicates the default values) Support screen (1/7) Fuel injection Item name
Unit (SI)
Applicable equipment
r/min
ENG
No.
ID
1
01002
Engine speed
2
04107
Coolant temperature
°C
ENG
3
04501
Engine oil level
—
MON
4
04401
Hydr. oil temperature
°C
PUMP
5
03203
Battery power supply
V
ENG
Unit (SI)
Applicable equipment
r/min
ENG
°C
ENG
Support screen (2/7) Fuel injection No.
ID
Item name
1
01002
Engine speed
2
04107
Coolant temperature
3
36400
Rail pressure
MPa
ENG
4
36200
Rail pressure command
MPa
ENG
5
18500
Boost temperature
°C
ENG
6
37400
Ambient pressure
kPa
ENG
Unit (SI)
Applicable equipment
Support screen (3/7) F & R pumps basic items No.
ID
Item name
1
01002
Engine speed
r/min
ENG
2
01100
F pump pressure
MPa
PUMP
3
01101
R pump pressure
MPa
PUMP
4
01300
PC-EPC sol current (F)
mA
PUMP
5
01302
PC-EPC sol current (R)
mA
PUMP
6
04401
Hydr. oil temperature
°C
PUMP
Unit (SI)
Applicable equipment
Support screen (4/7) F & R pumps application items No.
ID
1
01002
Engine speed
r/min
ENG
2
01100
F pump pressure
MPa
PUMP
3
01101
R pump pressure
MPa
PUMP
4
01300
PC-EPC sol current (F)
mA
PUMP
5
01302
PC-EPC sol current (R)
mA
PUMP
6
01500
LS-EPC sol current
mA
PUMP
PC200, 200LC, 220, 220LC-8M0
Item name
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Support screen (5/7) PPC pressure Unit (SI)
Applicable equipment
Engine speed
r/min
ENG
07400
Boom Raise PPC pressure
MPa
PUMP
No.
ID
1
01002
2
Item name
3
07500
Boom Lower PPC pressure
MPa
PUMP
4
07200
Arm In PPC pressure
MPa
PUMP
5
07600
Arm Out PPC pressure
MPa
PUMP
6
04401
Hydr. oil temperature
°C
PUMP
Unit (SI)
Applicable equipment
Support screen (6/7) PPC pressure No.
ID
Item name
1
01002
Engine speed
r/min
ENG
2
09002
Swing Right PPC pressure
MPa
PUMP
3
09001
Swing Left PPC pressure
MPa
PUMP
4
07300
Bucket Curl PPC pressure
MPa
PUMP
5
07301
Bucket Dump PPC pressure
MPa
PUMP
6
04401
Hydr. oil temperature
°C
PUMP
Unit (SI)
Applicable equipment
Support screen (7/7) PPC pressure
30-102
No.
ID
Item name
1
01002
Engine speed
r/min
ENG
2
07102
Travel Fwd LH PPC pressure
MPa
PUMP
3
07103
Travel Fwd RH PPC pressure
MPa
PUMP
4
07104
Travel Rev LH PPC pressure
MPa
PUMP
5
07105
Travel Rev RH PPC pressure
MPa
PUMP
6
04401
Hydr. oil temperature
AaC
PUMP
22
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
SEN06128-00 a
Monitoring / Custom The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which control them. The monitoring function allows you to select a desired monitoring item. 1. Selecting the menu Select “Monitoring” on the “Service Menu” screen.
3.
2.
Selecting monitoring item After the “Monitoring selection menu” screen for monitoring item selection is displayed, select the item to be monitored by using the function switches or numeral input switches. q [F1]: Moves to left item q [F2]: Moves to right item q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Deletes the entered numbers/ Returns the display to the service menu q [F6]: Validates the selection a In setting of the monitoring, each time function switch [F2] is pressed, sequential switching among [ENG] o [PUMP] o [MON] o [ENG] takes place in this order. (Pressing [F1] induces the sequential switching in the reverse order.) a Selection with function switches: Select an applicable equipment using [F1] or [F2], and select an item using [F3] or [F4] and determine it using [F6]. a Selection with numeral input switch: Select a desired item by entering the corresponding 5-digit code and then validate it using [F6]. a If the color of the selection cursor changes from yellow to red, selection of the item is entered.
PC200, 200LC, 220, 220LC-8M0
You can select up to six monitoring codes at the same time. Note, however, that six items may not be available depending on how they are displayed on the screen.
Getting machine monitor ready for monitoring After selecting monitoring items, set the machine monitor ready for monitoring by using the function switch or numeral input switch. a Execution by use of function switches: Double-click [F6] or hold it down (for approximately 2 seconds). a Execution using numeral input switch: [99999] and press [F6]. a When monitoring only two items, for example, select them and enter them by using [F6]. If [F6] is pressed once more at this time, the machine monitor is set ready for monitoring. a If monitoring items are selected up to the limit number, the machine monitor is automatically set ready for monitoring.
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4.
Performing monitoring After the “Monitoring” screen for execution is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be selected in SI unit, metric unit, or inch unit with the Default function in the service mode.
5.
Holding monitoring information The monitoring information can be held and released with the function switches. q [F4]: Selects hold or its releasing (If hold is selected, a diagonal line is displayed on the HOLD portion) q [F5]: Returns the display to monitoring selection menu screen
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6.
Changing machine setting mode during monitoring To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition to turn on the applicable mode. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the standard screen after monitoring is finished.
a
If the working mode is changed to breaker mode [B], the screen to confirm the change of the setting is displayed as in changing the working mode on the standard screen.
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
7.
SEN06128-00
Saving monitoring item A function switch lets you save and delete the selected item. q [F1]: MEMORY q [F2]: CLEAR
a
a a a
q q q q
When you saved a monitoring item, selecting “Monitoring” again displays the screen that confirms whether you want to display the once saved item. When you saved an item, you can display it as may times as you want until it is deleted. If you save an item when another item is saved already, the currently saved item is overwritten by the last one. In addition to [F2], using [F6] in the following screen allows deleting a saved monitoring item. KOMTRAX terminal screen With/Without Attachment screen Functional specification screen Air conditioner setting screen
PC200, 200LC, 220, 220LC-8M0
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Monitoring items table
Code No.
Monitoring item (Displayed on screen)
Unit (Default: SI) SI
Metric
Imperial
Equipment in charge
r/min
rpm
rpm
ENG
°F
ENG
01002
Engine speed
04107
Coolant temperature
°C
°C
03203
Battery power supply
V
V
36400
Rail pressure
MPa
V
ENG
2
psi
ENG
2
kg/cm
37400
Ambient pressure
kPa
kg/cm
psi
ENG
18500
Charge temperature
°C
°C
°F
ENG
36500
Charge pressure-A
36700
Engine Torque Ratio
18700
Engine Output Torque
03000
kPa
kg/cm2
psi
ENG
%
%
%
ENG
Nm
kgm
lbft
ENG
Throttle position sensor volt
V
V
V
ENG
04105
Coolant temp sensor volt
V
V
V
ENG
37401
Ambient pressure sensor volt
V
V
V
ENG
18501
Charge temp sensor volt
V
V
V
ENG
36501
Charge pressure sensor volt
V
V
V
ENG
17500
Engine power mode
-
ENG
31701
Throttle Position
%
%
%
ENG
31706
Final throttle position
%
%
%
ENG
18600
Inject fueling command
mg/st
mg/st
mg/st
ENG
2
MPa
kg/cm
psi
ENG
Injection Timing command
CA
CA
CA
ENG
37300
Fuel rate (Note 1)
l/h
l/h
gal/h
ENG
18800
Water in fuel
20216 20217
36200
Rail pressure command
36300
ON•OFF
ENG
ECM build version
—
ENG
Calibration data version
—
ENG
18900
ECM internal temp
20400
ECM S/N
°C
°C
°F
— kPa
kg/cm
psi
KDPF
01601
2nd Eng. Speed Command
r/min
rpm
01101 07400 07500 07200
R pump pressure Boom Raise PPC pressure Boom Lower PPC pressure Arm In PPC pressure
MPa MPa MPa MPa MPa
rpm
PUMP
2
psi
PUMP
2
psi
PUMP
2
psi
PUMP
2
psi
PUMP
2
psi
PUMP
2
kg/cm kg/cm kg/cm kg/cm kg/cm
07600
Arm Out PPC pressure
MPa
kg/cm
psi
PUMP
07300
Bucket Curl PPC pressure
MPa
kg/cm2
psi
PUMP
07301
Bucket Dump PPC pressure
MPa
kg/cm2
psi
PUMP
09001
Swing Left PPC pressure
MPa
kg/cm2
psi
PUMP
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26
WIF: Water In Fuel
ENG 2
KDPF outlet pressure
F pump pressure
Display in absolute value (including ambient pressure)
ENG
47000
01100
Remarks
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
Code No.
SEN06128-00
Monitoring item (Displayed on screen)
Unit (Default: SI) SI
Metric
Imperial
Equipment in charge
09002
Swing Right PPC pressure
MPa
kg/cm2
psi
PUMP
07102
Travel Fwd LH PPC pressure
MPa
kg/cm2
psi
PUMP
MPa
2
psi
PUMP
2
psi
PUMP
2
psi
PUMP
07103 07104 07105
Travel Fwd RH PPC pressure Travel Rev LH PPC pressure
MPa
Travel Rev RH PPC pressure
MPa
kg/cm kg/cm kg/cm
04401
Hydr. oil temperature
°C
°C
°F
PUMP
01300
PC-EPC sol current (F)
mA
mA
mA
PUMP
01302
PC-EPC sol current (R)
mA
mA
mA
PUMP
01500
LS-EPC sol current
mA
mA
mA
PUMP
08000
Merge-divide sol current main
mA
mA
mA
PUMP
08001
Merge-divide sol current LS
mA
mA
mA
PUMP
01700
Attachment sol current
mA
mA
mA
PUMP
03200
Battery voltage
V
V
V
PUMP
03701
Controller Output 2
04402
Hydr. temp. sensor volt
V
V
V
PUMP
01602
2nd Eng. Speed Command
%
%
%
PUMP
13113
Main Pump Absorb Torque
Nm
kgm
lbft
PUMP
psi
PUMP
15900
01900
01901
02300
02301
02200
—
Boom Bottom Pressure
Pressure Switch 1
Pressure Switch 2
Solenoid valve 1
Solenoid valve 2
Switch Input 1
PC200, 200LC, 220, 220LC-8M0
MPa
Remarks
PUMP
2
kg/cm
Swing
ON•OFF
PUMP
Travel
ON•OFF
PUMP
Boom Lower
ON•OFF
PUMP
Boom Raise
ON•OFF
PUMP
Arm In (Curl)
ON•OFF
PUMP
Arm Out (Dump)
ON•OFF
PUMP
Bucket Curl
ON•OFF
PUMP
Bucket Dump
ON•OFF
PUMP
Service
ON•OFF
PUMP
Travel steering
ON•OFF
PUMP
Travel Junction
ON•OFF
PUMP
Swing holding brake
ON•OFF
PUMP
Merge-divider
ON•OFF
PUMP
2-stage Relief
ON•OFF
PUMP
Travel Speed
ON•OFF
PUMP
Service Return
ON•OFF
PUMP
Variable back press
ON•OFF
PUMP
Lever Sw.
ON•OFF
PUMP
Swing Release SW.
ON•OFF
PUMP
Swing holding brake SW.
ON•OFF
PUMP
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Code No.
02201
Monitoring item (Displayed on screen)
Switch Input 2
02202
Switch Input 3
02203
Switch Input 4
02204
Switch Input 5
Unit (Default: SI) SI
Metric
Imperial
Equipment in charge
Model select 1
ON•OFF
PUMP
Model select 2
ON•OFF
PUMP
Model select 3
ON•OFF
PUMP
Model select 4
ON•OFF
PUMP
Model select 5
ON•OFF
PUMP
Overload Alarm
ON•OFF
PUMP
Key switch(ACC)
ON•OFF
PUMP
—
PUMP
Window Limit SW.
ON•OFF
PUMP
P Limit SW.
ON•OFF
PUMP
W Limit SW.
ON•OFF
PUMP
20229
Pump controller Ass'y P/N
—
PUMP
20403
Pump controller Serial No.
—
PUMP
20230
Pump controller prog. P/N
—
PUMP
—
PUMP
20212
—
04300
Battery charge volt
V
V
V
MON
04200
Fuel level sensor volt
V
V
V
MON
04500
04501
04502
04503
04504
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28
Monitor Input 1
Monitor Input 2
Monitor Input 3
Monitor Function Switches
Monitor 1st & 2nd Row Switches
Key switch
ON•OFF
MON
Start
ON•OFF
MON
Preheating
ON•OFF
MON
Light
ON•OFF
MON
Radiator coolant level
ON•OFF
MON
Aircleaner
ON•OFF
MON
Eng. oil level
ON•OFF
MON
Battery charge volt
ON•OFF
MON
Swing brake Sw.
ON•OFF
MON
F1
ON•OFF
MON
F2
ON•OFF
MON
F3
ON•OFF
MON
F4
ON•OFF
MON
F5
ON•OFF
MON
F6
ON•OFF
MON
SW1
ON•OFF
MON
SW2
ON•OFF
MON
SW3
ON•OFF
MON
SW4
ON•OFF
MON
SW5
ON•OFF
MON
SW6
ON•OFF
MON
Remarks
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
Code No.
04505
04506
SEN06128-00
Monitoring item (Displayed on screen)
Monitor 3rd & 4th Row Switches
Monitor 5th Row Switches
Unit (Default: SI) SI
Metric
Imperial
Equipment in charge
SW7
ON•OFF
MON
SW8
ON•OFF
MON
SW9
ON•OFF
MON
SW10
ON•OFF
MON
SW11
ON•OFF
MON
SW12
ON•OFF
MON
SW13
ON•OFF
MON
SW14
ON•OFF
MON
SW15
ON•OFF
MON
20227
Monitor Ass'y P/N
—
MON
20402
Monitor serial No.
—
MON
20228
Monitor prog. P/N
—
MON
20200
Monitor prog. version
—
MON
55300
Aircon compressor status
ON•OFF
MON
55000
Aircon outside temp. code
—
MON
Remarks
55100
Aircon inside temp. code
—
MON
55200
Aircon mode data(mon)
—
MON
55201
Aircon mode data(aircon ECU)
—
MON
20260
KOMTRAX Ass’y P/N
—
MON
Only when KOMTRAX is used
20418
KOMTRAX Serial No
—
MON
Only when KOMTRAX is used
20261
KOMTRAX Prog. P/N
—
MON
Only when KOMTRAX is used
a
Listing order of monitoring items in table The monitoring items are listed in the order of display on the Monitoring selection menu screen for monitoring item selection. a Unit The display unit can be set to SI, meter, or inch as required (select a desired unit from “Unit” of “Default”). mg/st in the display unit is an abbreviation for milligram/stroke. a Equipment in charge ENG: The engine controller detects monitoring information. PUMP: The pump controller detects monitoring information. MON: The machine monitor detects monitoring information. Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value, there is some differences between the actual fuel consumption ratio).
PC200, 200LC, 220, 220LC-8M0
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Abnormality Record (Mechanical Systems) The machine monitor classifies and logs the failures which occurred in the past or which are occurring at present into the mechanical system abnormality, and electrical system abnormality. To check the mechanical system abnormality record, perform the following procedures. a For the failure code list, see “40 Failure codes table”. 1.
Selecting the menu Select “Abnormality Record” on the “Service Menu” Screen.
2.
Selecting sub menu After the “Abnormality Record” screen is displayed, select “Mechanical Systems” by using the function switches or numeral input switches. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns the display to the service menu screen q [F6]: Validates the selection a You may enter a 2-digit code by using the numeral input switches to select the item of that code and enter it by using [F6].
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3.
Information displayed on abnormality record screen On the “Mechanical Systems” abnormality record screen, the following information is displayed. (a): Occurrence order of abnormalities from latest one/Total number of abnormalities in the log (b): Failure codes (c): Detail of failure (d): Number of occurrences (displayable range: 0 to 65,535 times) (e): Service meter reading at first occurrence (f): Service meter reading at last occurrence q [F1]: Moves to next page (screen) (if displayed) q [F2]: Moves to previous page (screen) (if displayed) q [F5]: Returns to the “Abnormality Record” screen a If no failure is logged, the message of “No Error” is displayed. a In the mechanical systems abnormality record screen, up to 50 cases currently stored are displayed. a If the number of occurrences is one (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. When the latest service meter reading is recovered, the value at the recovery time is displayed, thus the above readings may not be the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or restoration of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the “Failure codes table”.
4.
Clearing abnormality record A contents of the mechanical system abnormality record cannot be cleared.
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
Abnormality Record (Electrical Systems) The machine monitor classifies and logs the failures which occurred in the past or which are occurring at present into the mechanical system abnormality, and electrical system abnormality. To check the electrical system abnormality record, perform the following procedures. a For the failure code list, see “40 Failure codes table”. 1.
Selecting the menu Select “Abnormality Record” on the “Service Menu” Screen.
2.
Selecting sub menu After the “Abnormality Record” screen is displayed, select “Electrical Systems” by using the function switches or numeral input switches. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns the display to the service menu screen q [F6]: Validates the selection a You may enter a 2-digit code by using the numeral input switches to select the item of that code and enter it by using [F6].
PC200, 200LC, 220, 220LC-8M0
SEN06128-00
3.
Information displayed on abnormality record screen On the “Electrical Systems” abnormality record screen, the following information is displayed. (a): Occurrence order of abnormalities from latest one/Total number of abnormalities in the log (b): Failure codes (c): Detail of failure (d): Number of occurrences (displayable range: 0 to 65,535 times) (e): Service meter reading at first occurrence (f): Service meter reading at last occurrence q [F1]: Moves to next page (screen) (if displayed) q [F2]: Moves to previous page (screen) (if displayed) q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns to the “Abnormality Record” screen a If no failure is logged, the message of “No Error” is displayed. a In the electrical systems abnormality record screen, up to 20 cases currently stored are displayed. If the number of the cases reaches 21, the code that occurred most recently is displayed and the oldest code is deleted. a If the number of occurrences is one (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or restoration of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the “Failure codes table”.
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4.
Clearing abnormality record 1) While the “Electrical Systems” abnormality record screen is displayed, press the numeral input switches as follows. q Operation of switches (While pressing [4], press the switches in order): [4] + [1] o [ 2 ] o [ 3 ]
2)
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Check that the screen is set in the clear mode, and then clear the items one by one or together by using the function switches. a If the screen is set in the clear mode, icon [CLEAR] is indicated above [F2]. q [F2]: Deletes all items q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns to the “Abnormality Record” screen q [F6]: Deletes items one by one a To clear items one by one: Select the item to be cleared by using [F3] or [F4] and press [F6]. a To clear all items together: Press [F2], and all the items are cleared, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the clearing operation is accepted but the information is not cleared.
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3)
After the “Electrical Sys. Error Reset” screen is displayed, press the function switches. q [F5]: Returns to “Electrical Systems Abnormality Record” screen (delete mode) q [F6]: Performs deletion a The following figure shows the screen displayed when the items are cleared one by one (which is a little different from the screen displayed when all the items are cleared together).
4)
If the screen to notify completion of clearing is displayed and then the “Electrical Systems” (clear mode) screen is displayed, the clearing of the abnormality record is completed. a After a while, the screen returns to the “Electrical Systems” screen of abnormality record.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Maintenance record The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and checked by the following operations. When maintenance is performed, if the remaining time is reset in the operator mode, the number of maintenance times is recorded in this record. 1. Selecting the menu Select “Maintenance Record” on the “Service Menu” screen.
The following items can be selected on “Maintenance Record” screen. 49 Cleaning and replacement of cleaner 01 Engine Oil Change 02 Engine Oil Filter Change 03 Fuel Main Filter Change 41 Fuel Pre Filter Change 04 Hyd Oil Filter Change 05 H/Tank Breather Change 07 Damper Case Service 08 Final Drive Oil Change Interval 09 S/Machinery Oil Change 10 Hydraulic Oil Change
3.
2.
Selecting maintenance item After the “Maintenance Record” screen is displayed, select a maintenance item to be checked by using the function switches or numeral input switches. q [F1]: Moves to the next page (screen) q [F2]: Moves to the previous page (screen) q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns the display to the service menu screen a You may enter a 2-digit code by using the numeral input switches to select the item of that code.
PC200, 200LC, 220, 220LC-8M0
Items displayed on Maintenance Record screen The following information is displayed on the screen. (a): Maintenance items (b): Replacement time elapsed up to present (c): Service meter reading (SMR) at previous replacement
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Maintenance Mode Setting The actuating condition of the maintenance reminder function in the operation mode can be set and changed by using this menu. q To enable or disable the function q To change set replacement interval (by item) q To initialize all set replacement intervals
a
The following items can be selected on the “Maintenance Mode Setting” screen. 00 Maintenance Mode Change 49 Air Cleaner cleaning / Change Interval 01 Engine Oil Change Interval 02 Eng Oil Filter Change Interval
1.
Selecting the menu Select “Maintenance Mode Setting” on the “Service Menu” screen.
03 Fuel Main Filter Change Interval 41 Fuel Pre Filter Change Interval 04 Hyd. oil filter change interval 05 H/tank breather change interval 07 Damper Case Service Interval 08 Final Drive Oil Change Interval 09 S/Machinery oil change interval 10 Hydraulic Oil Change Interval 99 All Default Value
3.
2.
Selecting sub menu After the “Maintenance Mode Setting” screen is displayed, select an item to change the setting with the function switches or the numeral input switches. q [F1]: Moves to the next page (screen) q [F2]: Moves to the previous page (screen) q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Returns the display to the service menu screen q [F6]: Validates the selection a You may enter a 2-digit code by using the numeral input switches to select the item of that code and enter it by using [F6].
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Contents of “Maintenance Mode Change” After selecting “Maintenance Mode Change” and the screen is displayed, select the desired setting with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Maintenance reminder functions of all maintenance items are disabled in operator mode q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels selection and return to the “Maintenance Mode Change” screen q [F6]: Enters selection and return to the “Maintenance Mode Change” screen a Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting.
PC200, 200LC, 220, 220LC-8M0
102 Testing and adjusting, Part 2 Special functions of machine monitor
4.
Contents of “Maintenance Notice Time Setting” After selecting “Maintenance Notice Time Setting”, if the screen is displayed, select the desired setting with the function switches.
q
q
q q q
q
Default value: “Maintenance Notice Time” set in machine monitor (Recommended by the manufacturer and not changeable). Set value code: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (which is set in increments of 10 hours). [F3]: Decreases set value [F4]: Increases set value [F5]: Cancels setting before enter and return to the “Maintenance Mode Change” screen. [F6]: Enters selection and returns to the “Maintenance Mode Setting” screen
PC200, 200LC, 220, 220LC-8M0
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5.
Setting of each maintenance item After selecting each maintenance item to display its setting screen, perform the setting by using the function switches. q ON: Function of each maintenance item selected is enabled in the operator mode q OFF: Function of each maintenance item selected is disabled in the operator mode q [F3]: Moves to lower set value q [F4]: Moves to upper set value q [F5]: Cancels selection and returns to the “Maintenance Mode Change” screen q [F6]: Enters selection and returns to the “Maintenance Mode Change” screen a Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting.
6.
Contents of setting of set value of each maintenance item After selecting the set value of each maintenance item, if the screen is displayed, perform the setting for the item with the function switches.
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q
q
q q q
q
a
a
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Default value: “Maintenance Notice Time” set in machine monitor (Recommended by the manufacturer and not changeable). Set value code: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (which is set in increments of 25 hours). [F3]: Decreases set value [F4]: Increases set value [F5]: Cancels setting before enter and returns to the “Maintenance Mode Change” screen. [F6]: Enters setting and returns to “Maintenance Mode Change” screen After entering the selection with the [F6] key, return to the “Maintenance Mode Setting” screen by pressing [F5], and the setting will be made. If the set value of an item of which maintenance reminder function is set to “ON” is changed after one operating hours or more from the setup, the change is recognized as a reset of the remaining time.
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7.
Function of All Default Value After selecting “99 All Default Value” and the screen is displayed, set with the function switches.
q q q
a
If this function is executed, the set values of all the maintenance items are initialized. [F5]: Returns to “Maintenance Mode Setting” screen [F6]: Enters initialization A while after [F6] is pressed, the initialization completion screen is displayed. Then, if the “Maintenance Mode Setting” screen is displayed, initialization is completed.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
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Phone Number Entry The telephone number, which is displayed together with the “Occurred error list” in the operator mode, can be input and changed according to the following procedure. If a telephone number is not input by using this function, no telephone number is displayed in the operator mode.
q
If [F6] is pressed without inputting a digit, there is not information of phone number. Accordingly, no phone number is displayed in the operator mode.
1. Selecting the menu Select “Phone Number Entry” on the “Service Menu” screen.
Default (Key-On Mode) Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of “Key-on Mode” to set the working mode selected and displayed on the machine monitor when the starting switch is turned to ON position. 2.
Registering and changing phone number After the “Phone Number Entry” screen is displayed, register or change the phone number q [F2]: Deletes all input No. q [F3]: Moves to left position (if not blank) q [F4]: Moves to right position (if not blank) q [F5]: Resets input digit/Returns the display to the service menu screen q [F6]: Confirms input
q q
1.
Selecting the menu Select “Default” on the “Service Menu” screen.
Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (its background changes to orange) and overwrite it to correct.
PC200, 200LC, 220, 220LC-8M0
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2.
3.
Selecting sub menu After the “Default” screen is displayed, select “Key-on Mode” by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
Selecting mode After the “Key-on Mode” screen is displayed, select the mode to be set by using the function switches. q Power mode: [P] is displayed when the starting switch is set to the ON position q Economy mode: [E] is displayed when the starting switch is set to the ON position. q Lifting mode: [L] is displayed when the starting switch is set to the ON position. q Breaker mode: [B] is displayed when the starting switch is set to the ON position. q Attachment mode/P-mode: [ATT/P] is displayed when the starting switch is set to the ON position. q Attachment mode/E-mode: [ATT/E] is displayed when the starting switch is set to the ON position. q Mode at previous key-off: The mode selected the last time is displayed when the starting switch is set to the ON position. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the selection and returns the display to the default screen q [F6]: Validates the selection and returns the display to the default screen a Factory default is “Mode at Previous Keyoff”. a If “With Attachment” is not selected, selection of the Attachment /P-Mode and Attachment/E-mode is disabled. a If you change the setting to “Without attachment” when Attachment/P-mode [ATT/P] or Attachment/E-mode [ATT/E] is
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a
selected, turning on the starting switch displays Power mode [P] when [ATT/P] is selected and displays economy mode [E] when [ATT/E] is selected. If the engine is stopped with the working mode set to breaker mode [B] in the operator mode, Breaker Mode [B] is always displayed when the starting switch is turned to ON position, regardless of the above setting.
Default (Unit) Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of “Unit” to select the unit of the data displayed for monitoring, etc. 1.
Selecting the menu Select “Default” on the “Service Menu” screen.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
2.
3.
Selecting sub menu After the “Default” screen is displayed, select “Unit” by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
Selecting unit After the “Unit” screen is displayed, select the unit to be set by using the function switches. q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the selection and returns the display to the default screen q [F6]: Validates the selection and returns the display to the default screen a Factory default is “SI Unit”.
PC200, 200LC, 220, 220LC-8M0
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Default (With/Without Attachment) Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of “With/Without Attachment” to configure attachment setting when the attachment is installed or removed. 1.
Selecting the menu Select “Default” on the “Service Menu” screen.
2.
Selecting sub menu After the “Default” screen is displayed, select “With/Without Attachment” by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Selecting With/Without After the “With/Without Attachment” screen is displayed, select the setting by using the function switches. q Without Attachment: When attachment is not installed q With Attachment: For machines with provision for attachment q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the selection and returns the display to the default screen
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q
a
[F6]: Validates the selection and returns the display to the default screen When an attachment is installed, if this setting is not configured correctly, the setting of attachment in the operator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic components may be damaged.
Default (Camera) Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of “Camera” to configure camera setting when the camera is installed or removed. 1.
Selecting the menu Select “Default” on the “Service Menu” screen.
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2.
Selecting sub menu After the “Default” screen is displayed, select “Camera” using the function switch or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Selection of camera setting After the “Camera” screen for setting is displayed, select the setting by using the function switches. q Without Attachment: Camera is not selected. q With Attachment: Image of connected camera is displayed in original position (as in mirror, used for back monitor) q [ ]: Image of connected camera is displayed in reverse position (as seen directly, when used as front or side monitor) q [R]: Image of connected camera is displayed in original position (as in mirror, used for back monitor) q [F3]: Moves to lower item q [F4]: Moves to upper item q [F5]: Cancels the setting before validation and returns the display to the Default screen q [F6]: Validates the selection made in each step a Camera 1 does not provide switching between [ ] and [R] . a After entering the setting of each column by using [F6], return to the “Default” screen by using [F5], and the setting is effective. a If a camera is connected but not configured normally by using this function, the icon of camera is not displayed above [F3] in the operator mode. Accordingly, the image of the camera cannot be seen.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
a
If the camera is installed, check that the right and left portions of the displayed image are correct.
a
If two or more cameras are connected, be sure to configure them from camera 1 in order.
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The simultaneous display function of two images becomes effective when camera 1 and camera 2 are configured.
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Diagnostic Tests (Cylinder Cut-out) The operator can perform “Cylinder Cut-out mode” operation with the machine monitor. Cylinder Cut-out mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power normally (combustion in it is abnormal). 1.
Selecting the menu Select “Testing” on the “Service Menu” screen.
2.
Selecting sub menu After the “Testing” screen is displayed, select “Cylinder Cut-out” by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
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3.
Selecting cylinder to be cut out After the “Cylinder Cut-out” screen is displayed, select a cylinder to be Cut out by using the function switches. q [F1]: Moves to left item q [F2]: Moves to right item q [F4]: Selects hold or release (If hold is selected, a diagonal line is displayed on the HOLD portion) q [F5]: Returns to the testing screen q [F6]: Validates the selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is cut out. a If the machine monitor cuts out a cylinder but the engine controller cannot cut out that cylinder, the background (a) of the cylinder No. becomes yellow. a One or more cylinders can be cut-out. a During the Cylinder Cut-out operation, the auto-deceleration function can be enabled. If the auto-deceleration is set to ON, auto-deceleration monitor (b) is displayed.
4.
Resetting cutout cylinder When changing a cylinder to be cut out or when Cylinder Cut-out operation is finished, select a cut-out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a If the machine monitor resets a Cut-out cylinder but the engine controller cannot reset that Cut-out cylinder, the background (a) of the cylinder No. becomes red.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
a
The cut-out cylinder is not automatically reset even after returning to the operator mode. Accordingly, be sure to perform the resetting operation after the Cylinder Cut-out operation is finished.
5.
Holding displayed data Each time [F4] is pressed during the Cylinder Cut-out operation, the displayed data is newly held (c) (the real-time data is kept displayed on the left side). While the data is held, if [F4] is pressed, the data holding function is reset. a The holding function is available for a cylinder, regardless of whether it is cut out or not.
[Reference] q If a normally operating cylinder is disabled, the following phenomena occur. 1) The engine speed lowers. 2) The value (quantity) of final injection command increases. q If the engine is running near the full speed, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed by using the fuel control dial and judge by increase of the injection rate command.
PC200, 200LC, 220, 220LC-8M0
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Adjustment (Pump Absorption Torque (F)) The machine monitor allows for adjustment of various items related to the machine with the machine monitor. The sub menu of Pump Absorption Torque (F) is used to finely adjust the absorption torque of the front hydraulic pump. 1.
Selecting the menu Select “Adjustment” on the “Service Menu” screen.
2.
Selecting sub menu After the “Adjustment” screen is displayed, select “Pump Absorption Torque (F)” using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
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3.
Selecting pump absorption torque setting After the “Pump Absorption Torque (F)” screen is displayed, select a set value in the right column by using the function switches. q Set value code: For actual torque adjustment value, see the table shown below. q [F3]: Increases set value q [F4]: Decreases set value q [F6]: Confirms setting and returns to the adjustment menu screen a The 3-digit number in the left column do not change since it is the code of this function.
a
1.
Selecting the menu Select “Adjustment” on the “Service Menu” screen.
2.
Selecting sub menu After the “Adjustment” screen is displayed, select “Pump Absorption Torque (R)” using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Selecting pump absorption torque setting After the “Pump Absorption Torque (R)” screen is displayed, select a set value in the right column by using the function switches. q Set value code: For actual torque adjustment value, see the table shown below. q [F3]: Increases set value q [F4]: Decreases set value q [F6]: Confirms setting and returns to the adjustment menu screen
Relationship between set value code and torque offset value Code
021
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Adjustment (Pump Absorption Torque (R)) The machine monitor allows for adjustment of various items related to the machine with the machine monitor. The sub menu of Pump Absorption Torque (R) is used to finely adjust the absorption torque of the rear hydraulic pump.
44
Set value code
Torque offset value
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
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102 Testing and adjusting, Part 2 Special functions of machine monitor
a
a
The 3-digit number in the left column do not change since it is the code of this function.
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Adjustment (Low Speed) The machine monitor allows for adjustment of various items related to the machine with the machine monitor. The sub menu of Low Speed is used to finely adjust the travel speed at Low setting. 1.
Selecting the menu Select “Adjustment” on the “Service Menu” screen.
2.
Selecting sub menu After the “Adjustment” screen is displayed, select “Low speed” using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
Relationship between set value code and torque offset value Code
022
Set value code
Torque offset value
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
PC200, 200LC, 220, 220LC-8M0
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3.
Selecting low speed After the “Low Speed” screen for setting is displayed, select a set value in the right column by using the function switches. q Set value code: For the actual travel speed at Low setting, see the table shown below. q [F3]: Increases set value q [F4]: Decreases set value q [F6]: Confirms setting and returns to the adjustment menu screen a The 3-digit number in the left column do not change since it is the code of this function.
a
1.
Selecting the menu Select “Adjustment” on the “Service Menu” screen.
2.
Selecting sub menu After the “Adjustment” screen is displayed, select “Attachment Flow Adjustment” by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Selecting set value code for oil flow distribution After the screen of “Attachment Flow Adjustment” is displayed, select a set value in the right column by using the function switches. q Set value code: For actual distribution of oil flow, see the table shown below q [F3]: Increases set value q [F4]: Decreases set value q [F6]: Confirms setting and returns to the adjustment menu screen
Relationship between set value and travel speed at Low setting Code
020
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Adjustment (Attachment Flow Adjustment) The machine monitor allows for adjustment of various items related to the machine with the machine monitor. The sub menu of “Attachment Flow Adjustment” allows for fine adjustment of the oil flow to the attachment during combined operation.
46
Set value code
Travel speed at Low
000
3.0 km/h
001
2.8 km/h
002
3.2 km/h
003
3.4 km/h
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102 Testing and adjusting, Part 2 Special functions of machine monitor
a
a
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The 3-digit number in the left column do not change since it is the code of this function.
2.
Relationship between set value and distribution of oil flow to attachment Code
044
Set value code
Distribution of flow to attachment
000
50%
001
70%
002
100%
003
40%
After checking the communication, the message to ask if no injection cranking should be performed appears. Select the answer by using the function switch. 3.
Starting no injection cranking If no injection cranking (fuel injection in no cylinders) becomes effective, “No Injection.” is displayed on the screen. Under this condition, crank the engine by using the starting motor. q While the screen is changing to the following screen, the screen of “Getting Ready.” is displayed. q Limit the duration of cranking to 20 seconds to protect the starting motor.
4.
Finishing no injection cranking After cranking is finished, turn the key to the OFF position. a Switching from the above screen to another is not available.
5.
Prohibiting no injection cranking Even if the operator tries to perform the no injection cranking while the engine is running,
No Injection If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the machine monitor allows for cranking the engine without injecting fuel to lubricate the engine before starting it. Set the no injection cranking while the engine is stopped. 1.
Confirmation screen When "No Injection" screen is displayed, the monitor system checks whether the communication with the engine controller is available. The following screen is displayed during the communication.
Selecting the menu Select “No Injection” on the “Service Menu” screen.
PC200, 200LC, 220, 220LC-8M0
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the message "The engine is operating. Please turn the key off once." is displayed and the no injection cranking does not become effective.
And the “Confirmation screen” appears to disable the attempted no injection cranking in the following cases. q Communication between the monitor and engine controller is not normal. q Engine was started before the message “N o i nj e c t i o n c ra n k i n g i s a v a i l a ble ” appears on the screen.
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KOMTRAX Settings (Terminal Status) The setting and operating status of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”. “KOMTRAX Settings” is used to check the setting condition of the KOMTRAX terminal. 1.
Selecting the menu Select “KOMTRAX Settings” on the “Service Menu” screen.
2.
Selecting submenu After the “KOMTRAX Settings” screen is displayed, select “Terminal Status” with the function switches or numeral input switches. a Select this submenu as in the case of selecting a menu on the “Service Menu” screen.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
3.
Contents displayed on the terminal status screen On the “Terminal Status” screen, the following information is displayed. q Terminal Type: Model name of the KOMTRAX communication modem q KOMTRAX Communication : Status of sign-up test underway q GMT time: Greenwich Mean Time (add 9 hours to it for Japan time) q [F5]: Returns the display to the KOMTRAX settings screen
KOMTRAX Settings (GPS and Communication Status) The setting and operating status of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”. “GPS & Communication Status” is used to check the positioning and communication status of the KOMTRAX terminal. 1.
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2.
Selecting sub menu After the “KOMTRAX Settings” screen is displayed, select “GPS & Communication Status” with the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Contents displayed on GPS & Communication Status screen On the “GPS & Communication Status” screen, the following items are displayed. q Positioning: GPS positioning status q Communication: Communication environment and connection status of the communication modem q Number of message not yet sent: Number of mails that are saved on the machine monitor and have not yet been transmitted q [F5]: Returns the display to the KOMTRAX settings screen
Selecting the menu Select “KOMTRAX Settings” on the “Service Menu” screen.
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KOMTRAX Settings (Modem Information) The setting and operating status of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”. Modem status is used to check the IP address of the KOMTRAX communication modem. 1.
Selecting the menu Select “KOMTRAX Settings” on the “Service Menu” screen.
2.
Selecting sub menu After the “KOMTRAX Settings” screen is displayed, select “Modem Status” with the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the “Service Menu” screen.
3.
Service Message Special messages for the technician sent from the KOMTRAX base station (a distributor, etc.) can be checked by using this function. If a received message has return mail setting, a return mail can be sent by using the numeral input switches. 1.
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Modem status displayed IP addresses (2 addresses) of the modem are displayed. q [F5]: Returns the display to the KOMTRAX settings screen a An IP address is a unique number assigned to each modem that is used when communication between the modem and server is turned on.
Selecting menu Select “Service Message” on the Service Menu screen.
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102 Testing and adjusting, Part 2 Special functions of machine monitor
2.
Displaying message (read-only) If a message is received, the content is displayed. If there is no message, “No message” is displayed. q [F5]: Returns the display to the service menu screen a This message is different from that sent for the operator with the machine monitor in the operator mode. a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.
3.
Displaying message (message with return mail function) If a message provides the Numeric Input line under the text, input a proper number by using the numeral input switches and enter it by using the function switch, and the information is returned to the KOMTRAX base station. q [F5]: Returns the display to the KOMTRAX settings screen q [F6]: Validates and returns the input value. a This message is different from that sent for the operator with the machine monitor in the operator mode. a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.
PC200, 200LC, 220, 220LC-8M0
SEN06128-00
30-102
51
SEN06128-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06128-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
30-102
52
SEN06129-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
30 Testing and adjusting
1
103 Testing and adjusting, Part 3 Handling voltage circuit of engine controller ................................................................................................... 2 Preparation work for troubleshooting of electrical system .............................................................................. 3 Procedure for testing diodes ........................................................................................................................... 8 Pm Clinic service ............................................................................................................................................ 9
PC200, 200LC, 220, 220LC-8M0
30-103
1
SEN06129-00
103 Testing and adjusting, Part 3 Handling voltage circuit of engine controller
Handling voltage circuit of engine controller 1 1.
Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-103
2
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Preparation work for troubleshooting of electrical system
SEN06129-00
Preparation work for troubleshooting of electrical system a
a
1.
When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, pump contoller, or KOMTRAX communication MODEM, expose the related connectors according to the following procedure. Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below. Machine monitor 1) Remove the screws (three pcs.) mounting cover (1). a One of the three screws is covered with cap (2). a Disconnect connector P31 of the sunlight sensor and remove cover (1).
4)
2) 3)
Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM04 on machine monitor (7).
Remove a mounting bolt and duct (6). Insert a flat-head screwdriver in slit (3) and pull it up around projection (4) to remove cover (5).
PC200, 200LC, 220, 220LC-8M0
30-103
3
SEN06129-00
2.
Engine controller 1) Open the engine hood. a The engine controller is mounted on the engine (on the counterweight side). 2) Insert or connect troubleshooting T-adapters in or to connectors CE01, CE02, and CE03 of engine controller (5). a Connectors CE01 and CE02 are fixed with screws. When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
103 Testing and adjusting, Part 3 Preparation work for troubleshooting of electrical system
3.
Pump controller 1) Slide the operator's seat and seat stand to the forward end. 2) Remove the 5 mounting bolts and cool & hot box (6). a While removing the cool & hot box, disconnect the drain hose. 3) Remove the 2 mounting bolts, 1 fastener, and magazine box (7). 4) Remove the 3 mounting bolts and cover (8). 5) Remove fuse box cover (9) and cover (10). a Since the underside of cover (10) is clamped, pull it up. 6) Remove the 7 mounting bolts and cover (11).
7)
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4
Connect the troubleshooting adapters to connectors C01 and C02 of pump controller (12). a Install the adapters to only the wiring harness side.
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Preparation work for troubleshooting of electrical system
a
SEN06129-00
The connectors of the pump controller have a special locking mechanism. Disconnect them according to steps (a) to (c) and connect them according to steps (d) to (f) as shown below. Disconnection: (a) Unlock – (b) Slide lever – (c) Disconnect connector. Connection: (d) Position connector – (e) Slide lever – (f) Lock.
6)
5.
4.
KOMTRAX communication module 1) Slide the operator's seat and seat stand to the forward end. 2) Remove the five mounting bolts and cool & hot box (9). a While removing the cool and hot box, disconnect the drain hose. 3) Remove the two mounting bolts, one fastener, and magazine box (10). 4) Remove the three mounting bolts and cover (11). 5) Remove the seven mounting bolts and cover (14).
PC200, 200LC, 220, 220LC-8M0
Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (15).
Atmospheric pressure sensor (AMBAIR PRESSURE) Engine Ne speed sensor (CRANK SENSOR) Engine Bkup speed sensor (CAM SENSOR) Engine oil pressure switch (OIL PRESSURE SWITCH) a Disconnection and connection of connector The connectors of the atmospheric pressure sensor, engine Ne speed sensor, engine Bkup speed sensor, engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) to (c) and connect them according to steps (d) to (f) as shown below. Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect connector. Connection: (d) Connect connector – (e) Lock – (f) Slide lever.
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5
SEN06129-00 a
6.
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting, and troubleshooting".
103 Testing and adjusting, Part 3 Preparation work for troubleshooting of electrical system
7.
Supply pump IMV solenoid (FUEL REGULATOR) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) to (b) and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
8.
Common rail pressure sensor (FUEL RAIL PRESS) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) to (b) and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
Boost pressure and temperature sensor (BOOST PRESS & IMT) a Disconnection and connection of connector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnect it according to steps (a) to (b) and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
a
30-103
Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
6
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Preparation work for troubleshooting of electrical system
a
Precautions for disconnecting connector The direction of the lock of the connector varies with the position of the sensor is screwed in and the lock may face a direction in which it is difficult to unlock (on the underside or engine side). In this case, pinch the lock in direction (a) with bent-nose nippers [1] (commercially available), and the lock is reset. Since the lock clicks when it is unlocked, disconnect the connector after a click is heard.
a
Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular notch (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular notch (f)).
PC200, 200LC, 220, 220LC-8M0
SEN06129-00
9.
Engine coolant temperature sensor (COOLANT TEMP) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking mechanism. Disconnect it according to steps (a) to (b) and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock – (b) Disconnect connector. Connection: (c) Connect connector – (d) Lock.
a
Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
30-103
7
103 Testing and adjusting, Part 3 Procedure for testing diodes
SEN06129-00
Procedure for testing diodes a a
1
Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure. The conductive directions of the assembledtype diode are as follows.
2.
a
The conductive direction of the single diode is indicated on the surface of the diode.
1.
When using digital circuit tester 1) Set the tester in the diode range and read the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side and check the indicated value. 3) Judge the condition of the diode by the indicated value. q The indicated value does not change: The diode does not have continuity (Defective). q The indicated value changes: The diode has continuity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indicated.
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8
When using analog circuit tester 1) Set the tester in the resistance range. 2) Apply the leads of the tester as explained below and check the movement of the pointer. i) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side. ii) Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side. 3) Judge the condition of the diode by the movement of the pointer. q The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on the type and selected range of the tester, however). q The pointer moves in both i) and ii): The diode is defective (Internal short circuit). q The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
Pm Clinic service
1
Model name
Serial No.
Service meter
T PC200-8M0 T PC220-8M0 T PC200LC-8M0 T PC220LC-8M0
h
User's name
Date of execution /
Inspector
/
Specifications Main components Boom Arm Bucket
T Standard T ( T Standard T ( T Standard T (
Attachments ) ) )
Shoe width
T Breaker T( T(
) )
T 600 mm T 700 mm T(
)
Check of oil/coolant level T Radiator coolant T Engine oil T Hydraulic oil
When necessary T Damper case oil T Final drive case oil
T Machinery case oil T(
Ambient temperature
)
Altitude
°C
m Operator's opinion
Result of visual inspection
Mechanical equipment system fault history
Electrical equipment system fault history
989EKX
times/1st time
h/last
h
times/1st time
h/last
h
AA10NX
times/1st time
h/last
h
times/1st time
h/last
h
AB00KE
times/1st time
h/last
h
times/1st time
h/last
h
B@BAZG
times/1st time
h/last
h
times/1st time
h/last
h
B@BAZK
times/1st time
h/last
h
times/1st time
h/last
h
B@BCNS
times/1st time
h/last
h
times/1st time
h/last
h
B@BCZK
times/1st time
h/last
h
times/1st time
h/last
h
B@HANS
times/1st time
h/last
h
times/1st time
h/last
h
CA234
times/1st time
h/last
h
times/1st time
h/last
h
Max. range of engine coolant temperature gauge
PC200, 200LC, 220, 220LC-8M0
Max. range of hydraulic oil temperature gauge
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9
SEN06129-00
103 Testing and adjusting, Part 3 Pm Clinic service
Items related to engine
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10
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
Items related to oil pressure
PC200, 200LC, 220, 220LC-8M0
30-103
11
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
Check sheet (PC200/200LC-8M0) Model
Serial No.
Service meter
User's name
Date of execution /
Operation of work equipment
Engine speed
2
Engine oil pressure
3
Engine speed
All levers in neutral
MAX OFF
4
Engine oil pressure
5
Engine speed
6
Blow-by pressure
7
Engine speed
2.
All levers in neutral
OFF
MIN P
ON
Arm IN relief
OFF
All levers in neutral
MAX ON
Unit
Standard value for new machine
Repair limit
rpm
1,990 to 2,130
1,990 to 2,130
MPa {kg/cm2}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
rpm
1,000 to 1,100
1,000 to 1,100
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
rpm
1,850 to 2,050
1,850 to 2,050
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
rpm
950 to 1,050
950 to 1,050
Unit
Standard value for new machine
Repair limit
sec
2.9 to 3.7
Max. 4.7
sec
3.1 to 3.9
Max. 4.5
sec
3.2 to 4.0
Max. 4.5
Check item
1
Boom RAISE
2
Arm IN
3
Arm OUT
4
Bucket CURL
5
Swing (5 turns)
Fuel control dial
Working mode P E L
MAX
Checking posture, etc. Work equipment extended fully
Boom top horizontal
sec
6.0 to 7.4
Max. 7.7
sec
2.4 to 3.0
Max. 3.5
Boom top horizontal Arm cylinder retracted fully
sec
2.1 to 2.7
Max. 3.1
Work equipment extended fully Swing right and left
sec
21.7 to 26.7
Max. 30
44.6 to 54.9
44.6 to 58.8
48.6 to 59.8
48.6 to 63.8
33.7 to 41.3
33.7 to 45.3
36.7 to 44.9
36.7 to 48.9
25.2 to 27.8
25.2 to 29.8
27.3 to 30.3
27.3 to 32.3
P
6
Measured value
Work equipment speed Condition for check
No.
Measured value
Bad
Work- AutoLeft knob ing decelswitch mode eration
Bad
1
Check item
Fuel control dial
Good
Engine Condition for check
No.
/
Good
1.
Inspector
Travel (5 idle turns)
LO Oneside of track pushed up and turned forward and backward
MI
HI
30-103
12
STD LC STD LC STD LC
sec
sec
sec
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Pm Clinic service
1
4.
Check item
Hydraulic drift of Engine stopped bucket tip
Checked part
Self pressure reducing valve
2
Main relief valve (Low pressure)
3
Main relief valve (Low pressure)
4
Unload valve
Fuel control dial
Boom top horizontal Arm cylinder retracted fully Bucket loaded
7
WorkLeft knob ing switch mode
Max. 600
Max. 900
[1]
[2]
[3]
[4]
[5]
600K
600K
600K
60K
Operation of work equipment
F pump main
R pump main
F pump LS
R pump LS
Control
All lever in neutral
—
—
—
—
Arm out relief ON All levers in neutral
B
B
B
B
C
C
C
C
D1
D1
D2
D2
Right track driven idle E1 Lever moved halfway
LS valve
Left track driven idle Lever moved halfway
P
Swing motor safety valve
OFF
Main relief valve Travel motor Safety valve Travel junction valve
Testing oil pressure
Standard value
mm/ 15 min
Measured value
600K
OFF
MAX 6
Repair limit
Hydraulic circuit
1
5
Standard value for new machine
Checking posture, etc.
Condition for check No.
Unit
Bad
No.
Working mode
Good
Condition for check Fuel control dial
Bad
Hydraulic drift of work equipment
Good
3.
SEN06129-00
—
E1
Swing lock Right swing relief
F
F
Swing lock Left swing relief
F
F
E2
— — — —
—
—
E2
—
—
—
—
—
—
—
Right travel lock G Right forward relief
—
—
—
—
Right travel lock G Right reverse relief
—
—
—
—
—
—
—
—
—
—
Left travel lock Left forward relief
—
Left travel lock Left reverse relief
—
G G
Standard value for new machine
Repair limit
A (Control circuit source pressure)
2.93 to 3.43 {30 to 35}
2.74 to 3.43 {28 to 35}
B (Work equipment relief pressure, low)
33.6 to 36.3 {343 to 370}
33.1 to 37.2 {338 to 380}
36.1 to 38.7 {368 to 395}
36.1 to 39.7 {368 to 405}
D1 to D2 = 2.5 to 4.5 {26 to 46}
D1 to D2 = 2.5 to 4.5 {26 to 46}
E1 to E2 = 1.7 to 1.9 {17 to 19}
E1 to E2 = 1.7 to 1.9 {17 to 19}
C (Work equipment relief pressure, high) D (Unload pressure) E (LS differential pressure)
Unit
—
A
MPa {kg/cm2}
F (Swing relief pressure)
28.8 to 31.8 {295 to 325}
28.4 to 32.3 {290 to 330}
G (Travel relief pressure)
36.7 to 39.7 {375 to 405}
36.8 to 40.2 {375 to 410}
PC200, 200LC, 220, 220LC-8M0
30-103
13
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
No.
Standard value
8
Check item
Servo piston
Fuel control dial
WorkLeft knob ing switch mode
MAX
P
OFF
Checked oil pressure
Unit
H (Servo control pressure)
—
Operation of work equipment Arm out relief
[1]
[2]
[3a]
[4a]
[5]
600K
600K
600K
600K
60K
F pump main
R pump main
F pump servo
R pump servo
Control
H1
H1
H2
H2
Standard value for new machine
Bad
Condition for check
Good
* Gauge changing work: Change hoses of gauges [3] and [4].
—
Repair limit
H1 : H2 = 1 : 0.6 (Oil pressure ratio)
[2]
[3b]
[4b]
[5a]
600K
60K
60K
60K
No.
Check item
Fuel control dial
WorkLeft knob ing switch mode
F pump main
R pump main
F pump (F)
R pump (R)
LS-EPC
—
—
J1
J1
—
—
J2
J2
—
—
J3
J3
—
—
J4
J4
—
—
J5
J5
Travel speed: Lo travel lever in neutral
—
—
—
—
Travel speed: Mi Travel lever operated
—
—
—
—
Travel speed: Hi Travel lever operated
—
—
—
—
Operation of work equipment
MIN P
9
PC-EPC (F) valve PC-EPC (R) valve
E
All levers in neutral
L B
OFF
Bad
[1] 600K
Condition for check
Good
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4], and [5].
— — — — —
MAX
10
LS-EPC valve
P
Standard value
Testing oil pressure
Unit
K2
K3
Standard value for new machine
Repair limit
J1 (PC-EPC valve output pressure 1)
Approx. 2.9 {Approx. 30}
J2 (PC-EPC valve output pressure 2)
Approx. 0.7 {Approx. 7}
J3 (PC-EPC valve output pressure 3)
Approx. 0.78 {Approx. 8}
J4 (PC-EPC valve output pressure 4) J5 (PC-EPC valve output pressure 5)
MPa {kg/cm2}
Approx. 1.7 {Approx. 17.5} Approx. 1.57 {Approx. 16}
K1 (LS-EPC valve output pressure 1)
Approx. 2.45 {Approx. 25}
K2 (LS-EPC valve output pressure 2)
Approx. 0.74 {Approx. 7.5}
K3 (LS-EPC valve output pressure 3)
0 {0}
30-103
14
K1
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
Check sheet (PC220/220LC-8M0) Model
Serial No.
Service meter
User's name
Date of execution /
Operation of work equipment
Engine speed
2
Engine oil pressure
3
Engine speed
All levers in neutral
MAX OFF
4
Engine oil pressure
5
Engine speed
6
Blow-by pressure
7
Engine speed
2.
All levers in neutral
OFF
MIN P
ON
Arm IN relief
OFF
All levers in neutral
MAX ON
Unit
Standard value for new machine
Repair limit
rpm
2,090 to 2,230
2,090 to 2,230
MPa {kg/cm2}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
rpm
1,000 to 1,100
1,000 to 1,100
MPa {kg/cm2}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
rpm
1,850 to 2,050
1,850 to 2,050
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
rpm
950 to 1,150
950 to 1,150
Unit
Standard value for new machine
Repair limit
sec
3.1 to 3.9
Max. 4.9
sec
3.7 to 4.5
Max. 4.8
sec
3.8 to 4.6
Max. 4.9
Check item
1
Boom RAISE
2
Arm IN
3
Arm OUT
4
Bucket CURL
5
Swing (5 turns)
Fuel control dial
Working mode P E L
MAX
Checking posture, etc. Work equipment extended fully
Boom top horizontal
sec
7.0 to 8.6
Max. 9.0
sec
2.8 to 3.4
Max. 3.5
Boom top horizontal Arm cylinder retracted fully
sec
2.4 to 3.0
Max. 3.3
Work equipment extended fully Swing right and left
sec
22.9 to 28.5
Max. 31
46.6 to 57.4
46.6 to 61.5
50.5 to 62.3
50.5 to 66.3
35.6 to 43.6
35.6 to 47.6
38.6 to 46.2
38.6 to 51.2
26.7 to 29.5
26.7 to 31.5
28.9 to 31.9
28.9 to 33.9
P
6
Measured value
Work equipment speed Condition for check
No.
Measured value
Bad
Work- AutoLeft knob ing decelswitch mode eration
Good
1
Check item
Fuel control dial
Bad
Engine Condition for check
No.
/
Good
1.
Inspector
Travel (5 idle turns)
LO Oneside of track pushed up and turned forward and backward
MI
HI
PC200, 200LC, 220, 220LC-8M0
STD LC STD LC STD LC
sec
sec
sec
30-103
15
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
1
4.
Check item
Hydraulic drift of Engine stopped bucket tip
Checked part
Self pressure reducing valve
2
Main relief valve (Low pressure)
3
Main relief valve (Low pressure)
4
Unload valve
Fuel control dial
Boom top horizontal Arm cylinder retracted fully Bucket loaded
7
WorkLeft knob ing switch mode
Max. 600
Max. 900
[1]
[2]
[3]
[4]
[5]
600K
600K
600K
60K
Operation of work equipment
F pump main
R pump main
F pump LS
R pump LS
Control
All lever in neutral
—
—
—
—
Arm out relief ON All levers in neutral
B
B
B
B
C
C
C
C
D1
D1
D2
D2
Right track driven idle E1 Lever moved halfway
LS valve
Left track driven idle Lever moved halfway
P
Swing motor safety valve
OFF
Main relief valve Travel motor Safety valve Travel junction valve
Testing oil pressure
Standard value
mm/ 15 min
Measured value
600K
OFF
MAX 6
Repair limit
Hydraulic circuit
1
5
Standard value for new machine
Checking posture, etc.
Condition for check No.
Unit
Bad
No.
Working mode
Bad
Condition for check Fuel control dial
Good
Hydraulic drift of work equipment
Good
3.
—
E1
Swing lock Right swing relief
F
F
Swing lock Left swing relief
F
F
E2
— — — —
—
E2
— —
—
—
—
—
—
—
Right travel lock G Right forward relief
—
—
—
—
Right travel lock G Right reverse relief
—
—
—
—
—
—
—
—
—
—
Left travel lock Left forward relief
—
Left travel lock Left reverse relief
—
G G
Standard value for new machine
Repair limit
A (Control circuit source pressure)
2.93 to 3.43 {30 to 35}
2.75 to 3.43 {28 to 35}
B (Work equipment relief pressure, low)
33.6 to 36.3 {343 to 370}
33.1 to 37.2 {338 to 380}
36.1 to 38.8 {368 to 395}
36.1 to 39.7 {368 to 405}
D1 to D2 = 2.5 to 4.5 {26 to 46}
D1 to D2 = 2.5 to 4.5 {26 to 46}
E1 to E2 = 1.7 to 1.9 {17 to 19}
E1 to E2 = 1.7 to 1.9 {17 to 19}
C (Work equipment relief pressure, high) D (Unload pressure) E (LS differential pressure)
Unit
—
A
MPa {kg/cm2}
F (Swing relief pressure)
28.8 to 31.8 {295 to 325}
28.4 to 32.3 {290 to 330}
G (Travel relief pressure)
36.7 to 39.7 {375 to 405}
36.8 to 40.2 {375 to 410}
30-103
16
PC200, 200LC, 220, 220LC-8M0
103 Testing and adjusting, Part 3 Pm Clinic service
SEN06129-00
No.
Standard value
8
Check item
Servo piston
Fuel control dial
WorkLeft knob ing switch mode
MAX
P
OFF
Checked oil pressure
Unit
H (Servo control pressure)
—
Operation of work equipment Arm out relief
[1]
[2]
[3a]
[4a]
[5]
600K
600K
600K
600K
60K
F pump main
R pump main
F pump servo
R pump servo
Control
H1
H1
H2
H2
Standard value for new machine
Bad
Condition for check
Good
* Gauge changing work: Change hoses of gauges [3] and [4].
—
Repair limit
H1 : H2 = 1 : 0.6 (Oil pressure ratio)
[2]
[3b]
[4b]
[5a]
600K
60K
60K
60K
No.
Check item
Fuel control dial
WorkLeft knob ing switch mode
F pump main
R pump main
F pump (F)
R pump (R)
LS-EPC
—
—
J1
J1
—
—
J2
J2
—
—
J3
J3
—
—
J4
J4
—
—
J5
J5
Travel speed: Lo travel lever in neutral
—
—
—
—
Travel speed: Mi Travel lever operated
—
—
—
—
Travel speed: Hi Travel lever operated
—
—
—
—
Operation of work equipment
MIN P
9
PC-EPC (F) valve PC-EPC (R) valve
E
All levers in neutral
L B
OFF
Bad
[1] 600K
Condition for check
Good
* Gauge changing work: Change gauges [3] and [4] to 60K and change hose conditions of [3], [4], and [5].
— — — — —
MAX
10
LS-EPC valve
P
Standard value
Testing oil pressure
Unit
K2
K3
Standard value for new machine
J1 (PC-EPC valve output pressure 1)
Approx. 2.9 {Approx. 30}
J2 (PC-EPC valve output pressure 2)
Approx. 0.7 {Approx. 7}
J3 (PC-EPC valve output pressure 3)
Approx. 0.78 {Approx. 8}
J4 (PC-EPC valve output pressure 4) J5 (PC-EPC valve output pressure 5)
MPa {kg/cm2}
Repair limit
Approx. 1.7 {Approx. 17.5} Approx. 1.57 {Approx. 16}
K1 (LS-EPC valve output pressure 1)
Approx. 2.45 {Approx. 25}
K2 (LS-EPC valve output pressure 2)
Approx. 0.74 {Approx. 7.5}
K3 (LS-EPC valve output pressure 3)
0 {0}
PC200, 200LC, 220, 220LC-8M0
K1
30-103
17
SEN06129-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06129-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
30-103
18
SEN06131-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting
1
100 Failure code table and fuse locations Failure codes table.......................................................................................................................................... 2 Fuse locations................................................................................................................................................. 9
PC200, 200LC, 220, 220LC-8M0
40-100
1
100 Failure code table and fuse locations Failure codes table
SEN06131-00
Failure codes table Failure code
Trouble (Displayed on screen)
1 Component in charge
Action level
Category of record
879AKA
A/C Inner Sensor Open Circuit
MON
—
Electrical system
879AKB
A/C Inner Sensor Short Circuit
MON
—
Electrical system
879BKA
A/C Outer Sensor Open Circuit
MON
—
Electrical system
879BKB
A/C Outer Sensor Short Circuit
MON
—
Electrical system
879CKA
Ventilating Sensor Open Circuit
MON
—
Electrical system
879CKB
Ventilating Sensor Short Circuit
MON
—
Electrical system
879DKZ
Sunlight Sensor Open Or Short Circuit
MON
—
Electrical system
879EMC
Ventilating Damper Abnormality
MON
L01
Electrical system
879FMC
Air Mix Damper Abnormality
MON
L01
Electrical system
879GKX
Refrigerant Abnormality
MON
L01
Electrical system
989L00
Engine Controller Lock Caution1
MON
—
Electrical system
989M00
Engine Controller Lock Caution2
MON
—
Electrical system
989N00
Engine Controller Lock Caution3
MON
—
Electrical system
AA10NX
Air Cleaner Clogging
MON
L01
Mechanical system
AB00KE
Charge Voltage Low
MON
L03
Mechanical system
B@BAZG
Eng Oil Press Low
ENG
L03
Mechanical system
B@BAZK
Engine Oil Level Low
MON
L01
Mechanical system
B@BCNS
Eng Water Overheat
ENG
L02
Mechanical system
B@BCZK
Radiator Coolant Level Low
MON
L01
Mechanical system
B@HANS
Hyd Oil Overheat
PUMP
L02
Mechanical system
CA111
ECM Critical Internal Failure
ENG
L04
Electrical system
CA115
Eng Ne and Bkup Speed Sens Error
ENG
L04
Electrical system
CA122
Chg Air Press Sensor High Error
ENG
L03
Electrical system
CA123
Chg Air Press Sensor Low Error
ENG
L03
Electrical system
CA131
Throttle Sensor High Error
ENG
L03
Electrical system
40-100
2
Reference documents No.
See section 80, Appendix
Troubleshooting by failure code, Part 1 SEN06133-**
PC200, 200LC, 220, 220LC-8M0
100 Failure code table and fuse locations Failure codes table
Failure code
Trouble (Displayed on screen)
SEN06131-00
Component in charge
Action level
Category of record
CA132
Throttle Sensor Low Error
ENG
L03
Electrical system
CA144
Coolant Temp Sens High Error
ENG
L01
Electrical system
CA145
Coolant Temp Sens Low Error
ENG
L01
Electrical system
CA153
Chg Air Temp Sensor High Error
ENG
L03
Electrical system
CA154
Chg Air Temp Sensor Low Error
ENG
L03
Electrical system
CA155
Chg Air Temp High Speed Derate
ENG
L03
Electrical system
CA187
Sens Supply 2 Volt Low Error
ENG
L03
Electrical system
CA221
Ambient Press Sens High Error
ENG
L03
Electrical system
CA222
Ambient Press Sens Low Error
ENG
L03
Electrical system
CA227
Sens 2 Supply Volt High Error
ENG
L03
Electrical system
CA234
Eng Overspeed
ENG
—
Electrical system
CA238
Ne Speed Sens Supply Volt Error
ENG
L01
Electrical system
CA271
IMV/PCV1 Short Error
ENG
L03
Electrical system
CA272
IMV/PCV1 Open Error
ENG
L03
Electrical system
CA322
Inj #1(L#1) Open/Short Error
ENG
L03
Electrical system
CA323
Inj #5(L#5) Open/Short Error
ENG
L03
Electrical system
CA324
Inj #3(L#3) Open/Short Error
ENG
L03
Electrical system
CA325
Inj #6(L#6) Open/Short Error
ENG
L03
Electrical system
CA331
Inj #2(L#2) Open/Short Error
ENG
L03
Electrical system
CA332
Inj #4(L#4) Open/Short Error
ENG
L03
Electrical system
CA342
Calibration Code Incompatibility
ENG
L04
Electrical system
CA351
Injectors Drive Circuit Error
ENG
L03
Electrical system
CA352
Sens Supply 1 Volt Low Error
ENG
L03
Electrical system
CA386
Sens Supply 1 Volt High Error
ENG
L03
Electrical system
CA428
Water in Fuel Sensor High Error
ENG
L01
Electrical system
PC200, 200LC, 220, 220LC-8M0
Reference documents No.
Troubleshooting by failure code, Part 1 SEN06133-**
Troubleshooting by failure code, Part 2 SEN06134-**
40-100
3
100 Failure code table and fuse locations Failure codes table
SEN06131-00
Failure code
Trouble (Displayed on screen)
Component in charge
Action level
Category of record
CA429
Water in Fuel Sensor Low Error
ENG
L01
Electrical system
CA435
Eng Oil Press Sw Error
ENG
L01
Electrical system
CA441
Battery Voltage Low Error
ENG
L04
Electrical system
CA442
Battery Voltage High Error
ENG
L04
Electrical system
CA449
Rail Press Very High Error
ENG
L03
Electrical system
CA451
Rail Press Sensor High Error
ENG
L03
Electrical system
CA452
Rail Press Sensor Low Error
ENG
L03
Electrical system
CA488
Chg Air Temp High Torque Derate
ENG
L03
Electrical system
CA553
Rail Press High Error
ENG
L01
Electrical system
CA559
Rail Press Low Error
ENG
L01
Electrical system
CA689
Eng Ne Speed Sensor Error
ENG
L01
Electrical system
CA731
Eng Bkup Speed Sens Phase Error
ENG
L01
Electrical system
CA757
All Continuous Data Lost Error
ENG
L04
Electrical system
CA778
Eng Bkup Speed Sensor Error
ENG
L01
Electrical system
CA2185
Throt Sens Sup Volt High Error
ENG
L03
Electrical system
CA2186
Throt Sens Sup Volt Low Error
ENG
L03
Electrical system
CA2249
Rail Press Very Low Error
ENG
L03
Electrical system
CA2311
lMV Solenoid Error
ENG
L03
Electrical system
CA2555
Grid Htr Relay Open Circuit Error
ENG
L01
Electrical system
CA2556
Grid Htr Relay Short Circuit Error
ENG
L01
Electrical system
40-100
4
Reference documents No.
Troubleshooting by failure code, Part 2 SEN06134-**
PC200, 200LC, 220, 220LC-8M0
100 Failure code table and fuse locations Failure codes table
Failure code
Trouble (Displayed on screen)
SEN06131-00
Component in charge
Action level
Category of record
D110KB
Battery Relay Drive Short Circuit
PUMP
L01
Electrical system
D19JKZ
Personal Code Relay Abnormality
MON
L03
Electrical system
D811MC
KOMTRAX Error
KOMTRAX
—
Electrical system
D862KA
GPS Antenna Open Circuit
KOMTRAX
—
Electrical system
D8AQKR
CAN2 Discon (KOMTRAX)
MON
—
Electrical system
DA22KK
Pump Solenoid Power Low Error
PUMP
L03
Electrical system
DA25KP
5V Sensor 1 Power Abnormality
PUMP
—
Electrical system
DA26KP
5V Sensor 2 Power Abnormality
PUMP
—
Electrical system
DA29KQ
Model Selection Abnormality
PUMP
L01
Electrical system
DA2QKR
CAN2 Discon (Pump Con)
MON
L03
Electrical system
DAF0MB
Monitor ROM Abnormality
MON
—
Electrical system
DAF0MC
Monitor Error
MON
—
Electrical system
DAF8KB
Camera Power Supply Short Circuit
MON
L03
Electrical system
DAF9KQ
Model Selection Abnormality
MON
L03
Electrical system
DAFGMC
GPS Module Error
KOMTRAX
—
Electrical system
DAFQKR
CAN2 Discon (Monitor)
KOMTRAX
—
Electrical system
DAZ9KQ
A/C Model Selection Abnormality
MON
—
Electrical system
DAZQKR
CAN2 Discon (Aircon ECU)
MON
L01
Electrical system
DB2QKR
CAN2 Discon (Engine Con)
MON
L03
Electrical system
DGH2KB
Hyd Oil Sensor Short Circuit
PUMP
L01
Electrical system
DHA4KA
Air Cleaner Clog Sensor Open Circuit
MON
L01
Electrical system
DHPAMA
F Pump Press Sensor Abnormality
PUMP
L01
Electrical system
DHPBMA
R Pump Press Sensor Abnormality
PUMP
L01
Electrical system
PC200, 200LC, 220, 220LC-8M0
Reference documents No.
Troubleshooting by failure code, Part 3 SEN06135-**
40-100
5
100 Failure code table and fuse locations Failure codes table
SEN06131-00
Failure code
Trouble (Displayed on screen)
Component in charge
Action level
Category of record
DHS3MA
Arm Curl PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHS4MA
Bucket CURL PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHS8MA
Boom Raise PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHS9MA
Boom Lower PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSAMA
Swing RH PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSBMA
Swing LH PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSCMA
Arm Dump PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSDMA
Bucket Dump PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSFMA
Travel FW L PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSGMA
Travel FW R PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSHMA
Travel BW L PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHSJMA
Travel BW R PPC Press Sensor Abnormality
PUMP
L01
Electrical system
DHX1MA
Overload Sensor Abnormality
PUMP
L04
Electrical system
DR21KX
Camera 2 Picture Rev. Drive Abnormality
MON
L01
Electrical system
DR31KX
Camera 3 Picture Rev. Drive Abnormality
MON
L01
Electrical system
DV20KB
Travel Alarm Short Circuit
PUMP
L01
Electrical system
DW43KA
Travel Speed Sol Open Circuit
PUMP
L01
Electrical system
DW43KB
Travel Speed Sol Short Circuit
PUMP
L01
Electrical system
DW45KA
Swing brake Sol. Valve Open Circuit
PUMP
L01
Electrical system
DW45KB
Swing Brake Sol Short Circuit
PUMP
L01
Electrical system
DW91KA
Travel Neutral Sol Open Circuit
PUMP
L01
Electrical system
DW91KB
Travel Neutral Sol Short Circuit
PUMP
L01
Electrical system
40-100
6
Reference documents No.
Troubleshooting by failure code, Part 4 SEN06136-**
PC200, 200LC, 220, 220LC-8M0
100 Failure code table and fuse locations Failure codes table
Failure code
Trouble (Displayed on screen)
SEN06131-00
Component in charge
Action level
Category of record
DWA2KA
Attachment Sol Open Circuit
PUMP
L03
Electrical system
DWA2KB
Attachment Sol Short Circuit
PUMP
L03
Electrical system
DWK0KA
2-stage Relief Sol Open Circuit
PUMP
L01
Electrical system
DWK0KB
2-stage Relief Sol Short Circuit
PUMP
L01
Electrical system
DWK2KA
Variable Back Press Sol Open Circuit
PUMP
L01
Electrical system
DWK2KB
Variable Back Press Sol Short Circuit
PUMP
L01
Electrical system
DXA8KA
PC-EPC (F) Sol Open Circuit
PUMP
L03
Electrical system
DXA8KB
PC-EPC (F) Sol Short Circuit
PUMP
L03
Electrical system
DXA9KA
PC-EPC (R) Sol Open Circuit
PUMP
L03
Electrical system
DXA9KB
PC-EPC (R) Sol Short Circuit
PUMP
L03
Electrical system
DXE0KA
LS-EPC Sol Open Circuit
PUMP
L01
Electrical system
DXE0KB
LS-EPC Sol Short Circuit
PUMP
L01
Electrical system
DXE4KA
Attachment Flow EPC Open Circuit
PUMP
—
Electrical system
DXE4KB
Attachment Flow EPC Short Circuit
PUMP
—
Electrical system
DXE5KA
Merge-divide Main Sol Open Circuit
PUMP
L01
Electrical system
DXE5KB
Merge-divide Main Sol Short Circuit
PUMP
L01
Electrical system
DXE6KA
Merge-divide LS Sol Open Circuit
PUMP
L01
Electrical system
DXE6KB
Merge-divide LS Sol Short Circuit
PUMP
L01
Electrical system
DY20KA
Wiper Working Abnormality
PUMP
—
Electrical system
DY20MA
Wiper Parking Abnormality
PUMP
—
Electrical system
DY2CKB
Washer Drive Short Circuit
PUMP
—
Electrical system
DY2DKB
Wiper Drive (For) Short
PUMP
—
Electrical system
DY2EKB
Wiper Drive (Rev) Short
PUMP
—
Electrical system
PC200, 200LC, 220, 220LC-8M0
Reference documents No.
Troubleshooting by failure code, Part 5 SEN06137-**
40-100
7
SEN06131-00 a a
a a
100 Failure code table and fuse locations Failure codes table
In this table, failure codes are arranged in the order of characters from numeric to alphabetic character. A component in charge means a controller or the machine monitor that is in charge of the system check. MON: Machine monitor ENG: Engine controller PUMP: Pump controller KOMTRAX: KOMTRAX terminal The failure codes that do not have numbers in the action level columns are not displayed on the standard screen even when a failure related to them occurs. They are simply recorded in the abnormality record (electrical system and mechanical system) of the service menu. The "Category of record" shows the abnormality record into which the failure is classified, the electrical system or mechanical system, when it is recorded in the abnormality record of the service menu. For details, see "Troubleshooting by failure code (Display of code)".
40-100
8
PC200, 200LC, 220, 220LC-8M0
100 Failure code table and fuse locations Fuse locations
SEN06131-00
Fuse locations
1
Connection table of fuse box a This connection table shows the devices to which power supply from each fuse of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply
Fusible link
Fuse No.
Fuse capacity
Destination of power Lamp relay, rear lamp relay, cab lamp relay
1
10 A
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve [When pump drive switch is operated in emergency] Swing holding brake solenoid valve [When swing holding brake release switch is operated]
Switch power supply
F04 (60 A)
2
30 A
Pump controller (Solenoid power supply) PPC oil pressure lock solenoid valve
3
10 A
Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal code)
4
Switch power supply
Switch power supply
F04 (60 A)
F04 (60 A)
F05 (30 A)
Switch power Starting switch supply ACC
Cigarette lighter Windshield washer motor
5
10 A
Horn relay, horn
6
10 A
Electrical intake air heater relay
7
10 A
Rotary lamp
8
20 A
Right headlamp, working lamp (boom), working lamp (rear)
9
10 A
10
5A
11
20 A
12
10 A
(Spare)
13
10 A
Headlamp
14
10 A
Optional power supply (1)
15
10 A
16 Constant power supply
10 A
10 A
Radio Left knob switch (pump controller input) Air conditioner controller supply Air conditioner unit Air conditioner compressor electromagnetic clutch
Optional power supply (2) Radio (backup power supply) Room lamp Starting switch
17
20 A
Machine monitor Pump controller
18
5A
19
30 A
Engine controller
20
5A
Engine controller (ACC signal)
PC200, 200LC, 220, 220LC-8M0
Air conditioner controller backup
40-100
9
SEN06131-00
100 Failure code table and fuse locations Fuse locations
Locations of fusible links
Location of fuse box and fuse Nos.
40-100
10
PC200, 200LC, 220, 220LC-8M0
100 Failure code table and fuse locations Fuse locations
PC200, 200LC, 220, 220LC-8M0
SEN06131-00
40-100
11
SEN06131-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06131-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-100
12
SEN06132-00 SEN05984-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 200 General Information on troubleshooting Symptom and troubleshooting numbers .....................................................................................................
2
Sequence of events in troubleshooting .......................................................................................................
4
Checks before troubleshooting ...................................................................................................................
6
Classification and procedures for troubleshooting ......................................................................................
8
Symptom and troubleshooting numbers ..................................................................................................... 10 Information in troubleshooting table ............................................................................................................ 12 Connector list and layout ............................................................................................................................ 14 Connection table for connector pin numbers .............................................................................................. 24 T- branch box and T- branch adapter table ................................................................................................. 60 Troubleshooting method for open circuit in wiring harness of pressure sensor system.............................. 63
PC200, 200LC, 220, 220LC-8M0
40-200
1
200 General Information on troubleshooting Symptom and troubleshooting numbers
SEN06132-00
Symptom and troubleshooting numbers k k k k k k
(Rev. 2011/09) Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. When performing the operation with two or more service technicians, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the cable from the negative (–) terminal of the battery first. When removing the plug or cap from a component which is under pressure of oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to prevent reoccurrence of the failure. When performing troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation and to perform troubleshooting in accordance with the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before the failure? 4) Under what conditions did the failure occur? 5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the machine for other symptoms of failure.
40-200 2
2) Perform checks on items listed in "Checks before starting". 3) Perform checks on other checking items. 4) Check other maintenance matters which can be checked appearance and are considered to be necessary. 4. Checking failure symptom Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the method of operation, etc. a When operating the machine to reproduce the failure symptom, do not perform any inspection or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of the failure, then use the troubleshooting flowchart to locate the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the immediate failure is removed, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Symptom and troubleshooting numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
3
SEN06132-00
200 General Information on troubleshooting Sequence of events in troubleshooting
Sequence of events in troubleshooting (Rev. 2011. 7)
40-200 4
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Sequence of events in troubleshooting
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
5
200 General Information on troubleshooting Checks before troubleshooting
SEN06132-00
Checks before troubleshooting
a: Engine, lubricating oil and coolant
No.
Item
Criterion
Remedy
1 Check for unusual sounds and smells
–
Repair
2 Check for dirt around engine
–
Remove
3 Check for water leakage around engine
–
Repair
4 Check for oil leakage around engine
–
Repair
5 Check for leakage from fuel line
–
Repair
6 Check of radiator for clogging
–
Remove
7 Check of level and type of fuel
–
Refilling
8 Check for foreign matter in fuel
–
Clean and drain
9 Check of fuel pre-filter
–
Replace
10 Check of fuel main filter
–
Replace
11 Check of level (in oil pan) and type of engine oil 12 Check of coolant level (in sub tank)
b: Hydraulic and mechanical equipment
13 Check of air cleaner for clogging
Between H –L Between H –L Dust indicator does not show red piston.
Refilling Refill with coolant
Clean or replace
1 Check for unusual sounds and smells
–
Repair
2 Check for oil leakage
–
Repair
Between H –L
Refilling
4 Check of hydraulic oil strainer
–
Clean and drain
5 Check of hydraulic oil filter
–
Replace
6 Check of swing machinery case oil level
Between H –L
Refilling
7 Check of damper case oil level
Between H –L
Refilling
8 Check of final drive case oil level
–
Refilling
9 Air bleeding
–
Air bleeding
3 Check of hydraulic oil level
40-200 6
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Checks before troubleshooting
c: Electrical equipment
No.
SEN06132-00
Item
Criterion
Remedy
1 Check of battery terminal for looseness and corrosion
–
Retighten or replace
2 Check of alternator terminal for looseness and corrosion
–
Retighten or replace
3 Check of starting motor terminal for looseness and corrosion
–
Retighten or replace
4 Check of battery voltage (with engine stopped)
20 to 30 V
Charge or replace
5 Check of battery electrolyte level
Between H and L
Add or replace
6 Check of wiring harness for discoloration, burnt areas and cover peeling
–
Repair or replace
7 Check for removal of wiring harness clamp and sagging of wiring harness
–
Repair
8 Check of grounding
–
Repair
9 Check for loose connector and damaged lock
–
Repair or replace
10 Check of connector pin for corrosion, bends and deformation
–
Repair or replace
11 Check for water and foreign matter in connector
–
Dry, clean or replace
12 Check of wiring harness for open and short circuit
–
Repair or replace
13 Check of fuse for blowing out and corrosion
–
Replace
After several minutes operation: 27.5 – 29.5 V
Replace
–
Replace
16 Check and cleaning of rear view camera
–
Clean or repair
1 Check of undercarriage
–
Repair
2 Check of handrails and steps
–
Repair
3 Check of mirrors
–
Clean or repair
1 Check of gauges and monitors
–
Clean or replace
2 Check of seat belt
–
Repair
14 Check of alternator voltage (when engine speed is medium or higher)
e: Interior parts d: Exterior parts
15
Check of battery relay operation sound (when starting switch is turned to ON or OFF position)
PC200, 200LC, 220, 220LC-8M0
40-200
7
200 General Information on troubleshooting Classification and procedures for troubleshooting
SEN06132-00
Classification and procedures for troubleshooting Classification of troubleshooting Mode
Content
Display of code Troubleshooting by failure code E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting If a phenomenon which appears to be connected with machine trouble occurs on the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1. Procedure for troubleshooting to be taken when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the standard screen of the machine monitor, perform the troubleshooting for the corresponding "Display of code" according to the displayed failure code. a If multiple failures occur simultaneously, all the failure codes are displayed repeatedly in order. Note down all the codes. 2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine monitor: Check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. (See [*1].) 1) If a code is recorded, carry out troubleshooting for the "Display of code" corresponding to the recorded code. a If an electrical system failure code is recorded, delete all the codes once, follow the procedure to reproduce the failure code, and then see if the failure is still detected. (See [*2].) a A failure code of the mechanical system cannot be deleted. 2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon which appears to be connected with machine trouble again and select the same phenomenon from the list on the next page, and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode" troubleshooting. 3. Action to take after failure is eliminated Clear all the failure codes in the electrical system abnormality record, referring to the next page.
40-200 8
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Classification and procedures for troubleshooting
[*1], [*2] 1. While pressing numerical key [4] on the panel switch on the standard screen, press [1], [2] and [3] in order.
2. On the service menu screen, press switch [F3] (R) twice in the panel switch section, and select "03 Abnormality Record". 3. Press [F6] switch ( ) on the panel switch to enter the selection and go to "Abnormality Record" screen.
SEN06132-00 5. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all of the failure codes. a A failure code of the mechanical system cannot be deleted. 6. Press [F5] switch (RETURN) on the panel switch to return to the "Abnormality Record" screen. 7. Enter the "Electrical System Abnormality Record" screen similarly to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all of the failure codes. a "E" on the left of a failure code indicates that the failure is "active" (the failure remains or restoration to normal has not been confirmed). A failure code having no "E" on its left is a "non-active" one. Since it disappears at the following clear step, be sure to note it down. 9. While pressing numerical key [4] on the panel switch, press [1], [2] and [3] in this order to enter the "Clear mode". (Same as 1) 10. Press [F2] switch(CLEAR) on the panel switch.
4. Press [F6] switch ( ) on the panel switch to enter the selection and go to "Mechanical System Abnormality Record" screen.
11. Press [F6] switch ( ) on the panel switch to clear all the failure codes. 12. Press [F5] switch (RETURN) on the panel switch to return to "Electrical System Abnormality Record" screen. See if any failure code is still displayed and note down the displayed ones. 13. Press [F5] switch (RETURN) on the panel switch to return to the "Abnormality Record" screen.
PC200, 200LC, 220, 220LC-8M0
40-200
9
200 General Information on troubleshooting Symptom and troubleshooting numbers
SEN06132-00
Symptom and troubleshooting numbers Symptom and troubleshooting number Troubleshooting No.
Symptom of failure
Display of code
E-mode
H-mode
S-mode
User code and failure code 1 User code and failure code are displayed on machine monitor The failure code is displayed on the mechanical system abnormality Follow the troubleshooting procedure for 2 record screen the failure code. The failure code is displayed on the electrical system abnormality 3 record screen The failure code is displayed on the air conditioner or heater abnor"Inspection by self-diagnosis function" in 4 mality record screen Chapter 80 Check items related to engine 5 Startability is poor
S-1
6 Engine does not start
E-1
S-2
7 Engine does not pick up smoothly
S-3
8 Engine stops during operation
H-2
S-4
9 Engine runs rough or is unstable (hunts)
S-5
10 Engine lacks power
S-6
11 Exhaust smoke is black (incomplete combustion)
S-7
12 Oil consumption is too much (or exhaust smoke is blue)
S-8
13 Oil becomes contaminated early
S-9
14 Fuel consumption is excessive
S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
16 Oil pressure drops
S-12
17 Oil level rises (coolant or fuel in oil)
S-13
18 Coolant temperature rises too high (overheating)
S-14
19 Unusual noise is heard
S-15
20 Vibration is excessive
S-16
21 Preheater does not operate 22 Automatic warm-up system does not operate (in cold season)
E-2 E-13
23 Auto-decelerator does not operate normally
E-14
Symptom related to work equipment, swing and travel All of work equipment, swing, and travel does not work or can not 24 E-20 swing lock 25 All of work equipment, swing and travel work slow or lack power
H-1
26 Engine speed lowers significantly or engine stalls
H-2
27 Working mode does not change
H-3 S-6
E-15
28 Unusual sound is heard from around hydraulic pump
H-4
29 Fine control performance or response is poor
H-5
Symptom related to work equipment 30 Speed or power of boom is low
H-6
31 Speed or power of arm is low
H-7
32 Speed or power of bucket is low
H-8
33 Work equipment does not move in single operation
H-9
34 Hydraulic drift of work equipment is large
H-10
35 Time lag of work equipment operation is large
H-11
36 Other wok equipment moves when one of work equipment is relieved
H-12
37 One-touch power maximizing function does not work.
E-22
H-13
38 Attachment circuit can not be changed
E-35
H-28
40-200 10
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Symptom and troubleshooting numbers
SEN06132-00
Troubleshooting No.
Symptom of failure
Display of code
E-mode
39 Oil flow in attachment circuit cannot be changed
H-mode
S-mode
H-29
Symptom related to combined operation In combined operation of work equipment, equipment having heavier 40 load moves slower In combined operations of swing and boom RAISE, boom rising speed 41 is low 42 Travel speed drops largely in combined operation of swing and travel
H-14 H-15 H-16
Symptom related to travel 43 Machine does not travel straight
H-17
44 Travel speed is low
H-18
45 Machine is hard to steer or travel power is low
H-19
46 Travel speed does not change or travel speed is too low or high
E-16
47 One of tracks does not run
H-20 H-21
48 Travel alarm does not sound or does not stop sounding
E-23
Symptom related to swing 49 Upper structure does not swing
H-22
50 Swing acceleration is poor or swing speed is low
H-23
51 Upper structure overruns excessively when it stops swinging
H-24
52 Shock is larger when upper structure stops swinging
H-25
53 Large sound is made when upper structure stops swinging Swing brake does not operate properly 54 Swing drift on a slope is large Symptom is related to machine monitor When starting switch is turned to ON position, machine monitor dis55 plays nothing. When starting switch is turned ON (before starting engine), basic 56 check monitor lights up 57 Precaution monitor lights up while engine is running
H-26 E-21
E-3 E-4 E-5
58 Emergency stop monitor lights up while engine is running
E-6
59 Engine coolant temperature gauge does not indicate correctly
E-8
60 Hydraulic oil temperature gauge does not indicate correctly
E-9
61 Fuel level gauge does not indicate correctly Contents of display on machine monitor is different from that of actual 62 machine 63 Some areas of machine monitor are not displayed
E-7 E-10
64 Function switch does not work
E-12
65 Alarm buzzer cannot be stopped
E-17
66 While starting switch is in OFF position, service meter is not displayed
E-18
67 Service mode can not be selected
E-19
68 Horn does not sound or does not stop
E-24
69 Windshield wiper and window washer do not operate Air conditioner does not operate normally (including air conditioner 70 fault record) 71 Monitoring function does not display lever control signal normally
H-27
E-11
E-25 "Testing and troubleshooting procedure" in Chapter 80 E-26–34
Others 72 KOMTRAX system does not operate properly.
PC200, 200LC, 220, 220LC-8M0
E-36
40-200
11
200 General Information on troubleshooting Information in troubleshooting table
SEN06132-00
Information in troubleshooting table (Rev. 2011/12) a The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Action level Display on machine monitor Detail of failure Action of controller Problem on machine Related information
Failure code Display on machine monitor
Failure
Failure name displayed on the Abnormality Record screen of the machine monitor
Description of the failure detected by the machine monitor or controller An action that is performed to protect the system and devices when a failure is detected by the machine monitor or controller A problem that appears as a failure on the machine as a result of an action (above) that is performed by the machine monitor or controller. Information on occurred failure or troubleshooting Cause
1
2
3
4
5
6
7
Procedure, measuring location, criteria and remarks q Procedure q Measuring location Defective a "Between A and B" denotes measuring values such as voltage and resistance between A and B. a "Between A and ground" means the measurement of voltage, resistance or others between terminal A and the place which has a continuity with chassis frame such as unpainted hexagonal head bolt or bolt hole which has no rust, etc. Open or short circuit in wirq Criteria to judge probable causes (standard value), remarks ing harness q Perform troubleshooting procedures in numerical order. q If the check result does not meet the criteria, the probable cause described on the left column is the actual cause of the failure. Open circuit in wiring harq If the check result shows no failure, and unless otherwise specified, proceed to the ness next step (next cause item). (wire breakage or defective q If a defect is found and repaired, check that the defect has been corrected. contact of connector) q Open circuit in wiring Connection of connector is defective or wiring harness is broken. q Ground fault Ground fault in wiring harA harness not to be connected to the ground (earth) circuit comes into contact with ness the ground (earth) circuit or chassis accidentally. (contact with ground circuit) q Hot short circuit A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit Hot short circuit An independent wire in the harness erroneously comes into contact with another (contact with 24 V circuit) independent wire. (poor insulation at connector and others) (1) Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapter as follows unless otherwise specified. Short circuit in wiring harq When "male" or "female" is not indicated with a connector number, disconnect ness the connector, and insert T-adapter between the male and female connectors. q When "male" or "female" is indicated with a connector number, disconnect the connector, and connect T-adapter only to either male or female connector. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the positive (+) and negative (-) leads as shown beDefective controller low unless otherwise specified. q Connect the positive (+) lead to pin or wire indicated first. q Connect the negative (-) lead to a pin or wire indicated second.
40-200 12
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Information in troubleshooting table
SEN06132-00
Circuit diagram related to troubleshooting
This is the excerpted circuit diagram related to troubleshooting q The circuit diagram contains the connector Nos., pin Nos., and connector colors related to the failure. q The “/“ in a connector number is either: 1) An abbreviation (of more than three letters) Example: T/C (Torque Converter) 2) Different connector number at male and female sides Example: BREAK OUT/E24 q The circuit diagram contains the destination or source of the branch line in a wiring harness. q The arrow (io) indicates a rough installation position on the given machine. q NO: Normally Open q NC: Normally Closed q Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in circuit diagrams. q Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to another junction or controller at where the same signal name is indicated.
PC200, 200LC, 220, 220LC-8M0
40-200
13
200 General Information on troubleshooting Connector list and layout
SEN06132-00
Connector list and layout Connector No.
Model
Number of pins
A13
DT
2
Intermediate connector
H-1
A15
DT
2
Intermediate connector
K-9
Address of stereogram
Component name
A40
DT
4
Intermediate connector
S-1
A41
DT
4
Camera 2
S-1
AB
Terminal
1
Alternator (Terminal B)
10
Air conditioner unit
AC01 AC02
AG-9 X-5
4
Air conditioner unit
W-9
X
1
Air conditioner compressor electromagnetic clutch
AF-4
FRAMATOME
3
Ambient pressure sensor
AE-2
SUMITOMO
4
Boost pressure/temperature sensor intake manifold
AG-5
FRAMATOME
3
Engine Bkup speed sensor
AF-1
C01
AMP
80
Pump controller
AC03 AMB AIR PRESSURE BOOST PRESS. &IMT CAM SENSOR
V-9
C02
AMP
40
Pump controller
W-9
CE01
DRC
60
Engine controller
AG-1
CE02
DRC
50
Engine controller
AF-1
CE03
DTP
4
Engine controller
AG-1
CK01
070
18
KOMTRAX communication module
X-7
CK02
070
12
KOMTRAX communication module
X-7
CM01
070
18
Machine monitor
O-5
CM02
070
12
Machine monitor
O-5
CM04
070
COOLANT TEMP PACKARD CP3 PUMP 80SCH REGULATOR CRANK SENSOR FRAMATOME
8
Machine monitor
O-5
2
Engine coolant temperature sensor
AE-3
2
Pump regulator valve
AJ-2
3
Engine Ne speed sensor
AF-1
D01
SWP
8
Diode
N-9
D02
SWP
8
Diode
N-9
D03
SWP
8
Diode
N-9
D10
M
2
Diode
D11
M
2
Diode
E01
Terminal
1
Electrical intake air heater
AG-5
E06
DT
2
Intermediate connector
AI-1
E08
X
1
Intermediate connector
AG-9
E10
D
1
Intermediate connector
AE-6
3
Alternator (Terminals IG and L)
AH-8
20
Fuse box
E12 F01
Terminal
T-9
F04
L
2
Fusible link (65A)
B-9
F05 FUEL RAIL PRESS H09
M
2
Fusible link (30A)
C-8
BOSCH
3
Common rail pressure sensor
AI-5
M
8
Intermediate connector
X-4
H15
090
22
Intermediate connector
V-1
40-200 14
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connector list and layout
SEN06132-00
Connector No.
Model
Number of pins
H16
S
12
Intermediate connector
INJECTOR #1
DT
2
Injector #1
AE-4
INJECTOR #2
DT
2
Injector #2
AF-4
INJECTOR #3
DT
2
Injector #3
AF-5
INJECTOR #4
DT
2
Injector #4
AG-5
INJECTOR #5
DT
2
Injector #5
AH-5
INJECTOR #6 INJECTOR CYL. 1&2 INJECTOR CYL. 3&4 INJECTOR CYL. 5&6 J01
DT
2
Injector #6
AH-6
DT
4
Intermediate connector
AE-1
DT
4
Intermediate connector
AG-5
DT
4
Intermediate connector
AI-6
20
Junction connector (Black)
W-3
J02
20
Junction connector (Black)
W-2
J03
20
Junction connector (Green)
V-2
Component name
Address of stereogram X-3
J04
20
Junction connector (Green)
X-3
J05
20
Junction connector (Green)
X-6
J06
20
Junction connector (Green)
X-8 O-8
K01
M
2
Pump (PC) resistor
K02
DT
3
CAN terminal resistance
L01
DT
2
Working lamp (Boom)
E-8
L02
DT
2
Right headlamp
F-9
L03
M
2
Room lamp
T-9
L05
SWP
2
Intermediate connector
L09
DT
2
Rear working lamp [Rear working lamp specification]
L15
DT
2
Rotary lamp [Rotary lamp specification]
M01
PA
10
Radio
M02
M
2
Speaker (Left)
AC-8
M03
M
M04
AH-1
AC-8 AB-8 U-1
2
Speaker (Right)
AB-9
2
Cigarette lighter
S-9
M05
M
6
Wiper motor
O-4
M06
YAZAKI
2
Window washer tank
L-2
M07
090
2
Horn (High tone)
G-1
M08
090
2
Intermediate connector
G-1
M09
M
2
Optional power supply connector (1)
M-1
M10
M
2
Intermediate connector
N-1
M14
DT
2
Travel alarm
M40
X
2
Headlamp [Headlamp specification]
AB-1
M41
X
2
Headlamp [Headlamp specification]
Y-8
N08 OIL PRESSURE SWICH P01
DT
12
Service connector
T-9
FRAMATOME
2
Engine oil pressure switch
AI-1
AMP
3
Bucket curl PPC pressure sensor
K-9
P02
AMP
3
Boom lower PPC pressure switch
K-9
P03
AMP
3
Swing left PPC pressure sensor
L-6
PC200, 200LC, 220, 220LC-8M0
I-1
40-200
15
200 General Information on troubleshooting Connector list and layout
SEN06132-00
Connector No.
Model
Number of pins
P04
AMP
3
P05
AMP
3
Bucket dump PPC pressure sensor
L-7
P06
AMP
3
Boom raise PPC pressure sensor
L-7
P07
AMP
3
Swing right PPC pressure sensor
L-8
P08
AMP
3
Arm dump PPC pressure switch
L-5
Address of stereogram
Component name Arm curl PPC pressure sensor
L-8
P09
AMP
3
L.H. travel FORWARD PPC pressure sensor
P-1
P10
AMP
3
L.H. travel REVERSE PPC pressure sensor
Q-1
P11
AMP
3
R.H. travel FORWARD PPC pressure sensor
O-2
P12
AMP
3
R.H. travel REVERSE PPC pressure sensor
P-1
P13
X
2
O-3
P14
X
2
P15
X
2
P17
S090
2
Intermediate connector Attachment pedal front PPC pressure switch [Attachment specification] Attachment pedal rear PPC pressure switch [Attachment specification] Air conditioner high/low pressure switch
P18
090
2
Outside air temperature sensor
L-5
P20
M
3
Fuel control dial
P-8
O-3 O-2 S-9
P21
X
2
Fuel level sensor
G-9
P22
D
2
Hydraulic oil temperature sensor
I-9
P23
DT
2
Air cleaner clogging switch
L-4
P24
X
2
Radiator coolant level switch
L-3
P25
AMP
3
F pump pressure sensor
J-9
P26
AMP
3
R pump pressure sensor
J-9
2
Air conditioner daylight sensor
O-6
DT
2
Engine oil level sensor
P31 P44
AH-8
P47
DT
2
Water-in-fuel sensor
H-9
R01
Terminal
1
Battery relay (Terminal E)
C-8
R02
Terminal
1
Battery relay (Terminal BR)
C-8
R03
Terminal
1
Battery relay (Terminal M)
B-7
R04
Terminal
1
Battery relay (Terminal B)
C-9
R05
Relay
5
Light relay
T-9
R06
Relay
5
Starting motor cutout relay (PPC lock)
N-9
R07
Relay
5
Starting motor cutout relay (Personal code)
N-9
R08
Relay
5
Horn relay
U-9
R10
Relay
5
Rear light relay [Rear light specification]
T-9
R12
Relay
5
Cab light relay [Cab light specification]
T-9
R15
Terminal
1
Electrical intake air heater relay (Coil circuit)
A-8
R16A
Terminal
1
Electrical intake air heater relay (Switch circuit)
A-8
R16B
Terminal
1
Electrical intake air heater relay (Switch circuit)
A-9
R17
X
1
Intermediate connector
B-7
R18
Relay
5
Automatic preheater relay
V-9
R21
Relay
5
Air conditioner compressor relay
W-9
R23
Relay
5
Engine controller relay (1)
U-9
R24
Relay
5
Engine controller relay (2)
V-9
R28
Terminal
1
Starting safety relay (terminal C)
B-9
40-200 16
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connector list and layout
SEN06132-00
Connector No.
Model
Number of pins
S01
Terminal
6
Starting switch
S02
SWP
6
Light switch
P-8
S04
SWP
6
Swing lock switch
Q-8
S07
SWP
6
Rotary lamp switch [Rotary lamp specification]
Q-8
S10
Y090
2
Right knob switch
R-1
Component name
Address of stereogram P-7
S11
Y090
2
Left knob switch
U-1
S14
M
3
PPC oil pressure lock switch
U-1
S21
Terminal
12
Emergency pump drive switch
O-9
S22
Terminal
6
Swing holding brake release switch
O-9
S25
090
16
Intermediate connector
O-8
S30
S
8
Model selection connector
U-9
SB
Terminal
1
Starting motor (Terminal B)
AE-7
SC
Terminal
1
Starting motor (Terminal C)
AE-7
T01
Terminal
2
Floor frame ground
W-2 AD-2
T02
Terminal
1
Cab ground
T03
M
1
Radio body ground
U-1
T04
Terminal
1
Revolving frame ground
S-1
T05
Terminal
1
Revolving frame ground
S-1
T06
Terminal
1
Revolving frame ground
T-1
T07
Terminal
1
Revolving frame ground
T-1
T08
Terminal
1
Ground
B-8
T09
Terminal
1
Revolving frame ground
T-1
T10
Terminal
1
Revolving frame ground
T12
Terminal
1
Engine cylinder block ground
AH-1
TOOL PORT
DT
3
Communication connector
AE-2
V01
DT
2
PPC lock solenoid valve
T-1
J-1
V02
DT
2
2-stage relief solenoid valve
I-1
V03
DT
2
Swing holding brake solenoid valve
J-1
V04
DT
2
Travel speed shifting solenoid valve
G-9
V05
DT
2
K-1
V06
DT
2
H-9
V11
DT
2
Travel junction solenoid valve Attachment return selector solenoid valve [Attachment specification] F-PC-EPC valve
V12
D
2
R-PC-EPC valve
J-9
V19
D
2
LS-EPC valve
I-9
V23
D
2
Merge-divider EPC valve (Main)
I-9
V24
D
2
Merge-divider EPC valve (LS)
H-9
V25
DT
2
K-1
V30
DT
2
W03
X
2
Variable back pressure solenoid valve Attachment flow regulator EPC valve [Attachment specification] Window rear limit switch
PC200, 200LC, 220, 220LC-8M0
I-9
O-3 AB-9
40-200
17
SEN06132-00
200 General Information on troubleshooting Connector list and layout
Layout of connector (1/6)
40-200 18
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connector list and layout
SEN06132-00
(2/6)
PC200, 200LC, 220, 220LC-8M0
40-200
19
SEN06132-00
200 General Information on troubleshooting Connector list and layout
(3/6)
40-200 20
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connector list and layout
SEN06132-00
(4/6)
PC200, 200LC, 220, 220LC-8M0
40-200
21
SEN06132-00
200 General Information on troubleshooting Connector list and layout
(5/6)
40-200 22
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connector list and layout
SEN06132-00
(6/6)
PC200, 200LC, 220, 220LC-8M0
40-200
23
SEN06132-00
200 General Information on troubleshooting Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009. 04) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
40-200 24
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
25
SEN06132-00
40-200 26
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
27
SEN06132-00
40-200 28
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
29
SEN06132-00
40-200 30
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
31
SEN06132-00
40-200 32
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
33
SEN06132-00
40-200 34
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
35
SEN06132-00
40-200 36
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
37
SEN06132-00
40-200 38
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
39
SEN06132-00
40-200 40
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
41
SEN06132-00
40-200 42
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
43
SEN06132-00
40-200 44
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
45
SEN06132-00
40-200 46
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
47
SEN06132-00
40-200 48
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
49
SEN06132-00
40-200 50
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
51
SEN06132-00
40-200 52
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
53
SEN06132-00
40-200 54
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
55
SEN06132-00
40-200 56
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
57
SEN06132-00
40-200 58
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Connection table for connector pin numbers
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
59
200 General Information on troubleshooting T- branch box and T- branch adapter table
SEN06132-00
T- branch box and T- branch adapter table
799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780
T-box (for ECONO) T-box (for MS) T-box (for MS) Plate for MS (14-pin) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO
24 24 17 17 5 10 5 17 19 14
MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P
5 13 17 21 9 2 3 4 8
MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO 2P ECONO 3P ECONO 4P ECONO 8P ECONO 12P DLI-8P DLI-12P DLI-16P ECONO 12P
12
799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI
8 12 16
799-601-2840 Extension cable (ECONO type)
12
40-200 60
Case T-box (for DRC 60, ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M
q q q q
q q q q q q
q q q q
q q q q
q q q q q q q q q
X2P X3P X4P SW6P SW8P SW12P SW14P SW16P M2P M3P M4P M6P M8P
Out of kit
799-601-4201
799-601-9300
799-601-9200
799-601-4101
q q q q q q q q q q q q q q
q q q
q q q q q q q q q q
q
q
60 1 2 3 4 6 8 12 14 16 1 2 3 4 6 8
799-601-9100
q
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
q
799-601-7000
799-601-2800
q
21 37 37
799-601-2790 Adapter for ECONO
799-601-2850 799-601-4350 799-601-4360 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799 -601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799 -601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
Identificati-on symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
(Rev. 2009. 03) a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal column indicates a part number of harness checker assembly.
q q q q q
q q q q
q q q q q
q q q q
q q q q q q
q q q q
q
q
q q q q q
q q q q q
q q
q q
q
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting T- branch box and T- branch adapter table
799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601- 9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410*
Adapter for M Adapter for S (White) Adapter for S (Blue) Adapter for S (Blue) Adapter for S (White) Adapter for S (White) Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Short connector for X Case Case Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for relay Adapter for relay Adapter for JFC Adapter for DTM Adapter for DT Adapter for DT Adapter for DT Adapter for DT Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Plate for HD30 (24-pin) T-box (for ECONO) Case Case Adapter for DRC Adapter for DRC Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket for engine(CRI-T3) PCV
PC200, 200LC, 220, 220LC-8M0
24
q q q q q q q q q q q q q q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
q q
799-601-9000
799-601-8000
q q q q
799-601-7500
q q q q
799-601-7400
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P – DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31
q q q q
799-601-7100
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31
799-601-7000
S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P –
799-601-2800
8 10 12 16 16 12 8 12 16 20 2
799-601-2700
Identificati-on symbol
799-601-2500
Part name
T-adapter kit
Number of pins
Part No.
SEN06132-00
q
q q q q q q q q q
q q q q q q q q q q q q q q q q q q q q q q q q q
q q q q q q q q q q q q
q q q
q q q q q q q q q q q q q
q q q q
q q q q
40 24 2
DRC-40 DRC-24 G
3
A3
q q
2
P
q q
q
40-200
61
200 General Information on troubleshooting T- branch box and T- branch adapter table
SEN06132-00
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) 795-799-5540* Socket for engine(CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) 799-601-4140 Ambient pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Common rail pressure Socket for engine (CRI-T3) 799-601-4230* Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* Air intake pressure/temperature 799 -601-4260 Adapter for controller (ENG) 799 -601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280* Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 to 4 and DTM2
q q
3
FCIB
q q
2
4160
q q
3
4180
q q
3
1, 2, 3 L
q q
4
1, 2, 3, 4 C
q q
3 3 3
1, 2, 3 A 1, 2, 3 B 1, 2, 3, G
q q q q q q
2
2, PA
q q
4
1, 2, 3, 4T
4 50 60 60 121 16 16 26 2, 3, 4
DTP4 DRC50 DRC60 – – HST16A HST16B HST26A –
Out of kit
FCIG
799-601-4201
3
799-601-4101
q q q q
799-601-9300
– – – ITT3N FCIN
799-601-9200
3 3 3 4 3
799-601-9100
q q
799-601-9000
A
799-601-8000
2
799-601-7500
q q
799-601-7400
C
799-601-7100
2
799-601-7000
1, 2, 3 S
799-601-2800
3 2
799-601-2700
Identificati-on symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q q
q q q
q q q q q
q q q q q q
“*” Shows not T-adapter but socket.
40-200 62
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system
SEN06132-00
Troubleshooting method for open circuit in wiring harness of pressure sensor system a Since pressure sensors consisting not only of resistor but also electronic circuit components such as amplifiers have variation in measured value and its own polarities. So troubleshooting must be performed carefully. Failure codes applicable to this diagnosis q CA123: Charge air pressure sensor low error q CA451: Common rail pressure sensor high error Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector. 2) Measure resistances R1 and R2 between pins. a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore, when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor connector so that their polarities match these of the sensor. a If measured value is infinite, take measurements by applying the probes of opposite polarities and record the finite value obtained as a measured value. a Since measured values may be dispersed, take several measurements. Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times. Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller connected. 1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor connectors first. (*) 2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side, and connect T-adapter (4) to the harness side connector. 3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins. 3. Judging open circuit If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is open". a "Apparent difference" means a difference of 10 or more times.
PC200, 200LC, 220, 220LC-8M0
40-200
63
SEN06132-00
200 General Information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values Sensor
Measuring location at sensor pin
Charge pressure sen- R2: between (2) and (4) R1: between (1) and (4) sor R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)
Measured internal resisRemarks tance of sensor (reference) Approx. 100 z Sensor is common to engine models Approx. 200 z 107 and 114 Sensor is common to engine models Approx. 23 kz 107 and 114 If polarities are inverted, resistance is Approx. 10 Mz infinite
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each failure code) q When measuring R2' of charge pressure sensor (CA123): Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator) q When measuring R2' of common rail pressure sensor (CA451): Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator) Measurement record (For measuring locations, see circuit diagram related to each failure code.) Sensor
Sensor unit (Measuring location on sen- Measured value sor pin side connetor)
Charge pressure sen- R2: between (2) and (4) sor R1: between (1) and (4) R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)
40-200 64
Sensor + Wiring harness (Measuring location on wirMeasured value ing harness side connector of engine controller) R2': Between (37) and (47) (*) R1': Between (44) and (47) R2': Between (37) and (47) (*) R1': between (47)(+) and (25)(-)
PC200, 200LC, 220, 220LC-8M0
200 General Information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system
PC200, 200LC, 220, 220LC-8M0
SEN06132-00
40-200
65
SEN06132-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06132-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-200
66
SEN06133-00 SEN05985-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 301 Troubleshooting by failure code, Part 1 Failure code [879AKA] A/C Inner Sensor Open Circuit ..............................................................................
3
Failure code [879AKB] A/C Inner Sensor Short Circuit...............................................................................
3
Failure code [879BKA] A/C Outer Sensor Open Circuit..............................................................................
3
Failure code [879BKB] A/C Outer Sensor Short Circuit..............................................................................
3
Failure code [879CKA] Ventilating Sensor Open Circuit.............................................................................
3
Failure code [879CKB] Ventilating Sensor Short Circuit .............................................................................
4
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..................................................................
4
Failure code [879EMC] Ventilation Damper Abnormality............................................................................
4
Failure code [879FMC] Air Mix Damper Abnormality..................................................................................
4
Failure code [879GKX] Refrigerant Abnormality.........................................................................................
4
Failure code [989L00] Engine Controller Lock Caution1 ............................................................................
5
Failure code [989M00] Engine Controller Lock Caution2 ...........................................................................
6
Failure code [989N00] Engine Controller Lock Caution3............................................................................
7
Failure code [AA10NX] Air Cleaner Clogging .............................................................................................
8
Failure code [AB00KE] Charge Voltage Low .............................................................................................. 10 Failure code [B@BAZG] Eng Oil Press Low............................................................................................... 12 Failure code [B@BAZK] Engine Oil Level Low ........................................................................................... 13 Failure code [B@BCNS] Eng Water Overheat............................................................................................ 14 Failure code [B@BCZK] Radiator Coolant Level Low ................................................................................ 16 Failure code [B@HANS] Hyd Oil Overheat................................................................................................. 18
PC200, 200LC, 220, 220LC-8M0
40-301
1
SEN06133-00
301 Troubleshooting by failure code, Part 1
Failure code [CA111] ECM Critical Internal Failure ..................................................................................... 19 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................ 19 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................. 20 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................................. 22 Failure code [CA131] Throttle Sensor High Error ....................................................................................... 24 Failure code [CA132] Throttle Sensor Low Error ........................................................................................ 26 Failure code [CA144] Coolant Temp Sens High Error................................................................................. 28 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................. 30 Failure code [CA153] Chg Air Temp Sensor High Error.............................................................................. 32 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................................... 34 Failure code [CA155] Chg Air Temp High Speed Derate ............................................................................ 36 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................................... 38 Failure code [CA221] Ambient Press Sens High Error ............................................................................... 40 Failure code [CA222] Ambient Press Sens Low Error ................................................................................ 42 Failure code [CA227] Sens 2 Supply Volt High Error.................................................................................. 44 Failure code [CA234] Eng Overspeed ........................................................................................................ 44 Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................................ 45 Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 46 Failure code [CA272] IMV/PCV1 Open Error.............................................................................................. 48
40-301 2
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [879AKA] A/C Inner Sensor Open Circuit
SEN06133-00
Failure code [879AKA] A/C Inner Sensor Open Circuit See "Failure code [879AKA] A/C Inner Sensor Open Circuit" in chapter 80 "Others". a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879AKB] A/C Inner Sensor Short Circuit See chapter 80 Others "Failure code [879AKB] A/C Inner Sensor Short Circuit". a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879BKA] A/C Outer Sensor Open Circuit See chapter 80 Others "Failure code [879BKA] A/C Outer Sensor Open Circuit".
Failure code [879BKB] A/C Outer Sensor Short Circuit See chapter 80 Others "Failure code [879BKB] A/C Outer Sensor Short Circuit".
Failure code [879CKA] Ventilating Sensor Open Circuit See "Failure code [879CKA] Ventilating Sensor Open Circuit" in chapter 80 "Others". a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
PC200, 200LC, 220, 220LC-8M0
40-301
3
SEN06133-00
301 Troubleshooting by failure code, Part 1 Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit See chapter 80 Others "Failure code [879CKB] Ventilating Sensor Short Circuit". a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit See chapter 80 Others "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
Failure code [879EMC] Ventilation Damper Abnormality See chapter 80 Others "Failure code [879EMC] Ventilation Damper Abnormality". a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879FMC] Air Mix Damper Abnormality See chapter 80 Others "Failure code [879FMC] Air Mix Damper Abnormality". a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner controller or air conditioner unit must be replaced.
Failure code [879GKX] Refrigerant Abnormality See chapter 80 Others "Failure code [879GKX] Refrigerant Abnormality".
40-301 4
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [989L00] Engine Controller Lock Caution1
SEN06133-00
Failure code [989L00] Engine Controller Lock Caution1 Action level
Failure code
–
989L00
Detail of failure Action of controller Problem on machine Related information
Failure
Engine controller lock caution1 (Machine monitor system)
q
Engine controller lock up is detected (Factor 1).
q q
None in particular If cause of failure disappears, machine becomes normal by itself.
q
Engine cannot be started.
q
If this failure code is generated after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1 Replacement of machine monitor This problem may be caused by replacement of machine monitor.
PC200, 200LC, 220, 220LC-8M0
40-301
5
301 Troubleshooting by failure code, Part 1 Failure code [989M00] Engine Controller Lock Caution2
SEN06133-00
Failure code [989M00] Engine Controller Lock Caution2 Action level
Failure code
–
989M00
Detail of failure Action of controller Problem on machine Related information
Failure
Engine controller lock caution2 (Machine monitor system)
q
Engine controller lock up is detected (Factor 2).
q q
None in particular If cause of failure disappears, machine becomes normal by itself.
q
Engine cannot be started.
q
If this failure code is generated after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1 Replacement of machine monitor This problem may be caused by replacement of machine monitor. 2 Defective machine monitor
40-301 6
If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [989N00] Engine Controller Lock Caution3
SEN06133-00
Failure code [989N00] Engine Controller Lock Caution3 Action level
Failure code
–
989N00
Failure
Engine controller lock caution3 (Machine monitor system)
Detail of failure
q
Engine controller lock up is detected (Factor 3).
Action of controller
q
Tries automatic recovery. If cause of failure disappears, machine becomes normal by itself.
Problem on machine Related information
q
q
Method of reproducing failure code: Failure code cannot be reproduced since machine recovers when cause of failure disappears.
Cause 1 Defective engine controller
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks If this failure code is generated repeatedly, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-301
7
301 Troubleshooting by failure code, Part 1 Failure code [AA10NX] Air Cleaner Clogging
SEN06133-00
Failure code [AA10NX] Air Cleaner Clogging Action level
Failure code
L01
AA10NX
Failure
Air cleaner clogging (Machine monitor system)
q
Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and machine monitor detects clogging of air cleaner (open of sensor contacts).
Action of controller
q
Displays air cleaner clogging monitor in yellow on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may be damaged.
q
Input state (ON/OFF) from air cleaner clogging switch can be checked by using monitoring function. (Code 04501: Monitor Input 2) Method of reproducing failure code: Start engine.
Detail of failure
Related information q
Cause 1
Clogged air cleaner (when system is normal)
Procedure, measuring location, criteria and remarks Air cleaner may be clogged, Check it for clogging and then clean or replace if clogged. 1. Turn starting switch to OFF position. 2. Disconnect connector P23 and connect T-adapter to male side. 3. Start engine.
2
Defective air cleaner clogging switch (internal open circuit)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
Between P23 (male) (1) and (2)
When air cleaner works properly *1
Resistance
Max. 1 z
When air cleaner Resistance Min. 1 Mz is clogged *2 1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P23, and connect T-adapters to each female side. Between CM02 (female) (4) and P23 (female) (1)
Resistance
Max. 1 z
Between P23 (female) (2) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Start engine. 4 Defective machine monitor Between CM02 (4) and CM01 (3)
When air cleaner works properly
Voltage
Max. 1 V
When air cleaner is clogged
Voltage
7 – 11 V
Air cleaner suction resistance *1: -3,430 Pa Max. {-350 mmH2O} *2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
q
40-301 8
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [AA10NX] Air Cleaner Clogging
SEN06133-00
Circuit diagram related to air cleaner clogging
PC200, 200LC, 220, 220LC-8M0
40-301
9
301 Troubleshooting by failure code, Part 1 Failure code [AB00KE] Charge Voltage Low
SEN06133-00
Failure code [AB00KE] Charge Voltage Low Action level
Failure code
L03 Detail of failure Action of machine monitor Problem on machine Related information
AB00KE q q q
Charging voltage low (Machine monitor system)
While engine is running, voltage from alternator drops, and machine monitor detects that battery charge voltage is low (below 7.8 V). Displays charge level monitor red on machine monitor. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
If machine is operated as it is, battery may not be charged.
q
Signal voltage from alternator can be checked with monitoring function. (Code: 04300 Charge voltage) Method of reproducing failure code: Start engine.
q
Cause 1
Failure
Procedure, measuring location, criteria and remarks
Loose alternator terminal or open 1. Turn starting switch to OFF position. circuit at terminal 2. Check terminal.
1. Turn starting switch to OFF position. 2. Insert T-adapters into connector E12. Defective generation by alternator 2 3. Start engine. (when system is normal) Between E12 (1) and Engine speed: Medium Voltage 27.5 to 29.5 V ground or higher 1. Turn starting switch to OFF position. 2. Disconnect diode D01 and connect T-adapter to male side. a Check the continuity in diode range. 3 Defective diode Between D01 (male) (2) (+) and (6) (-) No continuity Between D01 (male) (6) (+) and (2) (-)
4
Defective wiring harness or machine monitor
1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Start engine. Between CM01 (16) and ground
Open circuit in wiring harness 5 (wire breakage or defective contact of connector)
Continuity
Voltage
Between C0M1 (female) (16) and E12 (female) (1) Resistance
6
Ground fault in wiring harness (contact with ground circuit)
7 Defective machine monitor
40-301 10
20 to 30 V
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and E12, and connect T-adapters to each female side. Max. 1 z
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and E12, and connect T-adapter to either female side. Between CM01 (female) (16) or E12 (female) (1) Resistance Min. 1 Mz and ground If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [AB00KE] Charge Voltage Low
SEN06133-00
Electrical diagram related to charging cricuit
PC200, 200LC, 220, 220LC-8M0
40-301
11
301 Troubleshooting by failure code, Part 1 Failure code [B@BAZG] Eng Oil Press Low
SEN06133-00
Failure code [B@BAZG] Eng Oil Press Low Action level
Failure code
L03
B@BAZG
Detail of failure Action of controller Problem on machine
While engine is running, engine controller detects engine oil pressure drop (sensor contact is closed) from signal voltage of engine oil pressure switch.
q q
Displays engine oil pressure monitor red on machine monitor. If cause of failure disappears, machine becomes normal by itself.
q
If machine is operated as it is, engine may be damaged.
q
Signal from engine oil pressure switch is input to engine controller. If engine oil pressure switch is determined to be closed (ON) while engine is running, engine controller transmitts this signal to machine monitor to display this failure code. Method of reproducing failure code: Start engine.
q
Cause Dropped engine oil pres1 sure (when system works properly) Defective engine oil pressure monitoring system
40-301 12
Engine Oil Pressure Low (Engine controller system)
q
Related information
2
Failure
Procedure, measuring location, criteria and remarks Engine oil pressure may be low. Check it and remove cause if it is low. If no failure is found by check on cause 1, engine oil pressure monitoring system may be defective. Perform troubleshooting for "E-6 Emergency stop monitor lights up while engine is running".
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [B@BAZK] Engine Oil Level Low
SEN06133-00
Failure code [B@BAZK] Engine Oil Level Low Action level
Failure code
L01
B@BAZK
Failure
Engine Oil Level Low (Machine monitor system)
q
While engine is running, signal voltage from engine oil level switch does not remain below 1 V, so machine monitor determines that engine oil level is low (oil level switch is open).
Action of controller
q
Displays engine oil level monitor yellow on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may seize up.
q
Input (ON/OFF) from engine oil level switch can be checked with monitoring function. (Code: 04501 Monitor input 2) Method of reproducing failure code: Start engine
Detail of failure
Related information
q
Cause 1
Engine oil level low (when system works properly)
Defective engine oil level switch 2 (internal defect)
Procedure, measuring location, criteria and remarks Check engine oil level. If it is low, remove cause. 1. Turn starting switch to OFF position. 2. Disconnect connector P44. 3. Turn starting switch to ON position. Between P44 (male) (1) and ground
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4 Defective machine monitor
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P44, and connect T-adapters to each female side. Between CM02 (female) (2) and P44 (female) (1)
Resistance
Max. 1 z
If no failure is found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Turn starting switch to ON position. Between CM02 (2) and CM01 (3)
Voltage
Min. 10 V
Circuit diagram related to engine oil level switch
PC200, 200LC, 220, 220LC-8M0
40-301
13
301 Troubleshooting by failure code, Part 1 Failure code [B@BCNS] Eng Water Overheat
SEN06133-00
Failure code [B@BCNS] Eng Water Overheat Action level
Failure code
L02
B@BCNS
Failure
Engine water overheat (Engine controller system)
q
While engine is running, voltage from engine coolant temperature sensor drops, and engine controller detects engine coolant overheated.
Action of controller
q
Displays engine coolant temperature monitor in red on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may seize up.
q
Signal voltage of engine coolant temperature sensor is input to engine controller that transmits information to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) Method of reproducing failure code: Start engine.
Detail of failure
Related information
q q
Cause
Procedure, measuring location, criteria and remarks
1
Overheating of engine coolant (when system is normal)
2
If no failure is found by checks on cause 1, engine coolant temperature sensor Defective engine coolant temperasystem may be defective. Perform troubleshooting for failure codes [CA144] ture sensor system and [CA145].
40-301 14
Engine coolant may overheat. Check it and remove cause if it overheats.
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [B@BCNS] Eng Water Overheat
PC200, 200LC, 220, 220LC-8M0
SEN06133-00
40-301
15
301 Troubleshooting by failure code, Part 1 Failure code [B@BCZK] Radiator Coolant Level Low
SEN06133-00
Failure code [B@BCZK] Radiator Coolant Level Low Action level
Failure code
L01
B@BCZK
Failure
Radiator Coolant Level Low (Machine monitor system)
q
While starting switch is at ON position (with engine stopped) or engine is running, radiator coolant level switch signal voltage does not remain below 1 V, so machine monitor determines that radiator coolant level is low (sensor contact is open).
Action of controller
q
Displays radiator coolant level monitor yellow on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may overheat.
q
Input (ON/OFF) from radiator coolant level switch can be checked with monitoring function. (Code: 04500 Monitor input 1) Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
Related information
1
2
q
Cause
Procedure, measuring location, criteria and remarks
Lowered radiator coolant level (when system works properly)
Check radiator sub tank for lowering of coolant level. If coolant level is low, add coolant.
Defective coolant level switch (internal defect)
Open circuit in wiring harness 3 (Wire breakage or defective contact)
1. Turn starting switch to OFF position. 2. Disconnect connector P24 and connect T-adapters to male side. Between FULL and Resistance Max. 1 z Between P24 (male) (1) and (2) LOW lines Below LOW Resistance Min. 1 Mz line 1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P24, and connect T-adapters to each female side. a Add coolant. Between CM02 (female) (3) and P24 (female) (1)
4 Defective machine monitor
40-301 16
Resistance
Max. 1 z
If no failure is found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector CM02. 3. Turn starting switch to ON position. Between FULL and Voltage Max. 1 V LOW lines Between CM02 (3) and CM01 (3) Below LOW Voltage 7 – 11 V line
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [B@BCZK] Radiator Coolant Level Low
SEN06133-00
Circuit diagram related to radiator coolant level switch
PC200, 200LC, 220, 220LC-8M0
40-301
17
301 Troubleshooting by failure code, Part 1 Failure code [B@HANS] Hyd Oil Overheat
SEN06133-00
Failure code [B@HANS] Hyd Oil Overheat Action level
Failure code
L02
B@HANS
Failure
Hydraulic oil overheat (Pump controller system)
Detail of failure
q
While engine is running, overheating of hydraulic oil (above approx. 102 °C) is detected from signal voltage of hydraulic oil temperature sensor.
Action of controller
q q
Displays hydraulic oil temperature monitor red on machine monitor. If cause of failure disappears, machine becomes normal by itself.
q
If machine is operated as it is, hydraulic components may be damaged.
q
Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) See E-mode troubleshooting E-9 in “Hydraulic oil temperature gauge does not indicate properly” Method of reproducing failure code: Start engine.
Problem on machine
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Overheating of hydraulic oil (when system works properly)
Hydraulic oil may overheat. Check it and remove cause if it overheats
2
Defective hydraulic oil temperature gauge system
If no failure is found by check on cause 1, hydraulic oil temperature monitoring system may be defective. Perform troubleshooting for failure code [DGH2KB].
40-301 18
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA111] ECM Critical Internal Failure
SEN06133-00
Failure code [CA111] ECM Critical Internal Failure Action level
Failure code
L04
CA111
Failure
Engine Controller Module Critical Internal Failure (Engine controller system)
Detail of failure
q
Memory or power supply circuit in engine controller is defective.
Action of controller
q
None in particular
Problem on machine
q
Engine may stop during operation or may not be able to start.
q
Power supply voltage to engine controller can be checked with monitoring function. (Code: 03203 Battery voltage) Method of reproducing failure code: Start engine.
Related information
q
Cause
Procedure, measuring location, criteria and remarks
1 Defect in related system
If another failure code is displayed, perform troubleshooting for it.
2 Perform troubleshooting for failure code [CA441].
Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action level
Failure code
L04
CA115
Failure
Engine Ne and Bkup speed sensor Error (Engine controller system)
Detail of failure
q
Signals from both engine Ne and Bkup speed sensors are abnormal.
Action of controller
q
None in particular
q q
Engine stops. Engine does not start
q
Method of reproducing failure code: Start engine.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
Connectors of Ne speed sensor and Bkup speed sensor may be connected defectively (wrong connection). Check them. Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code 2 Defective Ne speed sensor system [CA689]. Defective Bkup speed sensor sys3 Perform troubleshooting for failure code [CA778]. tem If no failure is found by above checks, engine controller is defective. (Since 4 Defective engine controller this is an internal defect, troubleshooting cannot be performed.) 1
Defective connection of sensor connector
PC200, 200LC, 220, 220LC-8M0
40-301
19
301 Troubleshooting by failure code, Part 1 Failure code [CA122] Chg Air Press Sensor High Error
SEN06133-00
Failure code [CA122] Chg Air Press Sensor High Error Action level
Failure code
L03
CA122
Failure
Charge Air Press Sensor High Error (Engine controller system)
Detail of failure
q
High voltage appears in signal circuit of charge (boost) pressure & temperature sensor.
Action of controller
q
Takes boost pressure to be at fixed value and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Input voltage from boost pressure sensor can be checked with monitoring function. (Code: 36501 (V)) Boost pressure sensed by boost pressure sensor can be checked with function. (Code: 36500 (kPa)) Method of reproducing failure code: Turn starting switch to ON position. If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal condition.
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them.
2
Defective sensor power supply 2 line
If failure code [CA227] is also displayed, perform troubleshooting for it first.
3
Defective boost pressure & temperature sensor
1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT. 3. Turn starting switch to ON position. If failure code changes from [CA122] to [CA123] ,boost pressure sensor is defective. a Failure code [CA153] for temperature sensor is displayed at the same time. Ignore this failure code since it appears because of disconnection of sensor. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters to connector ECM. 3. Turn starting switch to ON position. Between ECM (44) and (47)
4 Short circuit in wiring harness
Hot short circuit in wiring harness (Contact with 24 V circuit)
40-301 20
0.3 to 4.7 V
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to connector ECM. 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT disconnected). Between ECM (44) and (47)
6 Defective engine controller
Voltage
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (37) and (44)
5
Sensor output
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA122] Chg Air Press Sensor High Error
SEN06133-00
Circuit diagram related to charge pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-301
21
301 Troubleshooting by failure code, Part 1 Failure code [CA123] Chg Air Press Sensor Low Error
SEN06133-00
Failure code [CA123] Chg Air Press Sensor Low Error Action level
Failure code
L03
CA123
Failure
Charge Air Pressure Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in pressure signal circuit of charge (boost) pressure & temperature sensor.
Action of controller
q
Takes boost pressure to be at fixed value and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Input voltage from boost pressure sensor can be checked with monitoring function. (Code: 36501 (V)) Boost pressure sensed by boost pressure sensor can be checked with function. (Code: 36500 (kPa)) Method of reproducing failure code: Turn starting switch to ON position. Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-adapter). If sensor connector is disconnected, this failure code is displayed.
q
Related information
q q
q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them.
Defective power supply system of If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it 2 charge pressure sensor (boost first. pressure sensor) 1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapters to female side of ECM. 3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
Between ECM (female) (37) and (47)
Resistance Min. 100 kz
Between ECM (female) (44) and (47)
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (44) and ground
5 Open circuit in wiring harness Defective boost pressure & temperature sensor 6 (improper input voltage to engine controller)
7 Defective engine controller
Resistance Min. 100 kz
If no failure is found by above checks, there may be open circuit in wiring harness. (*) a If no failure is found by checks on causes 1 to 5 and check result on cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapters to connector ECM. 3. Turn starting switch to ON position. Sensor outBetween ECM (44) and (47) Voltage 0.3 to 4.7 V put If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting".
40-301 22
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA123] Chg Air Press Sensor Low Error
SEN06133-00
Circuit diagram related to charge pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-301
23
301 Troubleshooting by failure code, Part 1 Failure code [CA131] Throttle Sensor High Error
SEN06133-00
Failure code [CA131] Throttle Sensor High Error Action level
Failure code
L03
CA131
Detail of failure Action of controller Problem on machine Related information
Failure
Throttle Sensor High Error (Engine controller system)
q
High voltage appears in fuel control dial circuit.
q q
Uses throttle value obtained before failure detection to run engine if failure is detected with starting switch at ON position. Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
q
Engine speed cannot be controlled by using fuel control dial.
q
Signal voltage from fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment"of "Checks before troubleshooting" in "General information on troubleshooting", and check them.
2
Defective throttle sensor power supply system
If failure code [CA2185] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapters to male side.
3
Defective fuel control dial (throttle Between P20 (male) (1) and (3) sensor) Between P20 (male) (2) and (3)
Resistance 0.25 to 5.0 kz
Between P20 (male) (1) and (2)
Resistance 0.25 to 5.0 kz
Resistance 4.0 to 6.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapters to female side.
4
Open or short circuit in wiring harBetween CE02 (famale) (22) and (23) ness Between CE02 (famale) (9) and (23)
5 Short circuit in wiring harness
6
Hot short circuit in wiring harness (contact with 24 V circuit)
40-301 24
Resistance 0.25 to 5.0 kz
a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to either female side. Between CE02 (female) (9) and (22), or between Resistance Min. 1 Mz P20 (female) (1) and (2) 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapters to female side. 3. Turn starting switch to ON position. Between P20 (female) (2) and ground
7 Defective engine controller
Resistance 4.0 to 6.0 kz
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector CE02. 3. Turn starting switch to ON position. 4. Operate fuel control dial and perform troubleshooting. Power supBetween CE02 (22) and (23) Voltage 4.75 to 5.25V ply Sensor outBetween CE02 (9) and (23) Voltage 0.5 to 4.5 V put
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA131] Throttle Sensor High Error
SEN06133-00
Circuit diagram related to throttle sensor
PC200, 200LC, 220, 220LC-8M0
40-301
25
301 Troubleshooting by failure code, Part 1 Failure code [CA132] Throttle Sensor Low Error
SEN06133-00
Failure code [CA132] Throttle Sensor Low Error Action level
Failure code
L03
CA132
Detail of failure Action of controller Problem on machine Related information
Failure
Throttle Sensor Low Error (Engine controller system)
q
Low voltage appears in fuel control dial circuit.
q q
Uses throttle value obtained before failure detection to run engine if failure is detected with starting switch at ON position. Uses full throttle value to run engine if starting switch is set to ON position after failure detection.
q
Engine speed cannot be controlled by using fuel control dial.
q
Signal voltage from fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial votage) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment"of "Checks before troubleshooting" in "General information on troubleshooting", and check them.
2
Defective throttle sensor power supply system
If failure code [CA2186] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapters to male side.
3
Defective fuel control dial (throttle Between P20 (male) (1) and (3) sensor) Between P20 (male) (2) and (3)
Resistance
4.0 to 6.0 kz
Resistance
0.25 to 5.0 kz
Between P20 (male) (1) and (2)
Resistance
0.25 to 5.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapters to female side.
4
Open or short circuit in wiring harBetween CE02 (famale) (22) and (23) ness Between CE02 (famale) (9) and (23)
Open circuit in wiring harness 5 (wire breakage or defective contact of connector)
6 Short circuit in wiring harness
7
Ground fault of wiring harness (contact with ground circuit)
40-301 26
Resistance
4.0 to 6.0 kz
Resistance
0.25 to 5.0 kz
a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to each female side . Between CE02 (female) (22) and P20 Resistance Max. 1 z (female) (1) Between CE02 (female) (9) and P20 (female) Resistance Max. 1 z (2) Between CE02 (female) (23) and P20 Resistance Max. 1 z (female) (3) a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to either female side. Between CE02 (female) (9) and (23), or Resistance Min. 1 Mz between P20 (female) (2) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to either female side. Between CE02 (female) (9) or P20 (female) Resistance Min. 1 Mz (2) and ground
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA132] Throttle Sensor Low Error
Cause
8 Defective engine controller
SEN06133-00
Procedure, measuring location, criteria and remarks If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector CE02. 3. Turn starting switch to ON position. 4. Operate fuel control dial and perform troubleshooting. Between CE02 (22) and (23) Power supply
Voltage
4.75 to 5.25V
Between CE02 (9) and (23)
Voltage
0.5 to 4.5 V
Sensor output
Circuit diagram related to throttle sensor
PC200, 200LC, 220, 220LC-8M0
40-301
27
301 Troubleshooting by failure code, Part 1 Failure code [CA144] Coolant Temp Sens High Error
SEN06133-00
Failure code [CA144] Coolant Temp Sens High Error Action level
Failure code
L01
CA144
Failure
Coolant Temperature Sensor High Error (Engine controller system)
Detail of failure
q
High voltage appears in signal circuit of coolant temperature sensor .
Action of controller
q
Takes coolant temperature to be at fixed value and allows engine to run.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Input voltage from engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 (V)) Temperature sensed by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107 (°C)) Method of reproducing failure code: Turn starting switch to ON position. This failure code is displayed if temperature sensor connector is disconnected. Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter).
Problem on machine
q q q
Related information
q q q
Cause 1
Defective wiring harness connector
2
Defective coolant temperature sensor
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Between COOLANT TEMP (male) (A) and (B) a Coolant temperature -Resistaure characteristics
0 °C
Resistance
30 to 37 kz
25 °C
Resistance
9.3 to 10.7 kz
50 °C
Resistance
3.2 to 3.8 kz
80 °C
Resistance
1.0 to 1.3 kz
95 °C
Resistance
700 to 800 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side. Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem3 perature: Min. 0°C) ness Resisa Use "Coolant temperature-Resistance charac700 z to 37 kz tance teristics" table shown above as resistance criteria. If no failure is found by above checks, engine controller is defective. (Since 4 Defective engine controller this is an internal defect, troubleshooting cannot be performed.)
40-301 28
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA144] Coolant Temp Sens High Error
SEN06133-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC, 220, 220LC-8M0
40-301
29
301 Troubleshooting by failure code, Part 1 Failure code [CA145] Coolant Temp Sens Low Error
SEN06133-00
Failure code [CA145] Coolant Temp Sens Low Error Action level
Failure code
L01
CA145
Failure
Coolant Temperature Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in signal circuit of coolant temperature sensor .
Action of controller
q
Takes coolant temperature to be at fixed value and allows engine to run.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Input voltage from engine coolant temperature sensor can be checked with monitoring function. (Code: 04105 (V)) Temperature sensed by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107(°C) ) Method of reproducing failure code: Turn starting switch to ON position. If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA144] for "High Error" is displayed.
Problem on machine
q q q
Related information q q
Cause 1
2
Defective wiring harness connector
Defective coolant temperature sensor
3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective engine controller
40-301 30
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Between COOLANT TEMP (male) (A) and (B) a Coolant temperature -Resistaure characteristics
0 °C
Resistance
30 to 37 kz
25 °C
Resistance
9.3 to 10.7 kz
50 °C
Resistance
3.2 to 3.8 kz
80 °C
Resistance
1.0 to 1.3 kz
95 °C
Resistance
700 to 800 z
Whole coolBetween (B) and ground ant temper- Resistance Min. 100 kz ature range 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side. Between ECM (female) (15) and (38) (Coolant temperature: Min. 0 °C) Resisa Use "Coolant temperature-Resistance charac700 z to 37 kz tance teristics" table shown above as resistance criteria. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to female side of ECM. ResisBetween ECM (female) (15) and ground Min. 100 kz tance If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA145] Coolant Temp Sens Low Error
SEN06133-00
Circuit diagram related to coolant temperature sensor
PC200, 200LC, 220, 220LC-8M0
40-301
31
301 Troubleshooting by failure code, Part 1 Failure code [CA153] Chg Air Temp Sensor High Error
SEN06133-00
Failure code [CA153] Chg Air Temp Sensor High Error Action level
Failure code
L03
CA153
Failure
Charge Air Temperature Sensor High Error (Engine controller system)
q
High voltage appears in temperature signal circuit of charge (boost) pressure & temperature sensor.
Action of controller
q
Takes boost temperature to be at fixed value and allows engine to run.
Problem on machine
q
Engine protection function based on boost temperature does not work.
q
Input voltage from boost temperature sensor can be checked with monitoring function. (Code: 18501 (V)) Temperature sensed by boost temperature sensor can be checked with monitoring function. (Code: 18500(°C)) Method of reproducing failure code: Turn starting switch to ON position. Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter). This failure code is displayed if temperature sensor connector is disconnected.
Detail of failure
q
Related information
q q
q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
Between BOOST Defective charge temperature senPRESS & IMT (male) (3) 2 sor and (4) a Boost temperature-Resistance chariacteristic
-40 °C
Resistance
41 to 48 kz
-20 °C
Resistance
14 to 16 kz
0 °C
Resistance
5.4 to 6.1 kz
30 °C
Resistance
1.6 to 1.8 kz
60 °C
Resistance
560 to 600 z
90 °C
Resistance
230 to 250 z
130 °C
Resistance
80 to 90 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open or short circuit in wiring harBetween ECM (female) (23) and (47) ness a Use "Boost temperature-Resistance characteristics" table shown above as resistance criteria.
4 Defective engine controller
40-301 32
Resistance
80 z to 48 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA153] Chg Air Temp Sensor High Error
SEN06133-00
Circuit diagram related to charge temperature sensor
PC200, 200LC, 220, 220LC-8M0
40-301
33
301 Troubleshooting by failure code, Part 1 Failure code [CA154] Chg Air Temp Sensor Low Error
SEN06133-00
Failure code [CA154] Chg Air Temp Sensor Low Error Action level
Failure code
L03
CA154
Failure
Charge Air Temperature Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in temperature signal circuit of charge (boost) pressure & temperature sensor.
Action of controller
q
Takes boost temperature to be at fixed value and allows engine to run.
Problem on machine
q
Engine protection function based on boost temperature does not work.
q
Input voltage from boost temperature sensor can be checked with monitoring function. (Code: 18501 (V)) Temperature sensed by boost temperature sensor can be checked with monitoring function. (Code: 18500(°C)) If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA153] for "High Error" is displayed. Method of reproducing failure code: Turn starting switch to ON position.
Related information
q q q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
2
Defective charge temperature sen- Between BOOST sor PRESS & IMT (male) (3) and (4) a Boost temperature-Resistance chariacteristic
-40 °C
Resistance
41 to 48 kz
-20 °C
Resistance
14 to 16 kz
0 °C
Resistance
5.4 to 6.1 kz
30 °C
Resistance
1.6 to 1.8 kz
60 °C
Resistance
560 to 600 z
90 °C
Resistance
230 to 250 z
130 °C
Resistance
80 to 90 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side. 3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective engine controller
40-301 34
Between ECM (female) (23) and (47) a Use "Boost temperature-Resistance characteristics" table shown above as resistance criteria.
Resistance
80 z to 48 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. ResisBetween ECM (female) (23) and ground Min. 100 kz tance If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA154] Chg Air Temp Sensor Low Error
SEN06133-00
Circuit diagram related to charge temperature sensor
PC200, 200LC, 220, 220LC-8M0
40-301
35
301 Troubleshooting by failure code, Part 1 Failure code [CA155] Chg Air Temp High Speed Derate
SEN06133-00
Failure code [CA155] Chg Air Temp High Speed Derate Action level
Failure code
L03 Detail of failure Action of controller Problem on machine Related information
Failure
CA155
Charge Air Temperature High Speed Derate (Engine controller system)
q
Boost temperature sensed by charge (boost) pressure & temperature sensor exceeds upper limit of temperature control.
q
Restricts engine output and allows engine to run.
q
Engine output lowers. Engine stops.
q q q
Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature) Method of reproducing failure code: Start engine.
Cause Lowered cooling performance of 1 aftercooler
Procedure, measuring location, criteria and remarks Aftercooler cooling performance may degrade. Check it for following points: q Looseness and damage of fan belt q Insufficient cooling air q Clogging of aftercooler fins
2
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related let temperature parts.
3
Defective boost temperature sen- If no failure is found by above checks, boost temperature sensor system may sor be defective. Perform troubleshooting for failure codes [CA153] and [CA154].
40-301 36
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA155] Chg Air Temp High Speed Derate
PC200, 200LC, 220, 220LC-8M0
SEN06133-00
40-301
37
301 Troubleshooting by failure code, Part 1 Failure code [CA187] Sens Supply 2 Volt Low Error
SEN06133-00
Failure code [CA187] Sens Supply 2 Volt Low Error Action level
Failure code
L03
CA187
Failure
Sensor power Supply 2 Voltage Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in sensor power supply 2 circuit.
Action of controller
q
Takes charge (boost) pressure & temperature to be at fixed values and allows engine to run. Restricts engine output and allows engine to run.
Problem on machine Related information
q
q
q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect following connectors sequentially one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to 1. If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA187]. 2 Defective sensor or wiring harness Sensor or harness Connector 1
Defective wiring harness connector
3 Defective engine controller
Boost pressure/temperature sensor
BOOST PRESS & IMT
Common rail pressure sensor
FUEL RAIL PRESS
Bkup sensor
CAM SENSOR
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (37) and (47)
40-301 38
Voltage
4.75 to 5.25V
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA187] Sens Supply 2 Volt Low Error
SEN06133-00
Circuit diagram related to sensor power supply 2
PC200, 200LC, 220, 220LC-8M0
40-301
39
301 Troubleshooting by failure code, Part 1 Failure code [CA221] Ambient Press Sens High Error
SEN06133-00
Failure code [CA221] Ambient Press Sens High Error Action level
Failure code
L03
CA221
Failure
Ambient Pressure Sensor High Error (Engine controller system)
Detail of failure
q
High voltage appears in signal circuit of ambient pressure sensor.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q
Engine output lowers. Engine starting performance becomes deteriorated.
Problem on machine
q q
Related information
q q
Input voltage from ambient pressure sensor can be checked with monitoring function. (Code: 37401 (V)) Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function. (Code: 37400 (kPa)) Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective sensor power supply 1 system
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. If failure code [CA352] or [CA386] is displayed simultaneously, perform troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Turn starting switch to ON position. If failure code changes from [CA221] to [CA222], sensor is defective. 3 Defective ambient pressure sensor q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters to connector ECM. 3. Turn starting switch to ON position. Sensor outBetween ECM (3) and (38) Voltage 0.5 to 4.5 V put 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapters to either female side. 4 Short circuit in wiring harness Between ECM (female) (33) and (3), or between Resistance Min. 100 kz AMB. AIR PRESSURE (female) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or insert T-adapter in connector ECM. Hot short circuit in wiring harness 5 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE (Contact with 24 V circuit) disconnected). Between ECM (3) and (38), or between AMB. AIR Voltage Max. 1 V PRESSURE (female) (3) and (2) 6 Defective engine controller
40-301 40
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA221] Ambient Press Sens High Error
SEN06133-00
Circuit diagram related to ambient pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-301
41
301 Troubleshooting by failure code, Part 1 Failure code [CA222] Ambient Press Sens Low Error
SEN06133-00
Failure code [CA222] Ambient Press Sens Low Error Action level
Failure code
L03
CA222
Failure
Ambient Pressure Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in signal circuit of ambient pressure sensor.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q
Engine output lowers. Engine starting performance becomes deteriorated. Input voltage from ambient pressure sensor can be checked with monitoring function. (Code: 37401 (V)) Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function. (Code: 37400 (kPa)) If sensor connector is disconnected, this failure code is displayed. Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine
q q
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective power supply system of 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to 2 ambient pressure sensor female side. 3. Turn starting switch to ON position. Between AMB. AIR PRESSURE Power sup4.75 to Voltage (female) (1) and (2) ply input 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect T-adapters to each female side. a If power supply input in checks on cause 2 is normal, this check is not required. Resistance Max. 10 z Between ECM (female) (33) and AMB. AIR Short circuit in wiring harness PRESSURE (female) (1) 3 (wire breakage or defective cona If power supply input in checks on cause 2 is nortact of connector) mal, this check is not required. Resistance Max. 10 z Between ECM (female) (38) and AMB. AIR PRESSURE (female) (2) Between ECM (female) (3) and AMB. AIR PRESResistance Max. 10 z SURE (female) (3) (sensor output) 1
4
Defective wiring harness connector
Ground fault in wiring harness (contact with ground circuit)
5 Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapters to either female side. Between ECM (female) (3) and ground, or between Resistance Min. 100 kz AMB. AIR PRESSURE (female) (3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapters to either female side. Between ECM (female) (3) and (38), or between AMB. AIR PRESSURE (female) (2) and (3)
40-301 42
Resistance Min. 100 kz
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA222] Ambient Press Sens Low Error
Cause
SEN06133-00
Procedure, measuring location, criteria and remarks
a If no failure is found by checks on causes 1 to 5 and check result of cause 6 is abnormal, sensor is defective. Defective ambient pressure sensor 1. Turn starting switch to OFF position. 6 (improper input voltage to engine 2. Insert T-adapters to connector ECM. controller) 3. Turn starting switch to ON position. Sensor outBetween ECM (3) and (38) Voltage 0.5 to 4.5 V put If no failure is found by above checks, engine controller is defective. (Since 7 Defective engine controller this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to ambient pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-301
43
301 Troubleshooting by failure code, Part 1 Failure code [CA227] Sens 2 Supply Volt High Error
SEN06133-00
Failure code [CA227] Sens 2 Supply Volt High Error Action level
Failure code
L03
CA227
Failure
Sensor 2 Power Supply Voltage High Error (Engine controller system)
Detail of failure
q
High voltage appears in sensor power supply 2 circuit.
Action of controller
q
Takes boost pressure and boost temperature to be at fixed values and allows engine to run. Restricts engine output and allows engine to run.
Problem on machine Related information
q
q
q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA187].
Failure code [CA234] Eng Overspeed Action level
Failure code
–
CA234
Failure
Engine Overspeed (Engine controller system)
Detail of failure
q
Engine speed exceeds upper limit of speed control.
Action of controller
q
Stops injection until engine speed lowers to normal level.
Problem on machine
q
Engine speed fluctuates.
q
Engine speed can be checked with monitoring function. (Code: 01002 Engine speed) Method of reproducing failure code: Start engine and keep it running at high idle.
Related information
q
Cause 1 Use of improper fuel 2 Usage is improper 3 Defective engine controller
40-301 44
Procedure, measuring location, criteria and remarks Fuel used may be improper. Check it. Method of using machine may be improper, so instruct operator on how to use machine properly. If no failure is found by checks on causes 1 and 2, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA238] Ne Speed Sens Supply Volt Error
SEN06133-00
Failure code [CA238] Ne Speed Sens Supply Volt Error Action level
Failure code
L01
CA238
Ne Speed Sensor Supply Voltage Error (Engine controller system)
Failure
Detail of failure
q
Low voltage appears in power supply circuit of engine Ne speed sensor.
Action of controller
q
Controls engine with signal from engine Bkup speed sensor.
q
q
Running engine stops (when Bkup speed sensor is also defective). Stopped engine cannot be started (when Bkup speed sensor is also defective). Starting performance is poor. Engine hunts.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1. If this failure code is not displayed when a sensor is disconnected, sensor or engine wiring harness is defective. 2 Defective sensor or wiring harness a Other failure codes are also displayed. This is because of disconnection of connector. Ignore failure codes other than [CA238].
3 Defective engine controller
Sensor or harness
Connector
Ne speed sensor
CRANK SENSOR
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to male side. 3. Turn starting switch to ON position with engine wiring harness disconnected. 4.75 to Between ECM (male) (16) and (48) Voltage 5.25 V
Circuit diagram related to Ne speed sensor
PC200, 200LC, 220, 220LC-8M0
40-301
45
301 Troubleshooting by failure code, Part 1 Failure code [CA271] IMV/PCV1 Short Error
SEN06133-00
Failure code [CA271] IMV/PCV1 Short Error Action level
Failure code
L03
CA271
Failure
IMV/PCV1 Short circuit Error (Engine controller system)
Detail of failure
q
Short circuit is detected in drive circuit of supply pump actuator.
Action of controller
q
None in particular
q q
Engine speed does not increase from low idle. Engine output lowers. Common rail fuel pressure rises above command value.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q
Cause 1
Defective wiring harness connector
2 Defective supply pump actuator
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 3. Turn starting switch to ON position. If failure code changes from [CA271] to [CA272] , supply pump actuator is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Short circuit or ground fault in wirBetween ECM (female) (2) and (32) ing harness
Between ECM (female) (2) and ground
4 Short circuit in wiring harness
Ground fault in wiring harness (contact with ground circuit)
40-301 46
Resistance Min. 100 kz
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect T-adapter to female side of ECM. Between ECM (female) (2) and ground
6 Defective engine controller
1 to 5 z
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect T-adapter to female side of ECM. Between ECM (female) (2) and (32)
5
Resistance
Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA271] IMV/PCV1 Short Error
SEN06133-00
Circuit diagram related to IMV/PCV1
PC200, 200LC, 220, 220LC-8M0
40-301
47
301 Troubleshooting by failure code, Part 1 Failure code [CA272] IMV/PCV1 Open Error
SEN06133-00
Failure code [CA272] IMV/PCV1 Open Error Action level
Failure code
L03
CA272
Failure
IMV/PCV1 Open circuit Error (Engine controller system)
Detail of failure
q
Open circuit is detected in drive circuit of supply pump actuator.
Action of controller
q
None in particular
q
Engine runs but its speed does not stabilize. Common rail fuel pressure rises above command value. Method of reproducing failure code: Turn starting switch to ON position. Because troubleshooting "socket" for this sensor features female connector alone, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed as a T-adapter).
Problem on machine
q q
Related information
q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 2 Defective supply pump actuator Between CP3 PUMP REGULATOR (male) (1) and Resistance Max. 5 z (2) 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side. 3 ness Between ECM (female) (2) and (32) Resistance Max. 5 z 1
4
Defective wiring harness connector
Hot short circuit in wiring harness (contact with 24 V circuit)
1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector CP3 PUMP REGULATOR. Insert T-adapters to connector ECM. Turn starting switch to ON position and perform troubleshooting after one minute or longer (with connector CP3 PUMP REGULATOR disconnected). a Average voltage is displayed because of PWM. Between ECM (2) and (32)
5 Defective engine controller
40-301 48
Voltage
Max. 3 V
If no failure is found by above checks, engine controller is defective. (Since this is internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
301 Troubleshooting by failure code, Part 1 Failure code [CA272] IMV/PCV1 Open Error
SEN06133-00
Circuit diagram related to IMV/PCV1
PC200, 200LC, 220, 220LC-8M0
40-301
49
SEN06133-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06133-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-301
50
SEN06134-00 SEN05986-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 302 Troubleshooting by failure code, Part 2 Failure code [CA322] Inj #1(L#1) Open/Short Error....................................................................................
4
Failure code [CA323] Inj #5(L#5) Open/Short Error....................................................................................
6
Failure code [CA324] Inj #3(L#3) Open/Short Error....................................................................................
8
Failure code [CA325] Inj #6(L#6) Open/Short Error.................................................................................... 10 Failure code [CA331] Inj #2(L#2) Open/Short Error.................................................................................... 12 Failure code [CA332] Inj #4(L#4) Open/Short Error.................................................................................... 14 Failure code [CA342] Calibration Code Incompatibility............................................................................... 16 Failure code [CA351] Injectors Drive Circuit Error ...................................................................................... 17 Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................. 18 Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................. 20 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 22 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 24 Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 26 Failure code [CA441] Battery Voltage Low Error ........................................................................................ 28 Failure code [CA442] Battery Voltage High Error ....................................................................................... 30 Failure code [CA449] Rail Press Very High Error ....................................................................................... 31 Failure code [CA451] Rail Press Sensor High Error ................................................................................... 32 Failure code [CA452] Rail Press Sensor Low Error.................................................................................... 34 Failure code [CA488] Chg Air Temp High Torque Derate ........................................................................... 36 Failure code [CA553] Rail Press High Error ............................................................................................... 37
PC200, 200LC, 220, 220LC-8M0
40-302
1
SEN06134-00
302 Troubleshooting by failure code, Part 2
Failure code [CA559] Rail Press Low Error ................................................................................................ 38 Failure code [CA689] Eng Ne Speed Sensor Error..................................................................................... 40 Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................................... 42 Failure code [CA757] All Continuous Data Lost Error................................................................................. 43 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................. 44 Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................................. 48 Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................................... 50 Failure code [CA2249] Rail Press Very Low Error ...................................................................................... 51 Failure code [CA2311] lMV Solenoid Error ................................................................................................. 51 Failure code [CA2555] Grid Htr Relay Open Circuit Error........................................................................... 52 Failure code [CA2556] Grid Htr Relay Short Circuit Error........................................................................... 54
40-302 2
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2
PC200, 200LC, 220, 220LC-8M0
SEN06134-00
40-302
3
302 Troubleshooting by failure code, Part 2 Failure code [CA322] Inj #1(L#1) Open/Short Error
SEN06134-00
Failure code [CA322] Inj #1(L#1) Open/Short Error Action level
Failure code
L03
CA322
Failure
Injector #1 (L#1) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 1 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 1 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male side. Between INJECTOR CYL 1&2 (male) (C) and (D)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (C) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (45) and (53) ing harness
Resistance
Between ECM (female) (45) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapters to each female side. Between ECM (female) (45) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (C) Between ECM (female) (53) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (D) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of either one. Between ECM (female) (45) or INJECTOR CYL 1&2 (female) (C) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 4
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (45) and each pin other No continuity (no sound than (45) is heard.) Between ECM (female) (53) and each pin other No continuity (no sound than (53) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by checks on causes 1 to 7, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA322] Inj #1(L#1) Open/Short Error
SEN06134-00
Circuit diagram related to injector #1
PC200, 200LC, 220, 220LC-8M0
40-302
5
302 Troubleshooting by failure code, Part 2 Failure code [CA323] Inj #5(L#5) Open/Short Error
SEN06134-00
Failure code [CA323] Inj #5(L#5) Open/Short Error Action level
Failure code
L03
CA323
Failure
Injector #5(L#5) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 5 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 5 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male side. Between INJECTOR CYL 5&6 (male) (C) and (D)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (C) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (46) and (60) ing harness
Resistance
Between ECM (female) (46) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapters to each female side. Between ECM (female) (46) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (C) Between ECM (female) (60) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (D) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapters to either female side. Between ECM (female) (46) or INJECTOR CYL 5&6 (female) (C) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 6
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (46) and each pin other No continuity (no sound than (46) is heard.) Between ECM (female) (60) and each pin other No continuity (no sound than (60) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA323] Inj #5(L#5) Open/Short Error
SEN06134-00
Circuit diagram related to injector #5
PC200, 200LC, 220, 220LC-8M0
40-302
7
302 Troubleshooting by failure code, Part 2 Failure code [CA324] Inj #3(L#3) Open/Short Error
SEN06134-00
Failure code [CA324] Inj #3(L#3) Open/Short Error Action level
Failure code
L03
CA324
Failure
Injector #3 (L#3) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 3 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. But it is pulse voltage and cannot be measured with multimeter.
Cause 1
Defective wiring harness connector
2 Defective No. 3 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male side. Between INJECTOR CYL 3&4 (male) (C) and (D)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (C) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (55) and (52) ing harness
Resistance
Between ECM (female) (55) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapters to each female side. Between ECM (female) (55) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (C) Between ECM (female) (52) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (D) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapters to either female side. Between ECM (female) (55) or INJECTOR CYL 3&4 (female) (C) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 8
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (55) and each pin other No continuity (no sound than (55) is heard.) Between ECM (female) (52) and each pin other No continuity (no sound than (52) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA324] Inj #3(L#3) Open/Short Error
SEN06134-00
Circuit diagram related to injector #3
PC200, 200LC, 220, 220LC-8M0
40-302
9
302 Troubleshooting by failure code, Part 2 Failure code [CA325] Inj #6(L#6) Open/Short Error
SEN06134-00
Failure code [CA325] Inj #6(L#6) Open/Short Error Action level
Failure code
L03
CA325
Failure
Injector #6(L#6) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 6 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of apporx. 65 V is supplied to injector (+) side but cannot be measured with multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 6 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male side. Between INJECTOR CYL 5&6 (male) (A) and (B)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (A) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (57) and (59) ing harness
Resistance
Between ECM (female) (57) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapters to each female side. Between ECM (female) (57) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (A) Between ECM (female) (59) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (B) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapters to either female side. Between ECM (female) (57) or INJECTOR CYL 5&6 (female) (A) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 10
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (57) and each pin other No continuity (no sound than (57) is heard.) Between ECM (female) (59) and each pin other No continuity (no sound than (59) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA325] Inj #6(L#6) Open/Short Error
SEN06134-00
Circuit diagram related to injector #6
PC200, 200LC, 220, 220LC-8M0
40-302
11
302 Troubleshooting by failure code, Part 2 Failure code [CA331] Inj #2(L#2) Open/Short Error
SEN06134-00
Failure code [CA331] Inj #2(L#2) Open/Short Error Action level
Failure code
L03
CA322
Failure
Injector #2 (L#2) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 2 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. But it is pulse voltage and cannot be measured with multimeter.
Cause 1
Defective wiring harness connector
2 Defective No. 2 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male side. Between INJECTOR CYL 1&2 (male) (A) and (B)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (B) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (54) and (51) ing harness
Resistance
Between ECM (female) (54) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapters to each female side. Between ECM (female) (54) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (B) Between ECM (female) (51) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (A) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapters to either female side. Between ECM (female) (54) or INJECTOR CYL 1&2 (female) (B) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 12
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (54) and each pin other No continuity (no sound than (54) is heard.) Between ECM (female) (51) and each pin other No continuity (no sound than (51) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA331] Inj #2(L#2) Open/Short Error
SEN06134-00
Circuit diagram related to injector #2
PC200, 200LC, 220, 220LC-8M0
40-302
13
302 Troubleshooting by failure code, Part 2 Failure code [CA332] Inj #4(L#4) Open/Short Error
SEN06134-00
Failure code [CA332] Inj #4(L#4) Open/Short Error Action level
Failure code
L03
CA332
Failure
Injector #4 (L#4) Open or Short Circuit Error (Engine controller system)
Detail of failure
q
Open or short circuit is detected in drive circuit of No. 4 injector.
Action of controller
q
None in particular
q
Poor combustions or hunting occurs. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, approximately 65 V of pulse voltage is supplied to injector (+) side. But it is pulse voltage and cannot be measured with multimeter.
Cause 1
Defective wiring harness connector
2 Defective No. 4 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male side. Between INJECTOR CYL 3&4 (male) (A) and (B)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (B) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (56) and (58) ing harness
Resistance
Between ECM (female) (56) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapters to each female side. Between ECM (female) (56) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (B) Between ECM (female) (58) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (A) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapters to either female side. Between ECM (female) (56) or INJECTOR CYL 3&4 (female) (B) and ground
6 Short circuit in wiring harness
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-302 14
Max. 2 z
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (56) and each pin other No continuity (no sound than (56) is heard.) Between ECM (female) (58) and each pin other No continuity (no sound than (58) is heard.) If different failure codes are displayed, perform troubleshootings for them on ahead. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA332] Inj #4(L#4) Open/Short Error
SEN06134-00
Circuit diagram related to injector #4
PC200, 200LC, 220, 220LC-8M0
40-302
15
302 Troubleshooting by failure code, Part 2 Failure code [CA342] Calibration Code Incompatibility
SEN06134-00
Failure code [CA342] Calibration Code Incompatibility Action level
Failure code
L04
CA342
Failure
Calibration Code Incompatibility (Engine controller system)
Detail of failure
q
Matching error occurs in engine controller data.
Action of controller
q
None in particular
Problem on machine
q
Engine may run normally, or engine is stopped and cannot be restarted.
q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage to engine controller can be checked with monitoring function. (Code: 03203 (V))
Related information
q
Cause 1 Defect in related system 2
Defective power supply voltage system
40-302 16
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Perform troubleshooting for failure code [CA441].
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA351] Injectors Drive Circuit Error
SEN06134-00
Failure code [CA351] Injectors Drive Circuit Error Action level
Failure code
L03
CA351
Failure
Injectors Drive Circuit Error (Engine controller system)
Detail of failure
q
There is error in drive power circuit of injector.
Action of controller
q
Restricts engine output and allows engine to run.
q
Exhaust gas becomes black. Combustion becomes irregular. Engine output lowers. Engine cannot be started. Method of reproducing failure code: Start engine. Power supply voltage to engine controller can be checked with monitoring function. (Code: 03203 (V))
Problem on machine
q q q
Related information
q q
Cause 1 Defect in related system 2
Defective power supply voltage system
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Perform troubleshooting for failure code [CA441].
40-302
17
302 Troubleshooting by failure code, Part 2 Failure code [CA352] Sens Supply 1 Volt Low Error
SEN06134-00
Failure code [CA352] Sens Supply 1 Volt Low Error Action level
Failure code
L03
CA352
Failure
Sensor Power supply 1 Voltage Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in sensor power supply 1 circuit.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1. If this failure code is not displayed when a sensor is disconnected, sensor or engine wiring harness is defective. 2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because of disconnection of connector. Ignore all failure codes other than [CA352].
3 Defective engine controller
Sensor or harness
Connector
Ambient pressure sensor
AMB. AIR PRESSURE
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (33) and (38)
40-302 18
Voltage
4.75 to 5.25V
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA352] Sens Supply 1 Volt Low Error
SEN06134-00
Circuit diagram related to sensor power supply 1
PC200, 200LC, 220, 220LC-8M0
40-302
19
302 Troubleshooting by failure code, Part 2 Failure code [CA386] Sens Supply 1 Volt High Error
SEN06134-00
Failure code [CA386] Sens Supply 1 Volt High Error Action level
Failure code
L03
CA386
Failure
Sensor Power Supply 1 Voltage High Error (Engine controller system)
Detail of failure
q
High voltage appears in sensor power supply 1 circuit.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA352]
40-302 20
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA386] Sens Supply 1 Volt High Error
PC200, 200LC, 220, 220LC-8M0
SEN06134-00
40-302
21
302 Troubleshooting by failure code, Part 2 Failure code [CA428] Water in Fuel Sensor High Error
SEN06134-00
Failure code [CA428] Water in Fuel Sensor High Error Action level
Failure code
L01
CA428
Failure
Water-in-fuel Sensor High Error (Engine controller system)
Detail of failure
q
High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of controller
q
None in particular
Problem on machine
q
Water separator monitor is not displayed correctly.
q
Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function. (Code: 18800) Method of reproducing failure code: Turn starting switch to ON position.
Related information
q
Cause 1
Defective wiring harness connector
2
Defective water-in-fuel sensor installed to fuel pre-filter
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapters to female side. a If water is in water separator, drain it. Between P47 (female) (1) and (2)
Resistance Min. 100 kz
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side. 3 ness Between ECM (female) (14) and (47) Resistance Min. 100 kz (Resistance of water-in-fuel sensor) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to each Open circuit in wiring harness female side. 4 (wire breakage or defective contact of connector) Between ECM (female) (14) and P47 (female) (1) Resistance Max. 10 z Between ECM (female) (47) and P47 (female) (2)
5 Short circuit in wiring harness
6 Defective engine controller
40-302 22
Resistance
Max. 10 z
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (14) and each pin other No continuity (no sound than (14) is heard.) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA428] Water in Fuel Sensor High Error
SEN06134-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0
40-302
23
302 Troubleshooting by failure code, Part 2 Failure code [CA429] Water in Fuel Sensor Low Error
SEN06134-00
Failure code [CA429] Water in Fuel Sensor Low Error Action level
Failure code
L01
CA429
Failure
Water-in-fuel Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of controller
q
None in particular
Problem on machine
q
Water separator monitor is not displayed correctly.
q
Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function. (Code: 18800) Method of reproducing failure code: Turn starting switch to ON position.
Related information
q
Cause 1
Defective wiring harness connector
2
Defective water-in-fuel sensor installed to fuel pre-filter
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapters to female side. a If water is in water separator, drain it. Between P47 (female) (1) and (2)
Resistance Min. 100 kz
Between P47 (female) (1) and ground
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapters to female side. 3
Short circuit or ground fault in wirBetween ECM (female) (14) and (47) ing harness (Resistance of water-in-fuel sensor) Between ECM (female) (14) and ground
4 Short circuit in wiring harness
5
Ground fault in wiring harness (contact with ground circuit)
6 Defective engine controller
40-302 24
Resistance Min. 100 kz Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to female side of ECM. a Check with multimeter in continuity mode. Between ECM (female) (14) and each pin other No continuity (no sound than (14) is heard.) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to either female side. Between ECM (female) (14) or P47 (female) (1) and Resistance Min. 100 kz ground If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA429] Water in Fuel Sensor Low Error
SEN06134-00
Circuit diagram related to water-in-fuel sensor
PC200, 200LC, 220, 220LC-8M0
40-302
25
302 Troubleshooting by failure code, Part 2 Failure code [CA435] Eng Oil Press Sw Error
SEN06134-00
Failure code [CA435] Eng Oil Press Sw Error Action level
Failure code
L01
CA435
Failure
Engine Oil Pressure Switch Error (Engine controller system)
Detail of failure
q
Failure occurs in engine oil pressure switch signal circuit.
Action of controller
q
None in particular
q
Protection function by engine oil pressure does not operate. Engine oil pressure monitor is not displayed normally.
Problem on machine
q q q
Related information
q q
Method of reproducing failure code: Turn starting switch to ON position or start engine. Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running). To display this failure code, engine controller checks if engine oil pressure switch is in CLOSED (ON), that is, if signal voltage is zero or not, only when engine is stopped. Failure of engine oil pressure switch with engine running is shown by failure code [B@BAZG].
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to Defective engine oil pressure 2 male side of connector. switch Between OIL PRESSURE SWITCH (male) (1) and Resistance Max. 10 z ground 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapters to female side. 3 ness Between ECM (female) (17) and ground Resistance Max. 10 z 1
Defective wiring harness connector
4 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine oil pressure switch
40-302 26
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA435] Eng Oil Press Sw Error
PC200, 200LC, 220, 220LC-8M0
SEN06134-00
40-302
27
302 Troubleshooting by failure code, Part 2 Failure code [CA441] Battery Voltage Low Error
SEN06134-00
Failure code [CA441] Battery Voltage Low Error Action level
Failure code
L04
CA441
Failure
Battery Voltage Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in controller power supply circuit.
Action of controller
q
None in particular
q
Engine stops. Starting performance is poor.
Problem on machine Related information
q q q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage to engine controller can be checked with monitoring function. (Code: 03203 (V))
Cause
Procedure, measuring location, criteria and remarks
1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly. 2
Loose terminal or partial open cir- 1. Turn starting switch to OFF position. cuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
3
Defective wiring harness connector
4 Improper battery voltage
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Perform troubleshooting with starting switch at OFF position and at engine cranking. Between battery terminals (+) and (-).
5 Defective alternator
40-302 28
20 to 30 V
Voltage
27.5 to 29.5 V
1. Turn starting switch to OFF position. 2. Insert T-adapters into connector E12. 3. Start engine (Engine speed: Middle or faster). Between E12 (1) and ground
6 Defective engine controller
Voltage
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Insert T-adapters into connector CE03. 3. Connect battery ground cable. 4. Measure voltage with starting switch at ON position and when starting engine. Between CE03 (3) and Starting switch: ON Voltage 20 to 30 V (1) Between CE03 (3) and Starting switch: START Voltage Min. 12 V (1)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA441] Battery Voltage Low Error
SEN06134-00
Circuit diagram related to engine controller power supply
PC200, 200LC, 220, 220LC-8M0
40-302
29
302 Troubleshooting by failure code, Part 2 Failure code [CA442] Battery Voltage High Error
SEN06134-00
Failure code [CA442] Battery Voltage High Error Action level
Failure code
L04
CA442
Failure
Battery Voltage High Error (Engine controller system)
Detail of failure
q
High voltage (36 V or higher) appears in controller power supply circuit.
Action of controller
q
None in particular
q
Engine continues to run normally, but it may stop during running or may not be able to start if it is stopped.
q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage to engine controller can be checked with monitoring function. (Code: 03203 (V))
Problem on machine Related information
q
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA441].
40-302 30
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA449] Rail Press Very High Error
SEN06134-00
Failure code [CA449] Rail Press Very High Error Action level
Failure code
L03
CA449
Failure
Common Rail Pressure Very High Error (Engine controller system)
Detail of failure
q
High pressure error (2) occurs in common rail circuit.
Action of controller
q
Restricts engine output and allows engine to run.
q
Engine sound becomes large when no or light load is applied. Engine output lowers.
Problem on machine Related information
q q q
Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
2 Air in low pressure circuit
3 Defect in fuel return circuit parts
4
Defective common rail pressure sensor system
5 Defective pressure limiter
6 Defective supply pump
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Air may be in low-pressure circuit. Check it directly according to following procedure. 1. Remove fuel pressure pickup port plug (outlet side) of fuel main filter. 2. Operate feed pump of fuel pre-filter. 3. Check fuel and air from pressure pickup plug for leakage level. a For check of pressure in fuel return circuit, see Testing and adjusting, "Testing fuel pressure". Max. 0.02 MPa Fuel return circuit presEngine at low idle or sure cranking {Max. 0.19 kg/cm2} Perform troubleshooting for failure codes [CA451] and [CA452] a For check of leakage from pressure limiter, see "Checking fuel return rate and leakage" in Testing and adjusting. Leakage from pressure limiter
At low idle
0 cc (no leakage)
If no failure is found by above checks, supply pump may be defective.
40-302
31
302 Troubleshooting by failure code, Part 2 Failure code [CA451] Rail Press Sensor High Error
SEN06134-00
Failure code [CA451] Rail Press Sensor High Error Action level
Failure code
L03
CA451
Failure
Common Rail Pressure Sensor High Error (Engine controller system)
Detail of failure
q
High voltage appears in signal circuit of common rail pressure sensor.
Action of controller
q
Restricts engine output and allows engine to run.
q
Engine speed or output lowers. Engine does not start Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor volt) Method of reproducing failure code: Turn starting switch to ON position. This failure code is displayed if common rail pressure sensor connector is disconnected. Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-adapter).
Problem on machine
q q
Related information
q q q
Cause 1
Defective wiring harness connector
2
Defective common rail pressure sensor power supply system
3 Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. If failure code [CA227] or [CA187] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapters to female side of ECM. Between ECM (female) (25) and (37)
4
Hot short circuit in wiring harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to connector ECM. 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS disconnected). a Pin (25) of ECM is connected to 5V line via resistor inside engine controller. Between ECM (25) and (47)
5 Open circuit in wiring harness Defective common rail pressure sensor 6 (improper input voltage to engine controller)
7 Defective engine controller
Resistance Min. 100 kz
Voltage
Approx. 5 V
If no failure is found by above checks, there may be open circuit in wiring harness. (*) a If no failure is found by checks on causes 1 to 5 and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapters to connector ECM. 3. Turn starting switch to ON position. Sensor outBetween ECM (25) and (47) Voltage 0.2 to 4.6 V put If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting".
40-302 32
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA451] Rail Press Sensor High Error
SEN06134-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-302
33
302 Troubleshooting by failure code, Part 2 Failure code [CA452] Rail Press Sensor Low Error
SEN06134-00
Failure code [CA452] Rail Press Sensor Low Error Action level
Failure code
L03
CA452
Failure
Common Rail Pressure Sensor Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in signal circuit of common rail pressure sensor.
Action of controller
q
Restricts engine output and allows engine to run.
q
Engine speed or output lowers. Engine does not start
Problem on machine
q q
Related information
q q
Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor volt) Method of reproducing failure code: Turn starting switch to ON position. If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error" is displayed.
Cause 1
Defective wiring harness connector
2
Defective common rail pressure sensor power supply system
3
Defective common rail pressure sensor
4
Ground fault in wiring harness (contact with ground circuit)
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. If failure code [CA187] (ground fault in sensor power supply system) or [CA227] is displayed, perform troubleshooting for it first. a Check that failure code [CA187] (Ground fault in sensor power supply system) is not displayed. 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS. 3. Turn starting switch to ON position. If failure code [CA452] changes to [CA451] , sensor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters to connector ECM. 3. Turn starting switch to ON position. Sensor outBetween ECM (25) and (47) Voltage 0.2 to 4.6 V put 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and ground
5 Short circuit in wiring harness
Between ECM (female) (25) and (47) 6 Defective engine controller
40-302 34
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA452] Rail Press Sensor Low Error
SEN06134-00
Circuit diagram related to common rail pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-302
35
302 Troubleshooting by failure code, Part 2 Failure code [CA488] Chg Air Temp High Torque Derate
SEN06134-00
Failure code [CA488] Chg Air Temp High Torque Derate Action level
Failure code
L03
Failure
CA488
Charge air temperature high torque derate (Engine controller system)
q
Temperature signal from boost pressure & temperature sensor exceeds upper limit of temperature control.
Action of controller
q
Restricts engine output and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Boost temperature can be checked with monitoring function. (Code 18500: Boost temperature) Method of reproducing failure code: Start engine.
Detail of failure
Related information
q
Cause Lowered cooling performance of 1 aftercooler
Procedure, measuring location, criteria and remarks Cooling performance of aftercooler may degrade. Check following points: Looseness and damage of fan belt q Insufficient cooling air q Clogging of aftercooler fins q
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related let temperature parts. Defective boost temperature sen3 Perform troubleshooting for failure codes [CA153] and [CA154]. sor
2
40-302 36
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA553] Rail Press High Error
SEN06134-00
Failure code [CA553] Rail Press High Error Action level
Failure code
L01
CA553
Failure
Rail Press High Error (Engine controller system)
Detail of failure
q
Excessively high pressure trouble (1) has occurred in the common rail circuit.
Action of controller
q
None in particular
q
Engine noise becomes louder at no or light load. Engine output lowers.
Problem on machine Related information
q q q
Common rail pressure can be checked with monitoring function. (Code 36400: Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it.
2
Defective connection of ground terminal
Connection of ground terminals may be defective. Check the following terminals. q Ground terminal of machine ((–) terminal of battery) q Ground terminal of engine q Ground terminal of engine controller q Ground terminal of starting motor
3
Defective common rail pressure sensor system
Perform troubleshooting for failure code [CA451], [CA452]
PC200, 200LC, 220, 220LC-8M0
40-302
37
302 Troubleshooting by failure code, Part 2 Failure code [CA559] Rail Press Low Error
SEN06134-00
Failure code [CA559] Rail Press Low Error Action level
Failure code
L01
CA559
Failure
Common Rail Pressure Low Error (Engine controller system)
Detail of failure
q
Low pressure error (1) is detected in common rail circuit.
Action of controller
q
None in particular
q
Engine does not start at all or does not start easily. Exhaust gas becomes black. Engine output lowers.
Problem on machine Related information
q q q q
Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Use of improper fuel
Procedure, measuring location, criteria and remarks Check fuel used as it may be improper one.
Fuel may leak to outside. Check it (Check visually while running engine at low idle). a For more information on troubleshooting, see Note 1. a For check of fuel pressure in low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Negative pressure at fuel At high idle Max. -50.7 MPa supply pump inlet (outlet (if engine can be started) {Max. -380 mmHg} side of fuel pre-filter) Defect in low-pressure circuit parts During cranking 0.3 to 1.1 MPa (if engine cannot be Inlet pressure of fuel {3.1 to 11.3 kg/cm2} started) main filter 0.5 to 1.3 MPa At low idle (if engine can be started) {5.1 to 13.3 kg/cm2} a For check of leakage from pressure limiter, see Testing and adjusting, “Checking fuel return rate and leakage”. Defective pressure limiter Leakage from pressure At low idle 0 cc (no leakage) limiter a For check of return rate from injector, see Testing and adjusting, “Checking fuel return rate and leakage”. Defective injector During cranking (including high-pressure piping in (if engine cannot be Max. 90 cc/min cylinder head) started) Return rate from injector At low idle Max. 180 cc/min (if engine can be started) a For check of return rate from supply pump, see Testing and adjusting, “Checking fuel return rate and leakage”. During cranking Defective supply pump (if engine cannot be Max. 140 cc/min Return rate from supply started) pump At low idle Max. 1,000 cc/min (if engine can be started) Defective common rail pressure Perform troubleshooting for failure codes [CA451] and [CA452] sensor system
2 Fuel leakage to outside
3
4
5
6
7
Note 1: Check the low-pressure line parts for the following. 1) Fuel level 2) Clogging of fuel tank breather 3) Leakage or clogging of low-pressure fuel piping 4) Clogging of fuel pre-filter 5) Clogging of fuel main filter 6) Replace the fuel filter when the problem is not removed even if it is found to be not clogged.
40-302 38
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA559] Rail Press Low Error
PC200, 200LC, 220, 220LC-8M0
SEN06134-00
40-302
39
302 Troubleshooting by failure code, Part 2 Failure code [CA689] Eng Ne Speed Sensor Error
SEN06134-00
Failure code [CA689] Eng Ne Speed Sensor Error Action level
Failure code
L01
CA689
Failure
Engine Ne Speed Sensor Error (Engine controller system)
Detail of failure
q
Signal from engine Ne speed sensor is abnormal.
Action of controller
q
Continues to control engine by using signal from engine Bkup speed sensor.
q
Engine hunts. Starting performance is poor. Engine output lowers. Method of reproducing failure code: Start engine. Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured by using multimeter. Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of crankshaft vibration damper and rotated by crankshaft.
Problem on machine
q q q q
Related information
q q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them.
Defective Ne speed sensor power If failure code [CA238] is also displayed, perform troubleshooting for it first. supply system Breakage or improper installation Engine Ne speed sensor may be broken or may have improper installation 3 (looseness) of engine Ne speed (looseness). Check it directly. sensor 1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapter to female Defective Ne speed sensor power side. 4 supply input 3. Turn starting switch to ON position. Between CRANK SENSOR (female) Power supVoltage 4.75 to 5.25V (1) and (2) ply input 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. a If no failure is found in checks on cause 4, this check is not required. ResisMax. 10 z Between ECM (female) (16) and CRANK tance Open circuit in wiring harness SENSOR (female) (1) 5 (wire breakage or defective cona If no failure is found in checks on cause 4, this tact of connector) check is not required. ResisMax. 10 z Between ECM (female) (48) and CRANK tance SENSOR (female) (2) Between ECM (female) (27) and CRANK SENSOR ResisMax. 10 z (female) (3) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. 2
6 Short circuit in wiring harness
7
Ground fault in wiring harness (contact with ground circuit)
40-302 40
Between ECM (female) (16) and (27) or CRANK SENSOR (female) (1) and (3)
Resistance
Min. 100 kz
Between ECM (female) (27) and (48) or CRANK SENSOR (female) (2) and (3)
Resistance
Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. Between ECM (female) (27) or CRANK SENSOR (female) (3) and ground
Resistance
Min. 100 kz
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA689] Eng Ne Speed Sensor Error
Cause
SEN06134-00
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Disconnect connector CRANK SENSOR. 8 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between CRANK SENSOR (female) (3) and ground
Voltage
Max. 1 V
Damage or loose mounting of 9 speed sensing wheel
Check speed sensing wheel directly.
10 Defective Ne speed sensor
If no failure is found by above checks, Ne speed sensor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine Ne speed sensor
PC200, 200LC, 220, 220LC-8M0
40-302
41
302 Troubleshooting by failure code, Part 2 Failure code [CA731] Eng Bkup Speed Sens Phase Error
SEN06134-00
Failure code [CA731] Eng Bkup Speed Sens Phase Error Action level
Failure code
L01 Detail of failure Action of controller Problem on machine Related information
CA731
Failure
Engine Bkup Speed Sensor Phase Error (Engine controller system)
q
Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed sensor
q
Continues to control engine by using signal from engine Ne speed sensor.
q q
Engine does not start at all or does not start easily. Idle speed is unstable. Exhaust gas becomes black.
q
Method of reproducing failure code: Start engine.
q
Cause
Procedure, measuring location, criteria and remarks
Breakage of engine Ne speed sen1 Engine Ne speed sensor may be broken. Check it. sor Breakage of engine Bkup speed 2 Engine Bkup speed sensor may be broken. Check it. sensor Speed sensing wheel on crankshaft side may be installed defectively or broken. Check it according to following procedure. Defective installation or breakage 1. Align paint mark (M1) on damper with Ne speed sensor top (M2). 3 of speed sensing wheel on cranka Do not align with mark of No. 1 cylinder compression top dead center shaft side (approimately 80 deg. before compression top dead center). 2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed sensor top (M2), installation is correct. Speed sensing ring on camshaft may be installed defectively or broken. Check it according to the following procedure. Defective installation or breakage 1. Set No. 1 cylinder to compression TDC (align with mark). 4 of speed sensing ring on camshaft 2. Remove Bkup speed sensor. side 3. If you can see double-slot part (with one crest) (B) on speed sensing ring through sensor mounting hole (H), speed sensing ring is installed correctly. 5
6
Defective timing of crankshaft and Timing of crankshaft and camshaft may be defective. Check it. camshaft Defective connection of ground terminal
40-302 42
Connection of ground terminal may be defective. Check following terminals. q Ground terminal of machine ((-) terminal of battery) q Ground terminal of engine q Ground terminal of engine controller q Ground terminal of starting motor
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA757] All Continuous Data Lost Error
SEN06134-00
Failure code [CA757] All Continuous Data Lost Error Action level
Failure code
L04
CA757
Failure
All Continuous Data Lost Error (Engine controller system)
Detail of failure
q
All data in engine controller are lost.
Action of controller
q
None in particular
q q
Engine may stop and may not be started again. Monitoring function of machine monitor (engine controller system) may not work normally.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause 1 Defect in related system
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it.
2 Perform troubleshooting for failure code [CA441].
PC200, 200LC, 220, 220LC-8M0
40-302
43
302 Troubleshooting by failure code, Part 2 Failure code [CA778] Eng Bkup Speed Sensor Error
SEN06134-00
Failure code [CA778] Eng Bkup Speed Sensor Error Action level
Failure code
L01
CA778
Failure
Engine Bkup Speed Sensor Error (Engine controller system)
Detail of failure
q
Singal from engine Bkup speed (cam) sensor is abnormal.
Action of controller
q
Continues to control engine by using signal from engine Ne speed sensor.
q
Starting performance is poor. Engine output lowers. Method of reproducing failure code: Start engine. Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by using multimeter. Speed sensor scans rotating slot of speed sensing ring mounted on camshaft.
Problem on machine
q q q
Related information
q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them.
2
Defective sensor power supply 2 system
If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
Damage or incorrect (loose) instalEngine Bkup speed (CAM) sensor may be damaged or incorrectly (loosely) 3 lation of engine Bkup speed (CAM) installed. Check it. sensor 1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapter to female Defective power input to engine side. 4 Bkup speed sensor 3. Turn starting switch to ON position. Between CAM SENSOR (female) (1) Power supVoltage 4.75 to 5.25V and (2) ply 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to each female side. Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR ResisMax. 10 z 5 (wire breakage or defective con- (female) (1) tance Between ECM (female) (47) and CAM SENSOR Resistact of connector) Max. 10 z (female) (2) tance Between ECM (female) (26) and CAM SENSOR ResisMax. 10 z (female) (3) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to either female side. Between ECM (female) (26) and (37) or CAM SEN- Resis6 Short circuit in wiring harness Min. 100 kz SOR (female) (1) and (3) tance
7
Ground fault in wiring harness (contact with ground circuit)
8
Hot short circuit in wiring harness (contact with 24 V circuit)
Between ECM (female) (26) and (47) or CAM SEN- ResisMin. 100 kz SOR (female) (2) and (3) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to either female side. Between ECM (female) (26) or CAM SENSOR ResisMin. 100 kz (female) (3) and ground tance 1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CAM SENSOR (female) (3) and ground
40-302 44
Voltage
Max. 1 V
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA778] Eng Bkup Speed Sensor Error
Cause 9 Loose speed sensing ring 10
Defective engine Bkup speed (CAM) sensor
11 Defective engine controller
SEN06134-00
Procedure, measuring location, criteria and remarks Remove engine Bkup speed (CAM) sensor, and check ring through hole (H). a If speed sensing ring (B) is loosely installed, follow instructions given in the "Reference" column. If no failure is found by above checks, engine Bkup speed (CAM) sensor is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
PC200, 200LC, 220, 220LC-8M0
40-302
45
SEN06134-00 Reference for troubleshooting of CA778 (107 series engine) Checking camshaft ring for loose installation Remove the front cover and check the camshaft ring for looseness. a See "Removal and installation of front seal" in Disassembly and assembly. a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand. Removal 1. Remove the fan and fan belt. For details, see "Removal and installation of front seal" in Disassembly and assembly. 2. Remove damper assembly (1). (DP): Dowel pin
3. Remove front cover (2). 4. Remove front seal (3). (RING): Ring
40-302 46
302 Troubleshooting by failure code, Part 2 Failure code [CA778] Eng Bkup Speed Sensor Error
5. Check mounting bolt (4) of camshaft ring (5) for looseness. 3 Mounting bolt (4): 10 ± 2 Nm (DP): Dowel pin
Installation a See the figures in "Removal" for installation. 1. Install front cover (2). 3 Front cover: Liquid gasket (LG-7) 2. Install the front seal according to the following procedure. For details, see "Removal and installation of front seal" in Disassembly and assembly. 1) Install front seal (3). 2) Install the damper assembly with the dowel pin (DP). 3) Install fan belt, and install the fan. 4) Install the cooling system assembly.
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA778] Eng Bkup Speed Sensor Error
PC200, 200LC, 220, 220LC-8M0
SEN06134-00
40-302
47
302 Troubleshooting by failure code, Part 2 Failure code [CA2185] Throt Sens Sup Volt High Error
SEN06134-00
Failure code [CA2185] Throt Sens Sup Volt High Error Action level
Failure code
L03
CA2185
Failure
Throttle Sensor Power Supply Voltage High Error (Engine controller system)
Detail of failure
q
High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of controller
q
Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
q
Engine speed cannot be controlled by fuel control dial.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position. Defective throttle sensor (fuel con2 If this failure code is not displayed, throttle sensor is defective. trol dial) a Other failure codes are displayed, too. This is because connector is disconnected. Ignore failure codes other than [CA2185].
3 Short circuit in wiring harness
4
Hot short circuit in wiring harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to each female side of CE02 and CE03. Between CE02 (female) (22) and each pin other ResisMin. 1 Mz than (22) tance ResisBetween CE02 (female) (22) and CE03 (female) (3) Min. 1 Mz tance 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapters to female side. 3. Turn starting switch to ON position. Between P20 (female) (1) and ground
5 Defective engine controller
Voltage
4.75 to 5.25V
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapters to male side. 3. Turn starting switch to ON position with wiring harness disconnected. Between CE02 (male) (22) and (23)
Voltage
4.75 to 5.25V
Circuit diagram related to throttle sensor
40-302 48
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA2185] Throt Sens Sup Volt High Error
SEN06134-00
Circuit diagram related to engine controller power supply
PC200, 200LC, 220, 220LC-8M0
40-302
49
302 Troubleshooting by failure code, Part 2 Failure code [CA2186] Throt Sens Sup Volt Low Error
SEN06134-00
Failure code [CA2186] Throt Sens Sup Volt Low Error Action level
Failure code
L03
CA2186
Failure
Throttle Sensor Power Supply Voltage Low Error (Engine controller system)
Detail of failure
q
Low voltage appears in throttle sensor power supply circuit.
Action of controller
q
Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
q
Engine speed cannot be controlled by fuel control dial.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel conIf this failure code is not displayed, throttle sensor is defective. trol dial) a Other failure code is displayed too. This is because connector is disconnected. Ignore failure codes other than [CA2186]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to either Ground fault in wiring harness 3 female side. (contact with ground circuit) Between CE02 (female) (22) or P20 (female) (1) ResisMin. 1 Mz and ground tance 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapters to female side of CE02. 4 Short circuit in wiring harness 3. Turn starting switch to ON position. Between CE02 (female) (22) and each pin other ResisMin. 1 Mz than (22) tance 2
5 Defective engine controller
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapters to male side. 3. Turn starting switch to ON position with wiring harness disconnected. Between CE02 (male) (22) and (23)
Voltage
4.75 to 5.25V
Circuit diagram related to throttle sensor
40-302 50
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA2249] Rail Press Very Low Error
SEN06134-00
Failure code [CA2249] Rail Press Very Low Error Action level
Failure code
L03
CA2249
Failure
Rail Press Very Low Error (Engine controller system)
Detail of failure
q
No-pressure feed error (level 2) in supply pump was detected.
Action of controller
q
Restricts engine output and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Signal voltage from common rail pressure sensor can be checked with monitoring function (Code: 36401 (V)). Common rail pressure sensed by common rail pressure sensor can be checked by using monitoring function. (Code: 36400 (MPa)) Method of reproducing failure code: Start engine.
Related information
q q
Cause
Procedure, measuring location, criteria and remarks
1 Supply pump no pressure error
Perform troubleshooting for failure code [CA559] .
Failure code [CA2311] lMV Solenoid Error Action level
Failure code
L03
CA2311
Failure
IMV solenoid error (Engine controller system)
Detail of failure
q
Resistance value of supply pump actuator circuit is unusually high or low.
Action of controller
q
None in particular
q
Engine output lowers.
q
Method of reproducing failure code: Start engine.
Problem on machine Related information
Cause 1 IMV solenoid error
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [CA271] and [CA272].
40-302
51
302 Troubleshooting by failure code, Part 2 Failure code [CA2555] Grid Htr Relay Open Circuit Error
SEN06134-00
Failure code [CA2555] Grid Htr Relay Open Circuit Error Action level
Failure code
L01
CA2555
Failure
Intake air Heater Relay Open Circuit Error (Engine controller system)
Detail of failure
q
Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of controller
q
None in particular
q
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes) Temperature sensed by boost temperature sensor can be checked with monitoring function. (Code: 18500) Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil) side of preheater relay R18. For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in E-mode.
Problem on machine
q q
Related information
q q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapters to male side. Between R18 (male) (1) and (2)
2 Defective preheater relay R18
Resistance
200 to 400 z
1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector CE02, and connect T-adapters to female side. 3 ness Between CE02 (female) (40) and (42) 200 to Resistance a Preheater relay R18 coil resistance 400 z a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapters to each female side. 4 Open circuit in wiring harness Between CE02 (female) (40) and R18 (female) (1) Resistance Max. 1 z Between R18 (female) (2) and CE02 (42)
Resistance
Max. 1 z
5 Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapters to female side of CE02. a Check with multimeter in continuity mode. Between CE02 (female) (40) and each pin other No continuity than (40) (No sound is heard)
6 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-302 52
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA2555] Grid Htr Relay Open Circuit Error
SEN06134-00
Circuit diagram related to intake air heater relay
PC200, 200LC, 220, 220LC-8M0
40-302
53
302 Troubleshooting by failure code, Part 2 Failure code [CA2556] Grid Htr Relay Short Circuit Error
SEN06134-00
Failure code [CA2556] Grid Htr Relay Short Circuit Error Action level
Failure code
L01
CA2556
Failure
Intake air Heater Relay Short Circuit (Engine controller system)
Detail of failure
q
Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of controller
q
None in particular
q
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes) Temperature sensed by boost temperature sensor can be checked with monitoring function. (Code: 18500 ) Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil) side of preheater relay R18. For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in E-mode.
Problem on machine
q q
Related information
q q
Cause 1
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connecin "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them. 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapters to male side. Between R18 (male) (1) and (2)
2 Defective preheater relay R18
Resistance
200 to 400 z
1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective.
3 Ground fault in wiring harness
4 Short circuit in wiring harness
5 Defective engine controller
40-302 54
1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapters to either female side. Between CE02 (female) (40) or R18 (female) (1) Resistance Min. 1 Mz and ground 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapters to female side of CE02. a Check with multimeter in continuity mode. Between CE02 (female) (40) and each pin other No continuity than (40) (No sound is heard) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
302 Troubleshooting by failure code, Part 2 Failure code [CA2556] Grid Htr Relay Short Circuit Error
SEN06134-00
Circuit diagram related to intake air heater relay
PC200, 200LC, 220, 220LC-8M0
40-302
55
SEN06134-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06134-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-302
56
SEN06135-00 SEN05987-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 303 Troubleshooting by failure code, Part 3 Failure code [D110KB] Battery Relay Drive Short Circuit ...........................................................................
4
Failure code [D19JKZ] Personal Code Relay Abnormality .........................................................................
6
Failure code [D811MC] KOMTRAX Error ...................................................................................................
8
Failure code [D862KA] GPS Antenna Open Circuit....................................................................................
9
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)................................................................................... 10 Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................................... 12 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................................... 14 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................................... 16 Failure code [DA29KQ] Model Selection Abnormality ................................................................................ 18 Failure code [DA2QKR] CAN2 Discon (Pump Con) ................................................................................... 23 Failure code [DAF0MB] Monitor ROM Abnormality .................................................................................... 26 Failure code [DAF0MC] Monitor Error ........................................................................................................ 27 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................................... 28 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................ 30 Failure code [DAFGMC] GPS Module Error ............................................................................................... 31 Failure code [DAFQKR] CAN2 Discon........................................................................................................ 32 Failure code [DAZ9KQ] A/C Model Selection Abnormality ......................................................................... 33 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ................................................................................. 34 Failure code [DB2QKR] CAN2 Discon (Engine Con).................................................................................. 36 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 40
PC200, 200LC, 220, 220LC-8M0
40-303
1
SEN06135-00
303 Troubleshooting by failure code, Part 3
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .................................................................. 42 Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................................... 44 Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................................... 46
40-303 2
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3
PC200, 200LC, 220, 220LC-8M0
SEN06135-00
40-303
3
303 Troubleshooting by failure code, Part 3 Failure code [D110KB] Battery Relay Drive Short Circuit
SEN06135-00
Failure code [D110KB] Battery Relay Drive Short Circuit Action level
Failure code
L01
D110KB
Detail of failure Action of controller Problem on machine Related information
Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
q q
Stops 24 V output to battery relay primary circuit (coil side). Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Each controller may fail in writing of data into its ROM (non-volatile memory).
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Output state (ON/OFF) to battery relay can be checked with monitoring function. (Code: 03700 Controller output 1) Method of reproducing failure code: Turn starting switch to ON position, then turn it to OFF position.
q
Cause
2
Battery Relay Drive Short Circuit (Pump controller system)
q
q
1
Failure
Defective battery relay (Internal short circuit)
Ground fault in wiring harness (contact with ground circuit)
3 Defective pump controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Between terminal R01 and terminal BR
Between terminal R02 (BR) and ground
Resistance
Min. 1 Mz
Between any of terminal R02 (harness side), C02 (female) (108), D01 (female) (1) or (2) and ground
Resistance
Min. 1 Mz
Between D01 (female) (5) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector D01. 3. Turn starting switch to ON position. 4. Measure voltage during 4 to 7seconds after turning starting switch from ON to OFF position Between D01 (5) and ground
40-303 4
Continuity
1. Turn starting switch to OFF position. 2. Disconnect negative battery cable (in order not to make short circuit). 3. Disconnect connector R01, terminal R02, and connectors D01, H15 and C02.
Voltage
20 to 30 V
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [D110KB] Battery Relay Drive Short Circuit
SEN06135-00
Circuit diagram related to battery relay
PC200, 200LC, 220, 220LC-8M0
40-303
5
303 Troubleshooting by failure code, Part 3 Failure code [D19JKZ] Personal Code Relay Abnormality
SEN06135-00
Failure code [D19JKZ] Personal Code Relay Abnormality Action level
Failure code
L03
D19JKZ
Detail of failure
Personal Code Relay Abnormality (KOMTRAX system in machine monitor)
q
Open circuit or short circuit is detected in primary (coil) circuit of personal code relay.
q
None in particular (for open circuit) Stops output to personal code relay (for short circuit). If cause of failure disappears, machine becomes normal by itself (for open circuit). Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position (when short circuit is detected). When circuit is open, you can start the engine if engine start lock is enabled. When circuit has ground fault, you cannot start the engine. This failure code is displayed only when engine lock function is enabled. Method of reproducing failure code: Turn starting switch to ON position (open circuit). Failure code cannot be reproduced (short circuit). Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary (coil) circuit of personal code relay R07, to machine monitor.
Action of machine monitor
q
Problem on machine
q
q q
q q
Related information
Failure
q q
Cause 1 Blown fuse No. 3 of fuse box F01
Procedure, measuring location, criteria and remarks When fuse is blown, ground fault may have probably occurred in circuit. 1. Turn starting switch to OFF position. 2. Disconnect relay R07, and connect T-adapters to male side.
Between R07 (male) (1) and (2) Resistance 100 to 500 z 2 Defective personal code relay R07 1. Turn starting switch to OFF position. 2. Replace relay R07 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original personal code relay R07 is defective. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. Open circuit or short circuit or 3. Disconnect connector CM01 and connect T-adapter to female side. 3 ground fault in wiring harness Between F01-3 and CM01 (female) (6) Resistance 100 to 500 z
4 Open circuit in wiring harness
5 Ground fault in wiring harness
6 Short circuit in wiring harness
7
Defective machine monitor (KOMTRAX section)
40-303 6
Between F01-3 or CM01 (female) (6) and ground Resistance Min. 1 Mz a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connector CM01 and relay R07, and connect T-adapters to each female side. Between F01-3 and R07 (female) (1) Resistance Max. 1 z Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connector CM01 and relay R07, and connect T-adapters to either female side. Between F01-3 or R07 (female) (1) and ground Resistance Min. 1 Mz Between R07 (female) (2) and ground, or between Resistance Min. 1 Mz CM01 (female) (6) and ground 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connectors CM01 and relay R07, and connect T-adapters to female side of connector CM01. a Check with multimeter in continuity mode. Between CM01 (female) (6) and each pin other No continuity than pin (6) (No sound is heard) If no failure is found by above checks, machine monitor (KOMTRAX portion) is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [D19JKZ] Personal Code Relay Abnormality
SEN06135-00
Circuit diagram related to personal code relay
PC200, 200LC, 220, 220LC-8M0
40-303
7
303 Troubleshooting by failure code, Part 3 Failure code [D811MC] KOMTRAX Error
SEN06135-00
Failure code [D811MC] KOMTRAX Error Action level
Failure code
–
D811MC
Detail of failure
Failure
KOMTRAX error (KOMTRAX system)
q
KOMTRAX malfunctions.
q
KOMTRAX system does not operate properly.
q
Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine Related information
Cause 1 Malfunction of KOMTRAX
40-303 8
Procedure, measuring location, criteria and remarks KOMTRAX is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [D862KA] GPS Antenna Open Circuit
SEN06135-00
Failure code [D862KA] GPS Antenna Open Circuit Action level
Failure code
–
D862KA
Detail of failure Action of machine monitor Problem on machine Related information
GPS Antenna Open Circuit (KOMTRAX system)
q
Open circuit is detected in GPS antenna circuit.
q q
None in particular If cause of failure disappears, machine becomes normal by itself.
q
GPS positioning cannot work.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Failure
Defective GPS antenna or antenna cable
Procedure, measuring location, criteria and remarks Probable causes are defective GPS antenna, open circuit or short circuit in antenna GPS cable, and defective connection of antenna cable connector (A).
Structural illustration
PC200, 200LC, 220, 220LC-8M0
40-303
9
303 Troubleshooting by failure code, Part 3 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
SEN06135-00
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) Action level
Failure code
–
D8AQKR
Failure
CAN 2 Disconnection (KOMTRAX) (Detected by machine monitor) (Machine monitor system)
q
Machine monitor cannot recognize pump controller through CAN communication 2 line (KOMNET/c).
Action of machine monitor
q
None
Problem on machine
q
None
Detail of failure
Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. q Machine monitor indicates a CAN communication error in CAN2 with failure code [DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are displayed, harness (CAN communication line) may have ground fault, short circuit, or hot short circuit. Since air conditioner is also controlled via CAN communication, check whether air conditioner is operated (ON/OFF and Related inforair flow adjustment) on air conditioner screen. mation a Air conditioner can be operated even when failure code is displayed on machine monitor screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or hot short circuit in wiring harness (CAN communication line). q Since each controller and machine monitor are connected to continuous power supply, they receive continuous power even while starting switch is at OFF position. q Since active CAN communication line signal is pulse voltage, it cannot be measured by using multimeter. q q
No.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05
Between F05 (female) (1) and (2)
Resistance
Max. 1 z
a If fusible link is blown, circuit may have ground fault. 1. Turn starting switch to OFF position. Defective fuse No. 17 in fuse box 2. Remove fuse No. 17 in fuse box F01. 2 F01 If fuse is blown, circuit probably has ground fault. Power supply to KOMTRAX termiPerform troubleshooting for E mode, "E-36" nal defective Defective CAN communication 2 4 Perform checks on cause 4 to 9 in troubleshooting for failure code [DB2QKR]. line If no failure is found by above checks, KOMTRAX terminal is defective. 5 Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.)
3
6 Defective machine monitor
40-303 10
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
SEN06135-00
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0
40-303
11
303 Troubleshooting by failure code, Part 3 Failure code [DA22KK] Pump Solenoid Power Low Error
SEN06135-00
Failure code [DA22KK] Pump Solenoid Power Low Error Action level
Failure code
L03
DA22KK
Detail of failure Action of controller Problem on machine Related information
Pump Solenoid Power supply voltage Low Error (input) (Pump controller system)
q
Power supply supply voltage of controller for driving solenoids is below 20 V.
q q
Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this failure code is active. If cause of failure disappears, machine becomes normal by itself.
q
No solenoid valve is energized properly, so machine does not work properly.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. If failure code [D110KB] is displayed, troubleshoot it first. Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause 1
Failure
Defective fusible link F04 or fuse No.2 of fuse box F01
2 Improper battery voltage
Procedure, measuring location, criteria and remarks If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.) 1. Turn starting switch to OFF position. 2. After measuring voltage, measure it again when starting engine. Between battery (+) and ground
3 Defective wiring harness
4 Open circuit in wiring harness
5
Ground fault in wiring harness (contact with ground circuit)
Voltage
1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connector C02 and connect T-adapters to female side. 3. Connect battery ground cable and turn starting switch to ON position. Between each of (116), (118) and (121) of C02 and Voltage 20 to 30 V ground a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Remove fusible link F04 and fuse (2) in fuse box F01. 3. Disconnect connector C02 and connect T-adapters to female side. Between each of (116), (118) and (121) of C02 Resistance Max. 1 z (female) and F01-2 Between F01-1A and F04 (male) (2)
Resistance
Max. 1 z
Between F04 (male) (1) and terminal R03
Resistance
Max. 1 z
a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Remove fusible link F04 and fuse No. 2 of fuse box F01. 3. Disconnect connector C02 and connect T-adapters to female side. Between ground and each of (116), (118) and (121) Resistance Min. 1 Mz of C02 (female) or F01-2 Between F01-1A or F04 (male) (2) and ground
6 Defective pump controller
40-303 12
20 to 30 V
Resistance
Min. 1 Mz
Between F04 (male) (1) or terminal R03 and ground Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA22KK] Pump Solenoid Power Low Error
SEN06135-00
Circuit diagram related to solenoid power supply circuit
PC200, 200LC, 220, 220LC-8M0
40-303
13
303 Troubleshooting by failure code, Part 3 Failure code [DA25KP] 5V Sensor 1 Power Abnormality
SEN06135-00
Failure code [DA25KP] 5V Sensor 1 Power Abnormality Action level
Failure code
–
DA25KP
Failure
5 V Sensor 1 Power supply voltage Abnormality (Pump controller system)
Detail of failure
q
Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
Action of controller
q
Stops output of power from 5V sensor power supply output 1. Even if cause of failure disappears, machine does not become normal until starting switch is turned
Problem on machine Related information
q q q q q
Automatic travel speed selector function does not work (pump pressure sensor system). Auto-decelerator keeps working and is not canceled or fine control performance of work equipment is lowered (PPC pressure sensor system). As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following sensors one by one, and turn starting switch to ON position for each troubleshooting. a If this failure code disappears, disconnected sensor is defective. 3. After each troubleshooting, turn starting swith to OFF position.
1
2
Defective pressure sensor (Internal short circuit)
Hot short circuit in wiring harness (Contact with 24 V circuit)
Sensor
Connector
Bucket CURL PPC pressure sensor
P01
Boom DOWN PPC pressure sensor
P02
Bucket DUMP PPC pressure sensor
P05
Arm IN pressure sensor
P04
Boom RAISE PPC pressure sensor
P06
Swing RIGHT PPC pressure sensor
P07
Arm DUMP PPC pressure sensor
P08
Swing LEFT PPC pressure sensor
P03
F pump pressure sensor
P25
R pump pressure sensor
P26
a 1. 2. 3.
To measure voltage before controller stops output of power. Turn starting switch to OFF position. Disconnect connectors P01 to P08 and P25, and P26. Connect T-adapters to female side of either of disconnected connectors (e.g. P07). 4. Turn starting switch to ON position (with connectors P01 to P08, and P25 and P26 disconnected). Between P07 (female) (3) and ground
Ground fault in wiring harness 3 (contact with ground circuit) 4 Defective pump controller
40-303 14
Voltage
4.5 to 5.5 V
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P01 to P08, and P25 and P26. 3. Connect T-adapters to female side of connector C01. Between C01 (female) (9) and ground Resistance Min. 1 Mz If no failure is found by above checks, the pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA25KP] 5V Sensor 1 Power Abnormality
SEN06135-00
Circuit diagram related to 5 V sensor 1 power supply circuit
PC200, 200LC, 220, 220LC-8M0
40-303
15
303 Troubleshooting by failure code, Part 3 Failure code [DA26KP] 5V Sensor 2 Power Abnormality
SEN06135-00
Failure code [DA26KP] 5V Sensor 2 Power Abnormality Action level
Failure code
–
DA26KP
Failure
5V sensor 2 Power Supply voltage Abnormality (Pump controller system)
Detail of failure
q
Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action of controller
q q
Stops power supply from 5 V sensor power supply output 2 circuit. Even if cause of failure disappears, machine does not become normal until starting switch is turned
q
Travel does not stable
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following sensors one by one, and turn starting switch to ON position for each troubleshooting. a If this failure code disappears, disconnected sensor is defective. 3. After each troubleshooting, turn starting swith to OFF position.
1
2
Defective pressure sensor (Internal short circuit)
Hot short circuit in wiring harness (Contact with 24 V circuit)
Sensor
Connector
L.H. travel FORWARD PPC pressure sensor
P09
L.H. travel REVERSE PPC pressure sensor
P10
R.H. travel FORWARD PPC pressure sensor
P11
R.H. travel REVERSE PPC pressure sensor
P12
a 1. 2. 3.
To measure voltage before controller stops output of power. Turn starting switch to OFF position. Disconnect connectors P09 to P12. Connect T-adapter to female side of either of disconnected connectors (e.g. P09). 4. Turn starting switch to ON position (with connectors P09 to P12 disconnected). Between P09 (female) (3) and ground
3
Ground fault in wiring harness (contact with ground circuit)
Between C01 (female) (8) and ground 4 Defective pump controller
40-303 16
Voltage
4.5 to 5.5 V
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P09 to P12. 3. Connect T-adapters to female side of connector C01. Resistance
Min. 1 Mz
If no failure is found by above checks, the pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA26KP] 5V Sensor 2 Power Abnormality
SEN06135-00
Circuit diagram related to 5 V sensor 2 power supply circuit
PC200, 200LC, 220, 220LC-8M0
40-303
17
303 Troubleshooting by failure code, Part 3 Failure code [DA29KQ] Model Selection Abnormality
SEN06135-00
Failure code [DA29KQ] Model Selection Abnormality Action level
Failure code
L01
DA29KQ
Failure
Model Selection Abnormality (Pump controller system)
Detail of failure
q
Model code of input signal is not registered in controller.
Action of controller
q q
Controls machine, taking it that machine is default model (PC200). Even if cause of failure disappears, machine does not become normal until starting switch is turned
q
Because pump controller recognizes machine as "PC200", no particular problem occurs.
q
Model code input to pump controller can be checked by using monitoring function. (Code: 00200 Controller model code) Input of model selection signal can be checked with monitoring function. (Code: 02201 Switch Input 2) Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q q
q
PC200-8M0, PC200LC-8M0 Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S30 and connect T-adapters to female side. Between S30 (female) (1) and (2)
Resistance
Min. 1 Mz
Between S30 (female) (1) and (3) Defective model selection connecBetween S30 (female) (2) and (3) 1 tor (internal open or short circuit) Between S30 (female) (3) and (4)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between S30 (female) (4) and (7)
Resistance
Min. 1 Mz
Between S30 (female) (7) and (8)
Resistance
Min. 1 Mz
Between S30 (female) (3) and (8)
Resistance
Max. 1 z
2 Open circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. Between C01 (female) (77) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. 3 Short circuit in wiring harness
Between C01 (female) (21) and C01 (female) (77)
Resistance
Min. 1 Mz
Between C01 (female) (39) and C01 (77)
Resistance
Min. 1 Mz
Between C01 (female) (40) and C01 (77)
Resistance
Min. 1 Mz
Between C01 (female) (58) and C01 (77)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. Ground fault in wiring harness 4 (contact with ground circuit)
5 Defective pump controller
40-303 18
Between C01 (female) (21) and ground
Resistance
Min. 1 Mz
Between C01 (female) (40) and ground
Resistance
Min. 1 Mz
Between C01 (female) (58) and ground
Resistance
Min. 1 Mz
Between C01 (female) (39) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA29KQ] Model Selection Abnormality
SEN06135-00
Circuit diagram related to model selection signal (PC200-8M0, PC200LC-8M0)
PC200, 200LC, 220, 220LC-8M0
40-303
19
SEN06135-00
303 Troubleshooting by failure code, Part 3 Failure code [DA29KQ] Model Selection Abnormality
PC220-8M0, PC220LC-8M0
q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S30 and connect T-adapters to female side. Between S30 (female) (1) and (2)
Resistance
Min. 1 Mz
Between S30 (female) (2) and (3) Defective model selection connecBetween S30 (female) (3) and (4) 1 tor (internal open or short circuit) Between S30 (female) (4) and (7)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between S30 (female) (7) and (8)
Resistance
Min. 1 Mz
Between S30 (female) (1) and (3)
Resistance
Max. 1 z
Between S30 (female) (3) and (8)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. 2 Open circuit in wiring harness
Between C01 (female) (40) and ground
Resistance
Max. 1 z
Between C01 (female) (77) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. 3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective pump controller
40-303 20
Between C01 (female) (21) and C01 (77)
Resistance
Min. 1 Mz
Between C01 (female) (39) and C01 (77)
Resistance
Min. 1 Mz
Between C01 (female) (58) and C01 (77)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. Between C01 (female) (21) and ground Resistance Min. 1 Mz Between C01 (female) (39) and ground
Resistance
Min. 1 Mz
Between C01 (female) (58) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA29KQ] Model Selection Abnormality
SEN06135-00
Circuit diagram related to model selection signal (PC220-8M0, PC220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
40-303
21
SEN06135-00
40-303 22
303 Troubleshooting by failure code, Part 3 Failure code [DA29KQ] Model Selection Abnormality
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA2QKR] CAN2 Discon (Pump Con)
SEN06135-00
Failure code [DA2QKR] CAN2 Discon (Pump Con) Action level
Failure code
L03 Detail of failure Action of controller
Failure
DA2QKR
CAN2 Discon (Pump Con) (Detected by machine monitor) (Machine monitor system)
q
Machine monitor does not recognize pump controller through CAN communication 2 line (KOMNET/c).
q
Holds information at the time of occurrence of failure.
Information to be obtained from pump controller is not displayed or special function that uses information from pump controller does not work. Or received data (failure codes, monitoring codes, etc. transmitted from pump controller) is no longer updated. q Method of reproducing failure code: Turn starting switch to ON position. q Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. q Machine monitor uses four failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], to indicated failure in CAN communication through CAN 2 line. When all of these failure code are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). Since air conditioner is also controlled through CAN communication, check whether air conditioner is operated (ON/OFF and air flow adjustment) on air condiRelated infortioner screen. mation q This code appears even when pump controller power supply is shut off. a Air conditioner can be operated even when failure code is displayed on machine monitor screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or hot short circuit in wiring harness (CAN communication line). q Since each controller and machine monitor are connected to continuous power supply, they receive continuous power even while starting switch is at OFF position. q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05
Resistance Between F05 (female) (1) and (2)
Max. 1 z
a If fusible link is blown, circuit may have ground fault. 2
3
Defective fuse No. 17 in fuse box F01
Improper power supply to pump controller
1. Turn starting switch to OFF position. 2. Remove fuse No. 17 in fuse box F01. When fuse is blown, circuit may have ground fault. a 1. 2. 3.
Check ground terminal T04 for looseness and rust. Turn starting switch to OFF position. Disconnect connector C01 and connect T-adapters to female side. Turn starting switch to ON position. Voltage
a 1. 2. 3. Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
Defective CAN communication 2 line
PC200, 200LC, 220, 220LC-8M0
20 to 30 V
Between C01 (female) (4) and (5)
20 to 30 V
If no failure is found by check on cause 3, this check is not required. Turn starting switch to OFF position, and disconnect ground cable. Remove fuse No. 17 in fuse box F01. Disconnect fusible link F05 and connector C01, and connect Tadapters to each female side.
Resistance
5
Between C01 (female) (1) and (2)
Between terminal R04 and F05 (female) (1)
Max. 1 z
Between F05 (female) (2) and F01-16E
Max. 1 z
Between F01-17 and C01 (female) (1)
Max. 1 z
Between F01-17 and C01 (female) (4)
Max. 1 z
Perform checks on cause 4 to 9 in troubleshooting for failure code [DB2QKR].
40-303
23
SEN06135-00
Cause
303 Troubleshooting by failure code, Part 3 Failure code [DA2QKR] CAN2 Discon (Pump Con)
Procedure, measuring location, criteria and remarks
6 Defective pump controller
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
7 Defective machine monitor
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-303 24
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DA2QKR] CAN2 Discon (Pump Con)
SEN06135-00
Circuit diagram related to pump controller power supply
PC200, 200LC, 220, 220LC-8M0
40-303
25
303 Troubleshooting by failure code, Part 3 Failure code [DAF0MB] Monitor ROM Abnormality
SEN06135-00
Failure code [DAF0MB] Monitor ROM Abnormality Action level
Failure code
–
DAF0MB
Detail of failure
Failure
Monitor ROM Abnormality (Machine monitor system)
q
Program of machine monitor is rewritten (program error).
q q
Indication of machine monitor is unreliable. Machine monitor is incapable of normally exchanging data with controllers.
q
Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine Related information
Cause 1 Defective machine monitor
40-303 26
Procedure, measuring location, criteria and remarks Machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DAF0MC] Monitor Error
SEN06135-00
Failure code [DAF0MC] Monitor Error Action level
Failure code
–
DAF0MC
Detail of failure
Failure
Monitor Error (Machine monitor system)
q
Machine monitor malfunctions.
q q
Indication of machine monitor is unreliable. Machine monitor is incapable of normally exchanging data with controllers.
q
Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine Related information
Cause 1 Defective machine monitor
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks Machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-303
27
303 Troubleshooting by failure code, Part 3 Failure code [DAF8KB] Camera Power Supply Short Circuit
SEN06135-00
Failure code [DAF8KB] Camera Power Supply Short Circuit Action level
Failure code
L03 Detail of failure Action of machine monitor
DAF8KB q q q
Failure
Camera Power Supply Short Circuit (Machine monitor system)
Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V. Stops output of power supply voltage (Rating: 8 V) to camera. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
q
Camera image is not displayed on monitor screen.
Related information
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
Defective camera (internal short circuit)
2 Defective machine monitor
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect camera connector(s), and turn starting switch to ON position. After above operation (disconnecting camera connector and performing failure code reproducing procedure), if failure code disappears, camera has internal defect. 1. Turn starting switch to OFF position. 2. Disconnect connector CM04. 3. Connect T-adapters to male side of connector CM04. 4. Turn starting switch to ON position. Between CM04 (male) (1) and ground
3
Ground fault in wiring harness (contact with ground circuit)
Voltage
6 to 10 V
1. Turn starting switch to OFF position. 2. Disconnect connector CM04 and camera connector (s). 3. Connect T-adapters to female side of connector CM04. Between CM04 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect camera connector(s). Hot short circuit in wiring harness 3. Insert T-adapters into connector CM04. 4 4. Turn starting switch to ON position. (Contact with 24 V circuit) (Disconnect camera and check that camera is not defective in advance.) Between CM04 (1) and (5)
40-303 28
Voltage
Max. 10 V
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DAF8KB] Camera Power Supply Short Circuit
SEN06135-00
Circuit diagram related to camera power supply
PC200, 200LC, 220, 220LC-8M0
40-303
29
303 Troubleshooting by failure code, Part 3 Failure code [DAF9KQ] Model Selection Abnormality
SEN06135-00
Failure code [DAF9KQ] Model Selection Abnormality Action level
Failure code
L03
DAF9KQ
Detail of failure
Failure
Model selection abnormality (Machine monitor system)
q
Model registered in the machine monitor and pump controller differs. (Machine monitor or pump controller has been replaced with a wrong part.)
q
Machine does not operate normally
q
Assembly part No. of pump controller program can be checked by using monitoring function (Code: 20229) Assembly part No. of machine monitor program can be checked by using monitoring function (Code: 20227) Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine Related information
q q
Cause 1 Defective machine monitor
2 Defective pump controller
40-303 30
Procedure, measuring location, criteria and remarks 1. Use monitoring function to display assembly part number and check whether it is identical to that listed in Parts book. Defective machine monitor (a different model is registered) 1. Use monitoring function to display assembly part number and check whether it is identical to that listed in Parts book. Defective pump controller (a different model is registered)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DAFGMC] GPS Module Error
SEN06135-00
Failure code [DAFGMC] GPS Module Error Action level
Failure code
– Detail of failure Action of machine monitor
DAFGMC
Failure
GPS module error (KOMTRAX system)
q
Position data is not sent from GPS module (in KOMTRAX terminal) to KOMTRAX communication modem in 50 seconds after KOMTRAX started.
q
None in particular If cause of failure disappears, machine becomes normal by itself.
q
Problem on machine Related information
q
Method of reproducing failure code: Turn starting switch to ON position (wait at least 50 seconds after starting switch is turned to ON position).
Cause 1 Defective KOMTRAX terminal
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks GPS module in KOMTRAX terminal may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-303
31
303 Troubleshooting by failure code, Part 3 Failure code [DAFQKR] CAN2 Discon
SEN06135-00
Failure code [DAFQKR] CAN2 Discon Action level
Failure code
–
DAFQKR
Detail of failure
Failure
CAN 2 Disconnection (Detected by KOMTRAX terminal) (KOMTRAX system)
q
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
q
KOMTRAX system may not function normally.
q
Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is notified to each controller by ACC signal from starting switch. Failure code is transmitted to and displayed on machine monitor by CAN communication. Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed on machine monitor and it can be observed only through KOMTRAX system. Since each controller and machine monitor are connected to continuous power supply, they receive continuous power even while starting switch is at OFF position. Since active CAN communication line signal is pulse voltage, it cannot be measured by using multimeter.
Action of controller Problem on machine
q q
Related information
q q
Cause 1
Defective power supply to machine monitor
2 Defective CAN communication
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Procedure, measuring location, criteria and remarks Perform troubleshooting for "E-5" in E mode troubleshooting. Perform checks on cause 5 and up in troubleshooting for failure code [DB2QKR].
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DAZ9KQ] A/C Model Selection Abnormality
SEN06135-00
Failure code [DAZ9KQ] A/C Model Selection Abnormality Action level
Failure code
–
DAZ9KQ
Detail of failure
Failure
Air Conditioner Model Selection Abnormality (Machine monitor system)
q
Model registered in the machine monitor and air conditioner controller differs. (Machine monitor or air conditioner controller has been replaced with a wrong part.)
q
Machine does not operate normally
q
Model code registered in air conditioner controller can not be checked by using monitoring function. Model codes registered in machine monitor can be checked by using monitoring function. (Code: 00500) Air conditioner control data (series and model) in the machine monitor can be checked by using monitoring function. (Code: 55200) Air conditioner control data (series and model) in the air conditioner controller can be checked by using monitoring function. (Code: 55201) (It is normal if control data is 01 (which means PC).) Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine
q
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Defective machine monitor (a different model is registered)
2 Defective air conditioner controller
Defective air conditioner controller (a different model is registered)
PC200, 200LC, 220, 220LC-8M0
40-303
33
303 Troubleshooting by failure code, Part 3 Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
SEN06135-00
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) Action level
Failure code
L01 Detail of failure Action of controller
DAZQKR q q q q
Problem on machine
q q q q q q
Related information q q
Failure
CAN2 Disconnection (Air Conditioner ECU) (Detected by machine monitor) (Machine monitor system)
Machine monitor does not recognize air conditioner controller over CAN communication-2 line (KOMNET/c). Holds information at the time of occurrence of failure. If cause of failure disappears, machine becomes normal by itself. Failure codes to be generate by air conditioner controller are not displayed. Monitoring data for which air conditioner controller is responsible are not updated. Air conditioner will be inoperable. Air conditioner control screen will not be displayed correctly on the machine monitor. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. For CAN communication error over CAN communication-2 line, machine monitor can generate four failure codes; [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR]. When all of these four failure codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). Since each controller and machine monitor are connected to continuous power supply, they receive continuous power even while starting switch is at OFF position. Since active CAN communication line signal is pulse voltage, it cannot be measured by using multimeter.
Cause
Procedure, measuring location, criteria and remarks
Defective power supply to air con- a Perform troubleshooting in Chapter 80 "Troubleshooting for power supply ditioner controller system". Defective CAN2 communication 2 Perform checks on cause 4 to 9 in troubleshooting for failure code [DB2QKR]. system If no failure is found by above checks, air conditioner controller is defective. 3 Defective air conditioner controller (Since this is an internal defect, troubleshooting cannot be performed.) 1
4 Defective machine monitor
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If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
PC200, 200LC, 220, 220LC-8M0
SEN06135-00
40-303
35
303 Troubleshooting by failure code, Part 3 Failure code [DB2QKR] CAN2 Discon (Engine Con)
SEN06135-00
Failure code [DB2QKR] CAN2 Discon (Engine Con) Action level
Failure code
L03 Detail of failure Action of controller
Failure
DB2QKR
CAN 2 Disconnection Engine controller (Detected by machine monitor) (Machine monitor system)
q
Machine monitor cannot recognize engine controller through CAN communication 2 line (KOMNET/c).
q
Holds information at the time of occurrence of failure.
Information to be obtained from engine controller is not displayed and special functions that use them do not work. Or, received data is no longer updated. (such as failure codes and monitoring codes sent from engine controller) q Method of reproducing failure code: Turn starting switch to ON position. q Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. q Machine monitor indicates a CAN communication error in CAN2 with failure code [DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are displayed, harness (CAN communication line) may have ground fault, short circuit, or hot short circuit. Since air conditioner is also controlled via CAN communication, check whether air conditioner is operated (ON/OFF and Related inforair flow adjustment) on air conditioner screen. mation a Air conditioner can be operated even when failure code is displayed on machine monitor screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or hot short circuit in wiring harness (CAN communication line). q Since each controller and machine monitor are connected to continuous power supply, they receive continuous power even while starting switch is at OFF position. q Since active CAN communication line signal is pulse voltage, it cannot be measured by using multimeter. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks
Defective fuses Nos. No.19 (30 A) 1. Turn starting switch to OFF position. 1 for (engine controller) in fuse box 2. Remove fuses No.19 (30 A) from fuse box F01. q When fuse is blown, engine controller may have short circuit in it. F01 a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2 Defective engine controller 2. Disconnect connector CE03, and connect T-adapters to male side. Between CE03 (male) (3) and (1)
3
Improper power supply to engine controller
a 1. 2. 3. a
Between CE03 (female) (3) and (1) Defective CAN terminating resis4 tor (internal open or short circuit)
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Resistance
Min. 10 z
Check ground terminal T12 for looseness and rust. Turn starting switch to OFF position. Disconnect connector CE03, and connect T-adapters to female side. Turn starting switch to ON position. If result is abnormal, perform troubleshooting for [CA441]. Voltage
20 to 30 V
1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and K02, and connect T-adapters to each male side. Between K02 (male) (A) and (B)
Resistance 120 ± 12 z
Between CM02 (male) (7) and (9)
Resistance 120 ± 12 z
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DB2QKR] CAN2 Discon (Engine Con)
Cause
SEN06135-00
Procedure, measuring location, criteria and remarks
q CAN communication line a Machine monitor also has 120 z CAN terminating resistor in it. Since 120 z resistors are connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, there is no open circuit in wiring harness. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect related connectors and connect T-adapters to connector at which measurement is performed. a If short circuit occurs (if resistance between terminals is 1 z or less), disconnect all CAN communication connectors of each controller. Then, check whether short circuit is in wiring harness or within controller. Open or short circuit in wiring har5 Approx. ness Between CM02 (female) (8) and (9) Resistance 120 z Approx. Between CE02 (female) (46) and (47) Resistance 60 z Approx. Between C01 (female) (45) and (64) Resistance 60 z Approx. Between AC01 (female) (1) and (2) Resistance 60 z Approx. Between CK01 (female) (10) and (11) Resistance 60 z Approx. Between K02 (female) (A) and (B) Resistance 120 z q ACC signal from starting switch (CAN communication start is not recognized) 1. Turn starting switch to OFF position, and disconnect battery ground cable. 2. Disconnect connector at which measurement is performed and insert T-adapters into it. 3. Connect battery ground cable, and turn starting switch to ON position. Between CM01 (10) and (3) Voltage 20 to 30 V
Open circuit in wiring harness 6 (wire breakage or defective contact of connector)
Between CE02(39) and CE03(1)
Voltage
20 to 30 V
Between C01 (24), (43) and (79) and (2)
Voltage
20 to 30 V
Between AC02 (4) and (1)
Voltage
20 to 30 V
Between CK02 (3) and (1) Voltage 20 to 30 V a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position, and disconnect battery ground cable. 2. Disconnect related connectors and connect T-adapters to female side of connector at which measurement is performed. Between CM02 (female) (8) and C01 (female) (45) Resistance Max. 1 z Resistance
Max. 1 z
Between CM02 (female) (8) and CE02 (female) (46) Resistance
Max. 1 z
Between CM02 (female) (9) and CE02 (female) (47) Resistance
Max. 1 z
Between CM02 (female) (8) and AC01 (female) (2)
Resistance
Max. 1 z
Between CM02 (female) (9) and AC01 (female) (1)
Resistance
Max. 1 z
Between CM02 (female) (9) and C01 (female) (64)
7
Ground fault in wiring harness (contact with ground circuit)
PC200, 200LC, 220, 220LC-8M0
Between CM02 (female) (8) and CK01 (female) (10) Resistance
Max. 1 z
Between CM02 (female) (9) and CK01 (female) (11) Resistance
Max. 1 z
Between CE02 (female) (46) and K02 (female) (A)
Max. 1 z
Resistance
Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z a If no failure is found by checks on cause 5 (no open circuit), measure voltage at one connector. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect related connectors and connect T-adapters to female side of connector at which measurement is performed. Between ground and any point in C01 (female) (45), Resistance Min. 1 Mz CM02 (female) (7), (8) or CE02 (female) (46) Between ground and any point in C01 (female) (64), Resistance Min. 1 Mz CM02 (female) (9) or CE02 (female)(47)
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37
303 Troubleshooting by failure code, Part 3 Failure code [DB2QKR] CAN2 Discon (Engine Con)
SEN06135-00
Cause
Procedure, measuring location, criteria and remarks
a If no failure is found by check on cause 5 (no open circuit), measure in only one place each. 1. Turn starting switch to OFF position, and disconnect battery ground cable. 2. Disconnect connector at which measurement is performed and insert T-adapters into connector. 3. Connect battery ground cable. 4. Turn starting switch to ON position. Short circuit or hot short circuit in a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including during 8 wiring harness (contact with 24 V communication, harnesses are considered normal as long as their voltages (contact with 24 V circuit) are between 1 and 4 V. Between ground and any one of CM02 (female) (8), C01 (female) (45), CK01 (female) (10), AC01 Voltage 1 to 4 V (female) (2), CE02(female)(46) Between ground and any one of CM02 (female) (9), C01 (female) (64), CK01 (female) (11), AC01 Voltage 1 to 4 V (female) (1), CE02 (female) (47) If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR] are displayed a Repeat following steps 1. to 3. to disconnect controllers one by one from CAN communication and to identify defective controller. 1. Turn starting switch to OFF position and disconnect battery ground cable. Defective engine controller, pump 2. Disconnect CAN communication connector of engine controller (connector CE03), pump controller (connector CP01), air conditioner unit (connector 9 controller, air conditioner unit or AC01),and KOMTRAX terminal (connector CK01) one by one. KOMTRAX terminal 3. Connect battery ground cable, turn starting switch to ON position, then perform troubleshooting. 4. Return to step 1. and troubleshoot next controller. Has the number of displayed failure codes If YES, disconnected decreased from four? controller is defective. q
10 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
11 Defective machine monitor
If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-303 38
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DB2QKR] CAN2 Discon (Engine Con)
SEN06135-00
Circuit diagram related to CAN communication 2
PC200, 200LC, 220, 220LC-8M0
40-303
39
303 Troubleshooting by failure code, Part 3 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
SEN06135-00
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit Action level
Failure code
L01 Detail of failure Action of controller Problem on machine Related information
Failure
DGH2KB
Hydraulic Oil Sensor Short Circuit (Pump controller system)
q
Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller determines that circuit shorts.
q
If cause of failure disappears, machine becomes normal by itself.
q
Regardless of the hydraulic oil temperature, hydraulic oil temperature gauge meter is equivalent to 50 degrees. Signal voltage from hydraulic oil temperature sensor can be checked with monitoring function. (Code: 04402: Hydraulic oil temperature sensor voltage) Method of reproducing failure code: Start engine.
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector P22 and connect T-adapters to male side.
Defective hydraulic oil tempera1 ture sensor (internal open or short circuit)
Between P22 (male) (1) and (2) a Temperature-Resistance characteristics of oil temperature sensor
10 °C
Resistance
Approx. 90 kz
30 °C
Resistance
Approx. 35 kz
80 °C
Resistance
Approx. 6.5 kz
100 °C
Resistance
Approx. 3.5 kz
Resistance
Min. 1 Mz
Between P22 (male) (2) and ground 1. 2. 3. a
Turn starting switch to OFF position. Disconnect connector P22 and connect T-adapters to female side. Turn starting switch to ON position. Open circuit or short circuit or If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir2 ground fault or hot short circuit in cuit, and if voltage is 24 V, wiring harness has hot short circuit. wiring harness a Voltage of about 5 V is applied to temperature sensor signal lines through resistor in pump controller. Between P22 (female) (1) and (2)
Voltage
Approx. 5 V
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. a Use Temperature-Resistance characteristics table for troubleshooting on cause 1 as resistance criteria. Short circuit or ground fault in wira If resistance is above 1 Mz, wiring harness has open circuit. If resistance 3 ing harness is below 1 z, wiring harness has short circuit.
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective pump controller
40-303 40
Between C01 (female) (29) and (46)
Resistance
3.5 to 90 kz
Between C01 (female) (29) and ground
Resistance
Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P22, and connect T-adapters to either female side. Between C01 (female) (29) and ground, or Resistance Min. 1 Mz between P22 (female) (2) and ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
SEN06135-00
Circuit diagram related to hydraulic oil temperature sensor
PC200, 200LC, 220, 220LC-8M0
40-303
41
303 Troubleshooting by failure code, Part 3 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
SEN06135-00
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit Action level
Failure code
L01
DHA4KA
Failure
Air cleaner clogging sensor open circuit (Machine monitor system)
q
Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so machine monitor determines that air cleaner is clogged (switch contact is open).
Action of controller
q
Displays air cleaner clogging monitor in red on machine monitor.
Problem on machine
q
If machine is used as it is, engine may be broken.
q
Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using monitoring function (Code: 04501 Monitor input: 2). Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
Related information
q
Cause
Procedure, measuring location, criteria and remarks
Open circuit in air cleaner clogging 1 Perform troubleshooting for failure code [AA10NX]. sensor
40-303 42
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
PC200, 200LC, 220, 220LC-8M0
SEN06135-00
40-303
43
303 Troubleshooting by failure code, Part 3 Failure code [DHPAMA] F Pump Press Sensor Abnormality
SEN06135-00
Failure code [DHPAMA] F Pump Press Sensor Abnormality Action level
Failure code
L01
Failure
DHPAMA
Front Pump Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
q
Automatic travel speed selector function does not work. Straight travel performance or steering performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Front pump pressure can be checked with monitoring function. (Code: 01100 F pump pressure). q Method of reproducing failure code: Turn starting switch to ON position or start engine. q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
2
Defective front pump pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-303 44
Turn starting switch to OFF position. Disconnect connector P25, and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P25 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P25. 3. Turn starting switch to ON position. Sensor outBetween P25 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P25 with connector P26 of R pump PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, front pump pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P25, and connect T-adapters to each female side. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P25 (female) (1) Between C01 (female) (49) and P25 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P25 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P25, and connect T-adapters to either female side. Between C01 (female) (49) or P25 (female) (2) and Resistance Min. 1 Mz ground
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DHPAMA] F Pump Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V or 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P25. Connect T-adapters to female side of connector P25. Turn starting switch to ON position.
Between P25 (female) (2) and ground 6 Defective pump controller
SEN06135-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to front pump pressure sensor
PC200, 200LC, 220, 220LC-8M0
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45
303 Troubleshooting by failure code, Part 3 Failure code [DHPBMA] R Pump Press Sensor Abnormality
SEN06135-00
Failure code [DHPBMA] R Pump Press Sensor Abnormality Action level
Failure code
L01
DHPAMA
Failure
Rear Pump Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic travel speed selector function does not work. Straight travel performance or steering performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Rear pump pressure can be checked with monitoring function. (Code: 01101 R pump pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P26, and connect T-adapters to female side. 1 3. Turn starting switch to ON position. 1 system a If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P26 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Connect T-adapters to connector P26. 3. Turn starting switch to ON position. Sensor outBetween P26 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault Defective rear pump pressure senor hot short circuit in wiring harness. Check as below. 2 sor (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P26 with connector P25 of front pump PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, rear pump pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P26, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P26 (female) (1) tact of connector) Between C01 (female) (68) and P26 (female) (2) Resistance Max. 1 z
4
Ground fault in wiring harness (contact with ground circuit)
40-303 46
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P26 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P26, and connect T-adapters to either female side. Between C01 (female) (68) or P26 (female) (2) and Resistance Min. 1 Mz ground
PC200, 200LC, 220, 220LC-8M0
303 Troubleshooting by failure code, Part 3 Failure code [DHPBMA] R Pump Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P26. Connect T-adapters to female side of connector P26. Turn starting switch to ON position.
Between P26 (female) (2) and ground 6 Defective pump controller
SEN06135-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to rear pump pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-303
47
SEN06135-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06135-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-303
48
SEN06136-00 SEN05988-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 304 Troubleshooting by failure code, Part 4 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ............................................................
4
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ....................................................
6
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality.......................................................
8
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ...................................................... 10 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .......................................................... 12 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................................... 14 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ........................................................ 16 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................... 18 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality....................................................... 20 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................................... 22 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality ...................................................... 24 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ...................................................... 26 Failure code [DHX1MA] Overload Sensor Abnormality .............................................................................. 28 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality............................................................. 30 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality............................................................. 32 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................................... 34 Failure code [DW43KA] Travel Speed Sol Open Circuit ............................................................................. 36 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................. 38 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit ................................................................... 40 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................. 42
PC200, 200LC, 220, 220LC-8M0
40-304
1
SEN06136-00
304 Troubleshooting by failure code, Part 4
Failure code [DW91KA] Travel Neutral Sol Open Circuit ............................................................................ 44 Failure code [DW91KB] Travel Neutral Sol Short Circuit ............................................................................ 46
40-304 2
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4
PC200, 200LC, 220, 220LC-8M0
SEN06136-00
40-304
3
304 Troubleshooting by failure code, Part 4 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality Action level
Failure code
L01
DHS3MA
Failure
Arm Curl PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of arm IN deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Arm IN PPC pressure can be checked with monitoring function. (Code: 07200 Arm IN PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
2
Defective arm IN PPC pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 4
Turn starting switch to OFF position. Disconnect connector P04 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P04 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P04. 3. Turn starting switch to ON position. Sensor outBetween P04 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P04 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P04, and connect T-adapters to each female side. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P04 (female) (1) Between C01 (female) (17) and P04 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P04 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P04, and connect T-adapters to either female side. Between C01 (female) (17) or P04 (female) (2) and Resistance Min. 1 Mz ground
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P04. Connect T-adapters to female side of connector P04. Turn starting switch to ON position.
Between P04 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to arm in PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
5
304 Troubleshooting by failure code, Part 4 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality Action level
Failure code
L01
DHS4MA
Failure
Bucket CURL PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of bucket CURL deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Bucket CURL PPC pressure can be checked with monitoring function. (Code: 07300 Bucket CURL PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P01 and connect T-adapters to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P01 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P01. 3. Turn starting switch to ON position. Sensor outBetween P01 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault Defective bucket CURL PPC pres2 or hot short circuit in wiring harness. Check as below. sure sensor (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P01 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, bucket CURL PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P01, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P01 (female) (1) tact of connector) Between C01 (female) (73) and P01 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-304 6
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P01 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P01, and connect T-adapters to either female side. Between C01(female) (73) and ground, or between Resistance Min. 1 Mz P01 (female) (2) and ground
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P01. Connect T-adapters to female side of connector P01. Turn starting switch to ON position.
Between P01 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to bucket curl PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
7
304 Troubleshooting by failure code, Part 4 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality Action level
Failure code
L01
DHS8MA
Detail of failure
q
Failure
Boom Raise PPC Pressure Sensor Abnormality (Pump controller system)
Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself. q Automatic deceleration does not cancel. q Controllability of boom RAISE deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Boom RAISE PPC pressure can be checked with monitoring function. (code: 07400 Boom RAISE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Action of controller Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Turn starting switch to OFF position. Disconnect connector P06 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P06 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters in connector P06. 3. Turn starting switch to ON position. Sensor outBetween P06 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot Defective boom RAISE PPC short circuit in wiring harness. Check as below. 2 pressure sensor (internal 1. Turn starting switch to OFF position. defect) 2. Replace connector P06 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, boom RAISE PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P06, and connect T-adapters to each female side. a If power supply voltage measured in check on cause Open circuit in wiring har1 is normal, this check is not required. Resistance Max. 1 z ness (wire breakage or 3 defective contact of connec- Between C01 (female) (18) and P06 (female) (1) Between C01 (female) (53) and P06 (female) (2) Resistance Max. 1 z tor)
Defective 5V sensor power 1 supply 1 system
1. 2. 3. a
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P06 (female) (3) 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C01 and P06, and connect T-adapters to either female 4 ness (contact with ground side. Between C01 (female) (53) and ground, or between P06 circuit) Resistance Min. 1 Mz (female) (2) and ground 1. Turn starting switch to OFF position. Hot short circuit in wiring har- 2. Disconnect connector P06. 5 ness (contact with 24 V cir- 3. Connect T-adapters to female side of connector P06. 4. Turn starting switch to ON position. cuit) Between P06 (female) (2) and ground
40-304 8
Voltage
Max. 1 V
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Cause 6 Defective pump controller
SEN06136-00
Procedure, measuring location, criteria and remarks If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to boom raise PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
9
304 Troubleshooting by failure code, Part 4 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality Action level
Failure code
L01
DHS9MA
Failure
Boom Lower PPC pressure sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of boom LOWER pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
If cause of failure disappears, machine becomes normal by itself.
Automatic deceleration does not cancel. Controllability of boom LOWER deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Boom lower PPC pressure can be checked with monitoring function. (Code: 07500 Boom LOWER PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Defective 5 V sensor power sup1 ply 2 line
2
Defective boom LOWER PPC pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 10
1. 2. 3. a
Turn starting switch to OFF position. Disconnect connector P02 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P02 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P02. 3. Turn starting switch to ON position. Sensor outBetween P02 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P02 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, boom LOWER PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P02, and connect T-adapters to each female side. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P02 (female) (1) Between C01 (female) (14) and P02 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P02 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P02, and connect T-adapters to either female side. Between ground and C01 (female) (14) and ground, Resistance Min. 1 Mz or between P02 (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P02. Connect T-adapters to female side of connector P02. Turn starting switch to ON position.
Between P02 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to boom lower PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
11
304 Troubleshooting by failure code, Part 4 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality Action level
Failure code
L01
DHSAMA
Failure
Swing Right PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of swing RIGHT deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Swing RIGHT PPC pressure can be checked with monitoring function. (Code 09002: Swing RIGHT PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P07, and connect T-adapters to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P07 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Connect T-adapters to connector P07. 3. Turn starting switch to ON position. Sensor outBetween P07 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault Defective swing RIGHT PPC pres2 or hot short circuit in wiring harness. Check as below. sure sensor (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P07 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P07, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P07 (female) (1) tact of connector) Between C01 (female) (72) and P07 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-304 12
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P07 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P07, and connect T-adapters to either female side. Between ground and C01 (female) (72) or P07 Resistance Min. 1 Mz (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P07. Connect T-adapters to female side of connector P07. Turn starting switch to ON position.
Between P07 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to swing right PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
13
304 Troubleshooting by failure code, Part 4 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality Action level
Failure code
L01
DHSBMA
Failure
Swing Left PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of swing LEFT deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Swing LEFT PPC pressure can be checked with monitoring function. (Code 09001: Swing LEFT PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P03 and connect T-adapters to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P03 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P03. 3. Turn starting switch to ON position. Sensor outBetween P03 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective swing left PPC pressure is difficult to judge whether cause of failure is defective sensor, ground fault 2 sensor or hot short circuit in wiring harness. Check as below. (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P03 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P03, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P03 (female) (1) tact of connector) Between C01 (female) (16) and P03 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-304 14
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P03 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P03, and connect T-adapters to either female side. Between ground and C01 (female) (16) or P03 Resistance Min. 1 Mz (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P03. Connect T-adapters to female side of connector P03. Turn starting switch to ON position.
Between P03 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to swing left PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
15
304 Troubleshooting by failure code, Part 4 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality Action level
Failure code
L01
DHSCMA
Failure
Arm Dump PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
If cause of failure disappears, machine becomes normal by itself.
Automatic deceleration does not cancel. The operativity of arm dumping is bad. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Related inforq Arm OUT PPC pressure can be checked with monitoring function. mation (Code: 07600 Arm OUT PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine, and select arm crane mode (L). Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first. 1. 2. 3. a
Turn starting switch to OFF position. Disconnect connector P08, and connect T-adapters to female side. Defective 5 V sensor power sup1 Turn starting switch to ON position. ply 2 line If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P08 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P08. 3. Turn starting switch to ON position. Sensor outBetween P08 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault Defective arm OUT PPC pressure 2 or hot short circuit in wiring harness. Check as below. sensor (internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P08 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again in this failure code column, arm OUT PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P08, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P08 (female) (1) tact of connector) Between C01 (female) (15) and P08 (female) (2) Resistance Max. 1 z
4
Ground fault in wiring harness (contact with ground circuit)
40-304 16
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P08 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P08, and connect T-adapters to either female side. Between ground and C01 (female) (15) or P08 Resistance Min. 1 Mz (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P08. Connect T-adapters to female side of connector P08. Turn starting switch to ON position.
Between P08 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to arm out PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
17
304 Troubleshooting by failure code, Part 4 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality Action level
Failure code
L01
DHSDMA
Detail of failure
q
Failure
Bucket Dump PPC Pressure Sensor Abnormality (Pump controller system)
Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm2}. q If cause of failure disappears, machine becomes normal by itself. q Automatic deceleration does not cancel. q Controllability of bucket DUMP deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Bucket DUMP PPC pressure can be checked with monitoring function. (Code: 07301 Bucket DUMP PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Action of controller Problem on machine
q
Cause
1
2
3
4
5
Procedure, measuring location, criteria and remarks
If failure code [DA25KP] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P05 and connect T-adapters to female side. 3. Turn starting switch to ON position. 1 system a If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P05 (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P05. 3. Turn starting switch to ON position. Sensor outBetween P05 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault Defective bucket DUMP PPC presor hot short circuit in wiring harness. Check as below. sure sensor (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P05 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, bucket DUMP PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P05, and connect T-adapters to each female side. a If power supply voltage measured in check on Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z (wire breakage or defective con- Between C01 (female) (18) and P05 (female) (1) tact of connector) Between C01 (female) (34) and P05 (female) (2) Resistance Max. 1 z a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P05 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P05, and connect T-adapters to either Ground fault in wiring harness female side. (contact with ground circuit) Between ground and C01 (female) (34) or P05 Resistance Min. 1 Mz (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connector P05. Hot short circuit in wiring harness 3. Connect T-adapters to female side of connector P05. (contact with 24 V circuit) 4. Turn starting switch to ON position. Between P05 (female) (2) and ground Voltage Max. 1 V
40-304 18
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Cause 6 Defective pump controller
SEN06136-00
Procedure, measuring location, criteria and remarks If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to bucket dump PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
19
304 Troubleshooting by failure code, Part 4 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality Action level
Failure code
L01
DHSFMA
Failure
Travel Left Forward PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of right travel REVERSE deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Left travel FORWARD PPC pressure can be checked with monitoring function. (Code: 07102 Left travel FORWARD PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
Defective left travel FORWARD 2 PPC presure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 20
Turn starting switch to OFF position. Disconnect connector P09, and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P09 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P09. 3. Turn starting switch to ON position. Sensor outBetween P09 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P09 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, left travel FORWARD PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P09, and connect T-adapters to each female side. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P09 (female) (1) Between C01 (female) (54) and P09 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (8) and P09 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P09, and connect T-adapters to either female side. Between ground and C01 (female) (54) or P09 Resistance Min. 1 Mz (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P09. Connect T-adapters to female side of connector P09. Turn starting switch to ON position.
Between P09 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
21
304 Troubleshooting by failure code, Part 4 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality Action level
Failure code
L01
DHSGMA
Failure
Travel Right Forward PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of right travel REVERSE deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Right travel FORWARD PPC pressure can be checked with monitoring function. (Code: 07103 Right travel FORWARD PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
Defective right travel FORWARD 2 PPC pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 22
Turn starting switch to OFF position. Disconnect connector P11 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P11 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P11. 3. Turn starting switch to ON position. Sensor outBetween P11 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P11 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, right travel FORWARD PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P11 and connect T-adapters to each female side of them. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P11 (female) (1) Between C01 (female) (55) and P11 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (8) and P11 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P11 and connect T-adapter to female side of either connector. Between C01 (female) (55) or P11 (female) (2) and Resistance Min. 1 Mz ground
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P11. Connect T-adapters to female side of connector P11. Turn starting switch to ON position.
Between P11 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
23
304 Troubleshooting by failure code, Part 4 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality Action level
Failure code
L01
DHSHMA
Failure
Travel Left Backward PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of right travel REVERSE deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Left travel REVERSE PPC pressure can be checked with monitoring function. (Code: 07104 Left travel REVERSE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
Defective left travel REVERSE 2 PPC pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 24
Turn starting switch to OFF position. Disconnect connector P10 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P10 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P10. 3. Turn starting switch to ON position. Sensor outBetween P10 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P10 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, left travel REVERSE PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P10, and connect T-adapters to each female side. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P10 (female) (1) Between C01 (female) (35) and P10 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (8) and P10 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P10, and connect T-adapters to either female side. Between ground and C01 (female) (35) or P10 Resistance Min. 1 Mz (female) (2)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P10. Connect T-adapters to female side of connector P10. Turn starting switch to ON position.
Between P10 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
25
304 Troubleshooting by failure code, Part 4 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
SEN06136-00
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality Action level
Failure code
L01
DHSJMA
Failure
Travel Right Backward PPC Pressure Sensor Abnormality (Pump controller system)
Detail of failure
q
Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q
Automatic deceleration does not cancel. Controllability of right travel REVERSE deteriorates. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meaRelated inforsured at pump controller connector. mation q Right travel REVERSE PPC pressure can be checked with monitoring function. (Code: 07105 Right travel REVERSE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
1. Defective 5V sensor power supply 2. 1 3. 1 system a
Defective right travel REVERSE 2 PPC pressure sensor (internal defect)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
40-304 26
Turn starting switch to OFF position. Disconnect connector P12 and connect T-adapters to female side. Turn starting switch to ON position. If power supply voltage is abnormal, proceed to check on cause 3. Power supBetween P12 (female) (3) and (1) Voltage 4.5 to 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector P12. 3. Turn starting switch to ON position. Sensor outBetween P12 (2) and (1) Voltage 0.5 to 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause of failure is defective sensor, ground fault or hot short circuit in wiring harness. Check as below. 1. Turn starting switch to OFF position. 2. Replace connector P12 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, right travel REVERSE PPC pressure sensor is defective. a After finishing test, restore connectors. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P12, and connect T-adapters to each female side of them. a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and P12 (female) (1) Between C01 (female) (36) and P12 (female) (2)
Resistance
Max. 1 z
a If power supply voltage measured in check on cause 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (8) and P12 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P12, and connect T-adapter to female side of either connector. Between C01 (female) (36) or P12 (female) (2) and Resistance Min. 1 Mz ground
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P12. Connect T-adapters to female side of connector P12. Turn starting switch to ON position.
Between P12 (female) (2) and ground 6 Defective pump controller
SEN06136-00
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC200, 200LC, 220, 220LC-8M0
40-304
27
304 Troubleshooting by failure code, Part 4 Failure code [DHX1MA] Overload Sensor Abnormality
SEN06136-00
Failure code [DHX1MA] Overload Sensor Abnormality Action level
Failure code
L04
DHX1MA
Failure
Overload Sensor Abnormality (Pump controller system)
Detail of failure
q
Monitor (overload alarm monitor) which is not set to be displayed is displayed.
Action of controller
q q
None in particular If cause of failure disappears, machine becomes normal by itself.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause 1 Defective pump controller
40-304 28
Procedure, measuring location, criteria and remarks Pump controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DHX1MA] Overload Sensor Abnormality
PC200, 200LC, 220, 220LC-8M0
SEN06136-00
40-304
29
304 Troubleshooting by failure code, Part 4 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
SEN06136-00
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality Action level
Failure code
L01
DR21KX
Failure
Camera 2 Picture Reverse Drive Abnormality (Machine monitor system)
q
Output voltage of camera 2 image reverse drive line (pin 6 of connector CM04) differs from command voltage output from machine monitor.
Action of controller
q
Does not display image of camera 2.
Problem on machine
q
Image of camera 2 is not displayed.
q
When output voltage of camera 2 image reverse drive line (pin 6 of connect CM04) is 0 V, original image is sent. When it is 8 V, mirror image is sent (since power supply voltage of camera is 8 V, 8 V is used as command voltage to sent mirror image). You must check connector A41 to identify which camera is assigned to camera 2. Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
Related information
q q
Cause Open circuit in wiring harness 1 (wire breakage or defective contact of connector)
2
Ground fault in wiring harness (contact with ground circuit)
3
Hot short circuit in wiring harness (contact with 24 V circuit)
4 Short circuit in wiring harness
5 Defective camera 2 6 Defective machine monitor
40-304 30
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female side. Between CM04 (female) (6) and A46 (female) (3)
Resistance
Max. 1 z
Between CM04 (female) (5) and A46 (female) (4)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors CM04 and A46, and connect T-adapters to either female side. Between ground and CM04 (female) (6) or A46 Resistance Min. 1 Mz (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connector A46 and connect T-adapters to female side. 3. Turn starting switch to ON position. a Check that camera 2 is set for original images. Between A46 (female) (3) and (4), or between A46 Voltage Max. 1 V (female) (3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connector CM04, A46 and connect T-adapters to CM04 female side. Between CM04 (female) (6) and each pin other Resistance Max. 1 z than pin (6) If no failure is found by above checks, camera 2 is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
SEN06136-00
Circuit diagram related to camera
PC200, 200LC, 220, 220LC-8M0
40-304
31
SEN06136-00
304 Troubleshooting by failure code, Part 4 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality a This failure code does not relate to this machine because it is not equipped with camera 3. This failure code is provided in case where camera 3 is installed in future. a If this failure code appears, clear failure code by referring to "Classification and procedures for troubleshooting".
40-304 32
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
PC200, 200LC, 220, 220LC-8M0
SEN06136-00
40-304
33
304 Troubleshooting by failure code, Part 4 Failure code [DV20KB] Travel Alarm Short Circuit
SEN06136-00
Failure code [DV20KB] Travel Alarm Short Circuit Action level
Failure code
L01
DV20KB
Detail of failure Action of controller Problem on machine Related information
Failure
Travel Alarm Short Circuit (Pump controller system)
q
Abnormal current flows when pump controller drives travel alarm circuit.
q q
Stops driving travel alarm circuit. Even if cause of failure disappears, machine does not become normal until starting switch is set to OFF position.
q
Travel alarm does not sound.
q
Operation (ON or OFF) of travel alarm can be checked with monitoring function. (Code: 03701 Controller output 2) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector.
q
Cause
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
1
2
Defective travel alarm (internal defect)
Ground fault in wiring harness (contact with ground circuit)
3 Defective pump controller
40-304 34
Turn starting switch to OFF position. Disconnect connector M14, and connect T-adapters to female side. Turn starting switch to ON position. Operate travel lever to perform troubleshooting. Travel lever: Voltage Max. 1 V NEUTRAL Between M14 (female) (1) and (2) Travel lever: Voltage 20 to 30 V Operated a If the above voltage is normal but travel alarm does not sound, travel alarm is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M14, and connect T-adapters to either female side. Between C02 (female) (107) and ground, or Resistance Min. 1 Mz between M14 (female) (1) and ground 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector M14. 3. Turn starting switch to ON position. 4. Operate travel lever to perform troubleshooting. Travel lever: Voltage Max. 1 V NEUTRAL Between M14 (1) and (2) Travel lever: Voltage 20 to 30 V Operated
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DV20KB] Travel Alarm Short Circuit
SEN06136-00
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0
40-304
35
304 Troubleshooting by failure code, Part 4 Failure code [DW43KA] Travel Speed Sol Open Circuit
SEN06136-00
Failure code [DW43KA] Travel Speed Sol Open Circuit Action level
Failure code
L01 Detail of failure
DW43KA q
Action of controller
q
Problem on machine
q
q
q
Related information q
Failure
Travel Speed Solenoid Open Circuit (Pump controller system)
No current flows when pump controller drives travel speed selector solenoid, so pump controller determines that open circuit exists in travel speed selector solenoid circuit. None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself. "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still "Mi".) Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (As long as controller's command to solenoid is "ON", sensor status displayed on monitoring screen is "ON" even if solenoid is not energized due to short circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
Cause Defective travel speed selector 1 solenoid (Internal open circuit)
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04, and connect T-adapters to male side. Between V04 (male) (1) and (2)
Resistance
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Between C02 (female) (87) and each of (115) , Resistance 20 to 60 z (117) and (120) a If no failure is found by above checks , this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V04, and connect T-adapters to each female side. Between C02 (female) (87) and V04 (female) (1)
3 Defective pump controller
40-304 36
20 to 60 z
Resistance
Max. 1 z
Between V04 (female) (2) and each of C02 (female) Resistance Max. 1 z (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW43KA] Travel Speed Sol Open Circuit
SEN06136-00
Circuit diagram related to travel speed solenoid
PC200, 200LC, 220, 220LC-8M0
40-304
37
304 Troubleshooting by failure code, Part 4 Failure code [DW43KB] Travel Speed Sol Short Circuit
SEN06136-00
Failure code [DW43KB] Travel Speed Sol Short Circuit Action level
Failure code
L01
DW43KB
Detail of failure Action of controller Problem on machine Related information
q q q q q q
Failure
Travel Speed Solenoid Short Circuit (Pump controller system)
Abnormal current flows when pump controller drives travel speed selector solenoid, so pump controller determines that short circuit exists in travel speed selector solenoid circuit. Stops driving travel speed selector solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still "Mi".) Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
Cause Defective travel speed 1 selector solenoid (Internal short circuit, ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04, and connect T-adapters to male side. Between V04 (male) (1) and (2)
Resistance
20 to 60 z
Between V04 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault Between C02 (female) (87) and each of (115), (117) and 2 Resistance in wiring harness (120) Between C02 (female) (87) and ground
Resistance
20 to 60 z Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C02 and V04, and connect T-adapters to either female 3 ness side. (contact with ground circuit) Between C02 (female) (87) or V04 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an 4 Defective pump controller internal defect, troubleshooting cannot be performed.)
40-304 38
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW43KB] Travel Speed Sol Short Circuit
SEN06136-00
Circuit diagram related to travel speed solenoid
PC200, 200LC, 220, 220LC-8M0
40-304
39
304 Troubleshooting by failure code, Part 4 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit
SEN06136-00
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit Action level
Failure code
L03
DW45KA
q q
Upper structure does not swing (swing holding brake is not released).
q
If solenoid and wiring harness are normal, swing operation is possible by setting swing brake cancel switch to RELEASE position. (However, swing holding brake is not released while upper structure is stopped. swing holding brake continues to be applied.) Set swing brake cancel switch to RELEASE position during troubleshooting. When starting switch is turned to ON position in this condition, normally current can flow in swing holding brake solenoid circuit and break can be released. Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Turn starting switch to ON position. Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or No.1 of fuse box F01.
Detail of failure
Problem on machine
q
q
Related information
Swing Brake Solenoid Valve Open Circuit (Pump controller system)
Controller output voltage to solenoid is above standard value when pump controller does not drive swing holding brake solenoid, so pump controller determines that open circuit exists in swing holding brake solenoid circuit. None in particular. (Since no current flows, solenoid is not energized, so swing holding brake is kept applied.) If cause of failure disappears, machine becomes normal by itself.
q
Action of controller
Failure
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Blown fuse No. 1 (right top fuse) in If fuse is blown, see failure code [DW45KB]. fuse box F01
2
Defective swing holding brake solenoid
1. Turn starting switch to OFF position. 2. Disconnect connector V03, and connect T-adapters to male side. Between V03 (male) (1) and (2)
Resistance
20 to 60 z
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to each male side. a Check the continuity in diode range. 3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) Between D01 (male) (7) (+) and (3) (-)
No continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
1. 2. 3. a Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
Continuity
Turn starting switch to OFF position. Remove diode D01. Disconnect connector C02 and connect T-adapters to each female side. Swing lock switch OFF position.
Between C02 (female) (101) and D01 (female) (7)
Resistance
Max. 1 z
Between D01 (female) (3) and C02 (female) (115)
Resistance
20 to 60 z
a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors D01, C02, and V03, and connect T-adapters to each female side. Between D01 (female) (3) and V03 (female) (1)
5 Defective pump controller
40-304 40
Resistance
Max. 1 z
Between V03 (female) (2) and C02 (female) (115) Resistance Max. 1 z or (117) or (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit
SEN06136-00
Circuit diagram related to swing holding brake
PC200, 200LC, 220, 220LC-8M0
40-304
41
304 Troubleshooting by failure code, Part 4 Failure code [DW45KB] Swing Brake Sol Short Circuit
SEN06136-00
Failure code [DW45KB] Swing Brake Sol Short Circuit Action level
Failure code
L03
DW45KB
Detail of failure Action of controller Problem on machine
q q q
Abnormal current flows when pump controller drives swing holding brake solenoid, so pump controller determines that short circuit exists in swing holding brake solenoid circuit. Stops driving swing holding brake solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Upper structure does not swing (swing holding brake is not released).
q
If solenoid and wiring harness are normal, swing operation is possible by setting swing brake cancel switch to RELEASE position. (However, swing holding brake is not released while upper structure is stopped. swing holding brake continues to be applied.) Keep swing lock switch in OFF position and swing brake cancel switch in RELEASE position during troubleshooting. When starting switch is turned to ON position in this condition, normally current can flow in swing holding brake solenoid circuit and brake can be released. Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1) Method of reproducing failure code: Turn starting switch to ON position. swing holding brake solenoid circuit is powered from pin (101) of pump controller connector C02 or pin (1) of fuse box F01.
q q q
Cause 1
2
Swing Brake Solenoid Short Circuit (Pump controller system)
q
q
Related information
Failure
Procedure, measuring location, criteria and remarks
Blown fuse No. 1 (right top fuse) in Even if fuse is blown, perform troubleshooting according to following steps to fuse box F01 identify cause.
Defective swing holding brake solenoid
1. Turn starting switch to OFF position. 2. Disconnect connector V03, and connect T-adapters to male side. Between V03 (male) (1) and (2)
Resistance
20 to 60 z
Between V03 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to each male side. a Check the continuity in diode range. 3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) Between D01 (male) (7) (+) and (3) (-)
No continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
4
Ground fault in wiring harness (contact with ground circuit)
5 Short circuit in wiring harness
6 Defective pump controller
40-304 42
1. 2. 3. 4.
Continuity
Turn starting switch to OFF position. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01. Disconnect connectors C02, D01 and V03. Connect T-adapters to female sides of connectors C02 and D01.
Between C02 (female) (101) and ground
Resistance
Min. 1 Mz
Between D01 (female) (3) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01. 3. Disconnect connector C02. 4. Connect T-adapters to female sides of connectors D01 and C02. a Check the swing lock switch OFF position. Between D01 (female) (3) and C02 (female) (115) or (117) or (120) Resistance 20 to 60 z a Swing brake solenoid coil resistance. If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW45KB] Swing Brake Sol Short Circuit
SEN06136-00
Circuit diagram related to swing holding brake
PC200, 200LC, 220, 220LC-8M0
40-304
43
304 Troubleshooting by failure code, Part 4 Failure code [DW91KA] Travel Neutral Sol Open Circuit
SEN06136-00
Failure code [DW91KA] Travel Neutral Sol Open Circuit Action level
Failure code
L01
DW91KA
q q
Machine does not turn during travel.
q
Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine and turn machine with right and left travel levers.
Detail of failure
Problem on machine
Travel Neutral Solenoid Open Circuit (Pump controller system)
Controller output voltage to solenoid is above standard value when pump controller does not drive travel junction solenoid, so pump controller determines that open circuit exists in travel junction solenoid circuit. None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
Action of controller
Failure
q
Related information q
Cause Defective travel junction solenoid 1 (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V05, and connect T-adapters to male side. Between V05 (male) (1) and (2)
Resistance
20 to 60 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ness Between C02 (female) (110) and each of (115), Resistance 20 to 60 z (117) and (120) a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V05, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-304 44
Between C02 (female) (110) and V05 (female) (1)
Resistance
Max. 1 z
Between V05 (female) (2) and C02 (female) (115) Resistance Max. 1 z or (117) or (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW91KA] Travel Neutral Sol Open Circuit
SEN06136-00
Circuit diagram related to travel junction solenoid
PC200, 200LC, 220, 220LC-8M0
40-304
45
304 Troubleshooting by failure code, Part 4 Failure code [DW91KB] Travel Neutral Sol Short Circuit
SEN06136-00
Failure code [DW91KB] Travel Neutral Sol Short Circuit Action level
Failure code
L01
DW91KB
Detail of failure Action of controller Problem on machine
q q q
Travel Neutral Solenoid Short Circuit (Pump controller system)
Abnormal current flows when pump controller drives travel junction solenoid, so pump controller determines that short circuit exists in travel junction solenoid circuit. Stops driving travel junction solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine does not turn during travel.
q
Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine and turn machine with right and left travel levers.
Related information q
Cause Defective travel junction solenoid 1 (internal short circuit or ground fault)
2
Failure
Short circuit or ground fault in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V05, and connect T-adapters to male side. Between V05 (male) (1) and (2)
Resistance
20 to 60 z
Between V05 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Between V05 (female) (110) and each of (115), (117) Resistance 20 to 60 z and (120) Between C02 (female) (110) and ground
Ground fault in wiring har3 ness (contact with ground circuit)
4 Defective pump controller
40-304 46
Resistance
Min. 1 Mz
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V05, and connect T-adapter to female side of either of them. Between C02 (female) (110) or V05 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
304 Troubleshooting by failure code, Part 4 Failure code [DW91KB] Travel Neutral Sol Short Circuit
SEN06136-00
Circuit diagram related to travel junction solenoid
PC200, 200LC, 220, 220LC-8M0
40-304
47
SEN06136-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06136-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-304
48
SEN06137-00 SEN06009-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 305 Troubleshooting by failure code, Part 5 Failure code [DWA2KA] Attachment Sol Open Circuit................................................................................
4
Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................
6
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit............................................................................
8
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ............................................................................ 10 Failure code [DWK2KA] Variable Back Press Sol Open Circuit.................................................................. 12 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .................................................................. 14 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit................................................................................ 16 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................................ 18 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................................... 20 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................................... 22 Failure code [DXE0KA] LS-EPC Sol Open Circuit...................................................................................... 24 Failure code [DXE0KB] LS-EPC Sol Short Circuit ...................................................................................... 26 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ...................................................................... 28 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...................................................................... 30 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..................................................................... 32 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ..................................................................... 34 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit......................................................................... 36 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit......................................................................... 38 Failure code [DY20KA] Wiper Working Abnormality ................................................................................... 40 Failure code [DY20MA] Wiper Parking Abnormality ................................................................................... 42
PC200, 200LC, 220, 220LC-8M0
40-305
1
SEN06137-00
305 Troubleshooting by failure code, Part 5
Failure code [DY2CKB] Washer Drive Short Circuit.................................................................................... 44 Failure code [DY2DKB] Wiper Drive (Fwd) Short ....................................................................................... 46 Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................................ 48
40-305 2
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5
PC200, 200LC, 220, 220LC-8M0
SEN06137-00
40-305
3
305 Troubleshooting by failure code, Part 5 Failure code [DWA2KA] Attachment Sol Open Circuit
SEN06137-00
Failure code [DWA2KA] Attachment Sol Open Circuit Action level
Failure code
L03 Detail of failure Action of controller Problem on machine Related information
DWA2KA
Failure
Attachment Single/multiple selector Solenoid Open Circuit (Pump controller system)
q
Controller output voltage to ATT return selector solenoid exceeds standard value when it stops outputting drive current to ATT return selector solenoid. None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
Attachment return circuit does not change to 1-way circuit.
q
Controller's command (ON/OFF) to attachment return selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02301 Solenoid 2) Method of reproducing failure code: Turn starting switch to ON position and set machine in working mode other than breaker mode (B).
q q
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side. 1 tor solenoid (internal open circuit) Between V06 (male) (1) and (2) Resistance 20 to 60 z 1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ing harness Between C02 (female) (86) and ground Resistance 20 to 60 z
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 4
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V06, and connect T-adapters to each female side. Between C02 (female) (86) and V06 (female) (1)
Resistance
Max. 1 z
Between V06 (female) (2) and ground
Resistance
Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWA2KA] Attachment Sol Open Circuit
SEN06137-00
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
5
305 Troubleshooting by failure code, Part 5 Failure code [DWA2KB] Attachment Sol Short Circuit
SEN06137-00
Failure code [DWA2KB] Attachment Sol Short Circuit Action level
Failure code
L03 Detail of failure Action of controller Problem on machine Related information
DWA2KB q q q
Failure
Attachment single/multiple selector Solenoid Short Circuit (Pump controller system)
Abnormal current flows when pump controller drives attachment return selector solenoid, so pump controller determines that short circuit exists in attachment return selector solenoid circuit. Stops driving attachment return selector solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Attachment return circuit does not change to 1-way circuit.
q
Controller's command (ON/OFF) to attachment return selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02301 Solenoid 2) Method of reproducing failure code: Turn starting switch to ON position and set machine in breaker mode (B).
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapters to male side. 1 tor solenoid (internal short circuit Between V06 (male) (1) and (2) Resistance 20 to 60 z or ground fault) Between V06 (male) (1) and ground Resistance Min. 1 Mz 2
3
1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side. ing harness Between C02 (female) (86) and ground Resistance 20 to 60 z
Ground fault in wiring harness (contact with ground circuit)
4 Defective pump controller
40-305 6
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V06, and connect T-adapters to either female side. Between C02 (female) (86) or V06 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWA2KB] Attachment Sol Short Circuit
SEN06137-00
Circuit diagram related to ATT single/multiple selector solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
7
305 Troubleshooting by failure code, Part 5 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
SEN06137-00
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit Action level
Failure code
L01
DWK0KA q
Detail of failure Action of controller
q
Problem on machine
q
q
q q
Related information
q q q
2-stage Relief Solenoid Open Circuit (Pump controller system)
Controller output voltage to solenoid is above standard value when pump controller does not drive 2-stage relief solenoid, so pump controller determines that open circuit exists in 2-stage relief solenoid circuit. None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself. Travel power is low (main relief valve is not set to high-pressure setting). One-touch power maximizing function does not work. Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Controller detects open circuit only when it does not drive solenoid. Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Failure
Defective 2-stage relief solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V02, and connect T-adapters to male side. Between V02 (male) (1) and (2)
Resistance
20 to 60 z
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is 2 ness below 1 z, wiring harness has short circuit. Between C02 (female) (109) and each of Resistance 20 to 60 z (115), (117) and (120) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V02, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective conBetween C02 (female) (109) and V02 tact of connector) Resistance Max. 1 z (female) (1) Between V02 (female) (2) and each of C02 Resistance Max. 1 z (female) (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this 4 Defective pump controller is an internal defect, troubleshooting cannot be performed.)
40-305 8
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
SEN06137-00
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
9
305 Troubleshooting by failure code, Part 5 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
SEN06137-00
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit Action level
Failure code
L01 Detail of failure Action of controller Problem on machine
DWK0KB q q q q q q
Related information
q q q
2-stage Relief Solenoid Short Circuit (Pump controller system)
Abnormal current flows when pump controller drives 2-stage relief solenoid, so pump controller determines that short circuit exists in 2-stage relief solenoid circuit. Stops driving 2-stage relief solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is set to OFF position. Travel power is low (main relief valve is not set to high-pressure setting). One-touch power maximizing function does not work. Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Controller detects open circuit only when it does not drive solenoid. Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective 2-stage relief solenoid 1 (internal short circuit or ground fault)
2
Failure
Ground fault in wiring harness (contact with ground circuit)
3 Short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V02, and connect T-adapters to male side. Between V02 (male) (1) and (2)
Resistance
20 to 60 z
Between V02 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V02, and connect T-adapters to female side of V02. Between C02 (female) (109) or V02 (female) (1) Resistance Min. 1 Mz and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V02, and connect T-adapters to female side of V02. Between V02 (male) (1) and (2)
4 Defective pump controller
40-305 10
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
SEN06137-00
Circuit diagram related to 2-stage relief solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
11
305 Troubleshooting by failure code, Part 5 Failure code [DWK2KA] Variable Back Press Sol Open Circuit
SEN06137-00
Failure code [DWK2KA] Variable Back Press Sol Open Circuit Action level
Failure code
L01
DWK2KA
Detail of failure Action of controller Problem on machine Related information
Variable Back Pressure Solenoid Open Circuit (Pump controller system)
q
No current flows when pump controller drives variable back pressure solenoid, so pump controller determines that open circuit exists in variable back pressure solenoid circuit.
q q
None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
Set pressure of back pressure value cannot be changed.
q
Controller's command (ON/OFF) to variable back pressure solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02301 Solenoid 2) The set pressure of back pressure value becomes low by solenoid ON. Method of reproducing failure code: Turn starting switch to ON position.
q q
No.
Failure
Cause
Defective variable back pressure 1 solenoid valve (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V25, and connect T-adapter to male side. Between V25 (male) (1) and (2)
Resistance
20 to 60 z
1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side. 2 Between C02(female) (85) and each of ing harness Resistance 20 to 60 z C02(female) (115), (117), (120) a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V25, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective conBetween C02(female) (85) and V25(female) tact of connector) Resistance Max. 1 z (1) Between each of C02(female) (115), (117), Resistance Max. 1 z (120) and V25(female)(2) If no failure is found by above checks, pump controller is defective. 4 Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.)
40-305 12
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWK2KA] Variable Back Press Sol Open Circuit
SEN06137-00
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
13
305 Troubleshooting by failure code, Part 5 Failure code [DWK2KB] Variable Back Press Sol Short Circuit
SEN06137-00
Failure code [DWK2KB] Variable Back Press Sol Short Circuit Action level
Failure code
L01 Detail of failure Action of controller Problem on machine Related information
DWK2KB q q q
Variable Back Pressure Solenoid Short Circuit (Pump controller system)
Abnormal current flows when pump controller drives variable back pressure solenoid, so pump controller determines that short circuit exists in variable back pressure solenoid circuit. Stops driving variable back pressure solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Set pressure of back pressure value cannot be changed.
q
Controller's command (ON/OFF) to variable back pressure solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02301 Solenoid 2) The set pressure of back pressure value becomes low by solenoid ON. Method of reproducing failure code: Turn starting switch to ON position.
q q
No.
Failure
Cause
Defective variable back pressure solenoid valve 1 (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V25, and connect T-adapters to male side. Between V25 (male) (1) and (2)
Resistance
20 to 60 z
Between V25 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ing harness Between C02(female) (85) and each of (115), Resistance 20 to 60 z (117), (120) a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V25, and connect T-adapters to either Ground fault in wiring harness 3 female side. (contact with ground circuit) Between ground and C02 (female) (85) or Resistance Min. 1 Mz V25 (female)(1) 4 Defective pump controller
40-305 14
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DWK2KB] Variable Back Press Sol Short Circuit
SEN06137-00
Circuit diagram related to variable back pressure solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
15
305 Troubleshooting by failure code, Part 5 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
SEN06137-00
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit Action level
Failure code
L03
DXA8KA
Failure
PC-EPC (Front) Solenoid Open Circuit (Pump controller system)
Detail of failure
q
When PC-EPC (Front) solenoid is driven, no current flows and open circuit is detected.
Action of controller
q q
None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
If pump load increases, engine speed decreases largely and engine may stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by setting emergency pump drive switch to ON position. Drive current of PC-EPC (F) solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (F)) Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q q
Cause Defective PC-EPC (F) solenoid 1 (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V11, and connect T-adapters to male side. Between V11 (male) (1) and (2)
Resistance
3 to 14 z
1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side. Defective emergency pump drive 2 switch (Internal open circuit)
Between S25 (male) (3) and (2) Between S25 (male) (6) and (5)
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
Switch position: Normal
Resistance
Max. 1 z
Switch position: EmerResistance Min. 1 Mz gency 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Open or short circuit in wiring har3 a Check that emergency pump drive switch is at normal position (lower side). ness Between C02 (female) (96) and each of (115), (117) Resistance 3 to 14 z and (120) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V11, and connect T-adapters to each female side. Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z 4 (wire breakage or defective contact of connector) Between S25 (female) (2) and V11 (female) (1) Resistance Max. 1 z
5 Defective pump controller
40-305 16
Between S25 (female) (6) and each of C02 (female) Resistance (115), (117) and (120)
Max. 1 z
Between S25 (female) (5) and V11 (female) (2)
Max. 1 z
Resistance
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
SEN06137-00
Circuit diagram related to PC-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
17
305 Troubleshooting by failure code, Part 5 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
SEN06137-00
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit Action level
Failure code
L03 Detail of failure Action of controller Problem on machine Related information
DXA8KB q q q
Failure
PC-EPC (Front) Solenoid Short Circuit (Pump controller system)
When PC-EPC (Front) solenoid is driven, abnormal current flows in circuit and short circuit is detected. Stops outputting current to PC-EPC solennoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
If pump load increases, engine speed decreases largely and engine may stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by setting emergency pump drive switch to ON position. Drive current of PC-EPC (F) solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (F)) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause Defective PC-EPC (F) solenoid 1 (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V11, and connect T-adapters to male side. Between V11 (male) (1) and (2)
Resistance
3 to 14 z
Between V11 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side. Defective emergency pump drive Between S25 (male) and each of S25 2 switch (internal short circuit or Resistance Min. 1 Mz Switch posi(male) (2) and (3) ground fault) Between ground and each of S25 tion: Normal Resistance Min. 1 Mz (male) (2) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side). 3 Between C02 (female) (96) and each of (115), (117) ing harness Resistance 3 to 14 z and (120) Between C02 (female) (96) and ground
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective pump controller
40-305 18
Resistance
Min. 1 Mz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V11, and connect T-adapters to either female side. Between C02 (female) (96) or S25 (female) (3) and Resistance Min. 1 Mz ground Between ground and S25 (female) (5) or V11 Resistance Min. 1 Mz (female) (2) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
SEN06137-00
Circuit diagram related to PC-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
19
305 Troubleshooting by failure code, Part 5 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
SEN06137-00
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit Action level
Failure code
L03
DXA9KA
Failure
PC-EPC (Rear) Solenoid System Open Circuit (Pump controller system)
Detail of failure
q
When PC-EPC (Rear) solenoid is driven, no current flows and open circuit is detected.
Action of controller
q q
None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
If pump load increases, engine speed decreases largely and engine may stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by setting emergency pump drive switch to ON position. Drive current of PC-EPC (R) solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (R)) Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q q
Cause Defective PC-EPC (R) solenoid 1 (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V12, and connect T-adapters to male side. Between V12 (male) (1) and (2)
Resistance
3 to 14 z
1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side. Defective emergency pump drive 2 switch (Internal open circuit)
Between S25 (male) (3) and (2) Between S25 (male) (6) and (5)
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
Switch position: Normal
Resistance
Max. 1 z
Switch position: EmerResistance Min. 1 Mz gency 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Open or short circuit in wiring har3 a Check that emergency pump drive switch is at normal position (lower side). ness Between C02 (female) (96) and each of (115), (117) Resistance 3 to 14 z and (120) a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V12, and connect T-adapters to each female side. Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z 4 (wire breakage or defective contact of connector) Between S25 (female) (2) and V12 (female) (1) Resistance Max. 1 z
5 Defective pump controller
40-305 20
Between S25 (female) (6) and each of C02 (female) Resistance (115), (117) and (120)
Max. 1 z
Between S25 (female) (5) and V12 (female) (2)
Max. 1 z
Resistance
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
SEN06137-00
Circuit diagram related to PC-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
21
305 Troubleshooting by failure code, Part 5 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
SEN06137-00
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit Action level
Failure code
L03
DXA9KB
Detail of failure Action of controller Problem on machine Related information
Failure
PC-EPC (Rear) Solenoid System Short Circuit (Pump controller system)
q
When PC-EPC (Rear) solenoid is driven, abnomal current flows and short circuit is detected.
q q
Cuts output to PC-EPC (R) solenoid OFF. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
If pump load increases, engine speed decreases largely and engine may stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by setting emergency pump drive switch to ON position. Drive current of PC-EPC (R) solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (R)) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause Defective PC-EPC (R) solenoid 1 (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V12, and connect T-adapters to male side. Between V12 (male) (1) and (2)
Resistance
3 to 14 z
Between V12 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side. Defective emergency pump drive Between S25 (male) and each of S25 2 switch (internal short circuit or Resistance Min. 1 Mz Switch posi(male) (2) and (3) ground fault) Between ground and each of S25 tion: Normal Resistance Min. 1 Mz (male) (2) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault in wir- a Check that emergency pump drive switch is at normal position (lower side). 3 Between C02 (female) (96) and each of (115), (117) ing harness Resistance 3 to 14 z and (120) Between C02 (female) (96) and ground
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective pump controller
40-305 22
Resistance
Min. 1 Mz
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V12, and connect T-adapters to either female side. Between C02 (female) (96) or S25 (female) (3) and Resistance Min. 1 Mz ground Between ground and S25 (female) (5) or V12 Resistance Min. 1 Mz (female) (2) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
SEN06137-00
Circuit diagram related to PC-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
23
305 Troubleshooting by failure code, Part 5 Failure code [DXE0KA] LS-EPC Sol Open Circuit
SEN06137-00
Failure code [DXE0KA] LS-EPC Sol Open Circuit Action level
Failure code
L01
DXE0KA
Failure
LS-EPC Solenoid Open Circuit (Pump controller system)
Detail of failure
q
When LS-EPC solenoid is driven, no current flows and open circuit is detected.
Action of controller
q
None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
Related information
q
q q q
Travel speed is high with speed setting at Lo and Mi. Work equipment speed and swing speed are high in fine control mode (L). Drive current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500 LS-EPC solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective LS-EPC solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V19, and connect T-adapters to male side. Between V19 (male) (1) and (2)
Resistance
3 to 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ness Between C02 (female) (88) and each of (115), (117) Resistance 3 to 14 z and (120) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V19, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 24
Between C02 (female) (88) and V19 (female) (1)
Resistance
Max. 1 z
Between V19 (female) (2) and each of C02 (female) Resistance Max. 1 z (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE0KA] LS-EPC Sol Open Circuit
SEN06137-00
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
25
305 Troubleshooting by failure code, Part 5 Failure code [DXE0KB] LS-EPC Sol Short Circuit
SEN06137-00
Failure code [DXE0KB] LS-EPC Sol Short Circuit Action level
Failure code
L01
DXE0KB
Detail of failure Action of controller Problem on machine Related information
LS-EPC Solenoid Short Circuit (Pump controller system)
q
When LS-PEC solenoid is driven, abnormal current flows and short circuit is detected.
q
Stops driving LS-EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Travel speed is high with speed setting at Lo and Mi. Work equipment speed and swing speed are high in fine control mode (L). Drive current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500 LS-EPC solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
q q q q q
Cause Defective LS-EPC solenoid 1 (internal short circuit or ground fault)
2
Failure
Short circuit or ground fault in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V19 and connect T-adapters to male side. Between V19 (male) (1) and (2)
Resistance
3 to 14 z
Between V19 (male) (2) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Between C02 (female) (88) and each of (115), (117) Resistance 3 to 14 z and (120) Between C02 (female) (88) and ground
Ground fault in wiring har3 ness (contact with ground circuit)
4 Defective pump controller
40-305 26
Resistance
Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V19, and connect T-adapters to either female side. Between C02 (female) (88) or V19 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE0KB] LS-EPC Sol Short Circuit
SEN06137-00
Circuit diagram related to LS-EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
27
305 Troubleshooting by failure code, Part 5 Failure code [DXE4KA] Attachment Flow EPC Open Circuit
SEN06137-00
Failure code [DXE4KA] Attachment Flow EPC Open Circuit Action level
Failure code
–
DXE4KA
Failure
Attachment Flow EPC Open Circuit. (Pump controller system)
Detail of failure
q
When service flow throttle EPC solenoid is driven, no current flows and ope circuit is detected.
Action of controller
q q
None in particular (Since no current flows, solenoid is not energized.) If cause of failure disappears, machine becomes normal by itself.
q
Attachment does not move.
q
Drive current of service current EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
Problem on machine Related information
q
Cause Defective attachment flow rate 1 adjustment (service current) EPC solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V30, and connect T-adapters to male side. Between V30 (male) (1) and (2)
Resistance
3 to 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ness Between C02 (female) (97) and each of (115), (117) Resistance 3 to 14 z and (120) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V30, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 28
Between C02 (female) (97) and V30 (female) (1)
Resistance
Max. 1 z
Between V30 (female) (2) and each of C02 (female) Resistance Max. 1 z (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE4KA] Attachment Flow EPC Open Circuit
SEN06137-00
Circuit diagram related to service flow throttle EPC
PC200, 200LC, 220, 220LC-8M0
40-305
29
305 Troubleshooting by failure code, Part 5 Failure code [DXE4KB] Attachment Flow EPC Short Circuit
SEN06137-00
Failure code [DXE4KB] Attachment Flow EPC Short Circuit Action level
Failure code
– Detail of failure Action of controller Problem on machine Related information
Failure
DXE4KB q q q
Attachment Flow EPC Short Circuit (Pump controller system)
When service flow throttle EPC solenoid is driven, abnormal current flows and short circuit is detected . Stops outputting current to service EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Attachment does not move.
q
Drive current of service flow adjust EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
q
Cause Defective attachment flow rate adjustment (service current) EPC 1 solenoid (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V30, and connect T-adapters to male side. Between V30 (male) (1) and (2)
Resistance
3 to 14 z
Between V30 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault in wirBetween C02 (female) (97) and each of (115), (117) 2 Resistance 3 to 14 z ing harness and (120) Between C02 (female) (97) and ground
3
Ground fault in wiring harness (contact with ground circuit)
4 Defective pump controller
40-305 30
Resistance
Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V30, and connect T-adapters to either female side. Between C02 (female) (97) or V30 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE4KB] Attachment Flow EPC Short Circuit
SEN06137-00
Circuit diagram related to service flow throttle EPC
PC200, 200LC, 220, 220LC-8M0
40-305
31
305 Troubleshooting by failure code, Part 5 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
SEN06137-00
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit Action level
Failure code
L01 Detail of failure
DXE5KA q q
Action of controller Problem on machine Related information
q q q q q
Failure
Merge-divide Main Solenoid Open Circuit (Pump controller system)
When pump merge-divider (main) EPC solenoid is driven, no current flows and open circuit is detected . None in particular (Since no current flows, merge-divider main solenoid does not operate. Since no current flows, merge-divider LS solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine does not turn easily during travel. Drive current to merge-divider main EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (main) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapters to male side. 1 solenoid (internal open circuit) Between V23 (male) (1) and (2) Resistance 3 to 14 z 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ness Between C02 (female) (112) and each of (115), Resistance 3 to 14 z (117) and (120) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V23, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 32
Between C02 (female) (112) and V23 (female) (1)
Resistance
Max. 1 z
Between V23 (female) (2) and each of C02 (female) Resistance Max. 1 z (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
SEN06137-00
Circuit diagram related to pump merge-divider main EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
33
305 Troubleshooting by failure code, Part 5 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
SEN06137-00
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit Action level
Failure code
L01 Detail of failure
DXE5KB q q
Action of controller Problem on machine Related information
q q q q q
Failure
Merge-divide Main Solenoid Short Circuit (Pump controller system)
When pump merge-divider (main) EPC solenoid is driven, abnormal current flows and short circuit is detected. Stops outputting current to merge-divider (main) EPC solenoid. (Since no current flows, mergedivider LS solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine does not turn easily during travel. Drive current to merge-divider main EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (main) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapters to male side. 1 solenoid (internal short circuit or Between V23 (male) (1) and (2) Resistance 3 to 14 z ground fault) Between V23 (male) (1) and ground Resistance Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault in wirBetween C02 (female) (112) and each of (115), 2 Resistance 3 to 14 z ing harness (117) and (120) Between C02 (female) (112) and ground
3
Ground fault in wiring harness (contact with ground circuit)
4 Defective pump controller
40-305 34
Resistance
Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V23, and connect T-adapters to either female side. Between C02 (female) (112) or V23 (female) (1) Resistance Min. 1 Mz and ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
SEN06137-00
Circuit diagram related to pump merge-divider main EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
35
305 Troubleshooting by failure code, Part 5 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
SEN06137-00
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit Action level
Failure code
L01 Detail of failure
DXE6KA q q
Action of controller Problem on machine Related information
q q q q q
Failure
Merge-divide LS Solenoid Open Circuit (Pump controller system)
When pump merge-divider (LS) EPC solenoid is driven, no current flows and open circuit is detected. None in particular (Since no current flows, merge-divider LS solenoid does not operate. Since no current flows, merge-divider main solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine does not turn easily during travel. Drive current to merge-divider LS EPC solenoid can be checked with monitoring function. (Code: 08001 Merge-divider (LS) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective merge-divider LS EPC 1 solenoid (internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V24, and connect T-adapters to male side. Between V24 (male) (1) and (2)
Resistance
3 to 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapters to female side. 2 ness Between C02 (female) (89) and each of (115), (117) Resistance 3 to 14 z and (120) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V24, and connect T-adapters to each Open circuit in wiring harness female side. 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 36
Between C02 (female) (89) and V24 (female) (1)
Resistance
Max. 1 z
Between V24 (female) (2) and each of C02 (female) Resistance Max. 1 z (115), (117) and (120) If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
SEN06137-00
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
37
305 Troubleshooting by failure code, Part 5 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
SEN06137-00
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit Action level
Failure code
L01 Detail of failure
DXE6KB q q
Action of controller Problem on machine Related information
q q q q q
Failure
Merge-divide LS Solenoid Short Circuit (Pump controller system)
When pump merge-divider (LS) EPC solenoid is driven, abnormal current flows and short circuit is detected. Stops outputting current to merge-divider (LS) EPC solenoid. (Since no current flows, merge-divider main solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine does not turn easily during travel. Drive current to merge-divider LS EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (LS) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective merge-divider LS EPC 1 solenoid (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V24, and connect T-adapters to male side. Between V24 (male) (1) and (2)
Resistance
3 to 14 z
Between V24 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapters to female side. Short circuit or ground fault in wirBetween C02 (female) (89) and each of (115), (117) 2 Resistance 3 to 14 z ing harness and (120) Between C02 (female) (89) and ground
3
Ground fault in wiring harness (contact with ground circuit)
4 Defective pump controller
40-305 38
Resistance
Min. 1 Mz
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V24, and connect T-adapters to either female side. Between C02 (female) (89) or V24 (female) (1) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
SEN06137-00
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 200LC, 220, 220LC-8M0
40-305
39
305 Troubleshooting by failure code, Part 5 Failure code [DY20KA] Wiper Working Abnormality
SEN06137-00
Failure code [DY20KA] Wiper Working Abnormality Action level
Failure code
–
DY20KA
Failure
Wiper Working Error (Pump controller system)
Detail of failure
q
When windshield wiper works, W signal of working ends is not input.
Action of controller
q q
Shuts off power supply to wiper motor. If cause of failure disappears, machine becomes normal by itself.
q
Wiper motor does not work.
Problem on machine
Signal input (ON/OFF) of W contact that indicates wiper working area end can be checked with monitoring function. (Code: 02204 Switch input 5) Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be meamation sured at pump controller connector. a Single wiper does not have lower wiper of double wiper (Upper wiper is called wiper). q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON. q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapters to female side. Wiper position: working Resistance Max. 1 z Defective wiper motor area end Between M05 (female) 1 (Internal open circuit) Wiper position: other than (6) and (5) Resistance Min. 1 Mz working area end Between M05 (female) Wiper position: whole Resistance Max. 20 z (1) and (3) range 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and C02 and connect T-adapters to each female side. Wiper position: working Resistance Max. 1 z Open or short circuit in wiring hararea end 2 Between C01 (female) ness Wiper position: other than (56) and ground Resistance Min. 1 Mz working area end Between C02 (female) Wiper position: whole Resistance Max. 20 z (114) and (119) range a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01, C02, and M05. 3. Connect T-adapters to female sides of connector C01 and C02 and to male side of M05. Open circuit in wiring harness 3 (wire breakage or defective con- Between C01 (female) (56) and M05 (male) (6) Resistance Max. 1 z tact of connector) Between M05 (male) (5) and ground (T05) Resistance Max. 1 z
4 Defective pump controller
40-305 40
Between C02 (female) (114) and M05 (male) (1)
Resistance
Max. 1 z
Between C02 (female) (119) and M05 (male) (3)
Resistance
Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DY20KA] Wiper Working Abnormality
SEN06137-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0
40-305
41
305 Troubleshooting by failure code, Part 5 Failure code [DY20MA] Wiper Parking Abnormality
SEN06137-00
Failure code [DY20MA] Wiper Parking Abnormality Action level
Failure code
–
DY20MA
Failure
Wiper Parking Abnormality (Pump controller system)
Detail of failure
q
When windshield wiper rests, P signal for rest area is not input.
Action of controller
q q
Stops output for resting to wiper motor. If cause of failure disappears, machine becomes normal by itself.
q
Wiper motor does not rest.
q
Condition of P contact signal of wiper resting area can be checked with monitoring function. (Code: 02204 Switch input 5) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch from INT/ON to OFF.
Problem on machine
Related information
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapters to female side.
1
Defective wiper motor (Internal open circuit)
2
Open or short circuit in wiring harBetween C01 (female) ness (75) and ground
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4 Defective pump controller
40-305 42
Between M05 (female) (4) and (5)
Wiper position: rest area Resistance
Max. 1 z
Wiper position: working Resistance Min. 1 Mz area Between M05 (female) Wiper position: whole Resistance Max. 20 z (1) and (3) range 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and C02 and connect T-adapters to each female side. Wiper position: rest area Resistance
Max. 1 z
Wiper position: working Resistance Min. 1 Mz area Between C02 (female) Wiper position: whole Resistance Max. 20 z (114) and (119) range a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01, C02, and M05. 3. Connect T-adapters to female sides of connector C01 and C02 and to male side of M05. Between C01 (female) (75) and M05 (male) (4)
Resistance
Max. 1 z
Between M05 (male) (5) and ground (T05)
Resistance
Max. 1 z
Between C02 (female) (114) and M05 (male) (1)
Resistance
Max. 1 z
Between C02 (female) (119) and M05 (male) (3)
Resistance
Max. 1 z
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DY20MA] Wiper Parking Abnormality
SEN06137-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0
40-305
43
305 Troubleshooting by failure code, Part 5 Failure code [DY2CKB] Washer Drive Short Circuit
SEN06137-00
Failure code [DY2CKB] Washer Drive Short Circuit Action level
Failure code
–
DY2CKB
Detail of failure Action of controller Problem on machine Related information
q q q
Window Washer Drive Short Circuit (Pump controller system)
When outputting current to window washer motor, abnormal current flows and short circuit is detected. Shuts of power supply to washer motor. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Window washer does not operate.
q
Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to ON position.
Cause 1 Defective fuse No.4 Defective washer motor 2 (internal open circuit or ground fault)
3
Failure
Defective diode array D02 (Internal short circuit)
4
Ground fault in wiring harness (contact with ground circuit)
5
Hot short circuit in wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks If the fuse is broken, the circuit probably has a grounding fault, etc. 1. Turn starting switch to OFF position. 2. Disconnect connector M06 and connect T-adapters to male side. Between M06 (male) (1) and (2)
Resistance
5 to 20 z
Between ground and M06 (male) (1) or (2)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector D02 and connect T-adapters to male side. a Check the continuity in diode range. Between D02 (male) (7) (+) and (3) (-)
Continuity
Between D02 (male) (3) (+) and (7) (-)
No continuity
1. Turn starting switch to OFF position. 2. Remove fuse No.4 3. Disconnect connectors M06, C01, and D02, and connect T-adapters to either female side. Between F01 (4) or M06 (female) (2) or D02 Resistance Min. 1 Mz (female) (3) and ground Between C01 (female) (3) or M06 (female) (1) or Resistance Min. 1 Mz D02 (female) (7) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and M06 and connect T-adapters to female side of C01. 3. Remove fuse No.4 4. Turn starting switch to ON position. a Ignore failure code displayed on machine monitor. Between C01 (female) (3) and ground
6 Defective pump controller
40-305 44
Voltage
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DY2CKB] Washer Drive Short Circuit
SEN06137-00
Circuit diagram related to window washer motor
PC200, 200LC, 220, 220LC-8M0
40-305
45
305 Troubleshooting by failure code, Part 5 Failure code [DY2DKB] Wiper Drive (Fwd) Short
SEN06137-00
Failure code [DY2DKB] Wiper Drive (Fwd) Short Action level
Failure code
–
DY2DKB
Detail of failure Action of controller Problem on machine Related information
q q q
Failure
Wiper motor Drive Foward rotation Short Circult (Pump controller system)
When outputting current to normal rotation side of wiper motor drive, abnormal current flows in circuit and short circuit is detected. Stops outputting current to wiper motor drive forward side. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Windshield wiper does not operate.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON.
q
Cause Defective wiper motor 1 (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapters to female side. Between M05 (female) (3) and (1)
Continuity
Between M05 (female) (3) and ground
2 Short circuit in wiring harness
3
Ground fault in wiring harness (contact with ground circuit)
1. 2. 3. 4.
Reference Turn starting switch to OFF position. Insert T-adapters into connector M05. Turn starting switch to ON position. Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (3) and (5)
40-305 46
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) and (114), or between Resistance Min. 1 Mz M05 (male) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) or M05 (male) (3) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) q
4 Defective pump controller
Resistance
Wiper switch: OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io above 20 V
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DY2DKB] Wiper Drive (Fwd) Short
SEN06137-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0
40-305
47
305 Troubleshooting by failure code, Part 5 Failure code [DY2EKB] Wiper Drive (Rev) Short
SEN06137-00
Failure code [DY2EKB] Wiper Drive (Rev) Short Action level
Failure code
–
DY2EKB
Detail of failure Action of controller Problem on machine Related information
q q q
Failure
Wiper motor Drive Reverse rotation Short Circuit (Pump controller system)
When outputting current to reverse rotation side of wiper motor drive is turned ON, abnormal current flows in circuit and short circuit is detected. Shuts off power supply to reverse rotation system of wiper motor drive. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Windshield wiper does not operate.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON.
q
Cause Defective wiper motor 1 (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapters to female side. Between M05 (female) (1) and (3)
Continuity
Between M05 (female) (1) and ground
2 Short circuit in wiring harness
3
Ground fault in wiring harness (contact with ground circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) and (114), or between Resistance Min. 1 Mz M05 (male) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (114) or M05 (male) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) q
4 Defective pump controller
1. 2. 3. 4.
Reference Turn starting switch to OFF position. Insert T-adapters into connector M05. Turn starting switch to ON position. Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (1) and (5)
40-305 48
Resistance Min. 1 Mz
Wiper switch: OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io above 20 V
PC200, 200LC, 220, 220LC-8M0
305 Troubleshooting by failure code, Part 5 Failure code [DY2EKB] Wiper Drive (Rev) Short
SEN06137-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0
40-305
49
SEN06137-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06137-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-305
50
SEN06138-00 SEN05989-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 400 Troubleshooting of electrical system (E-mode) Fuse locations.............................................................................................................................................
4
Information contained in troubleshooting table ...........................................................................................
6
E-1 Engine does not start (Engine does not crank) ....................................................................................
8
E-2 Preheater does not operate.................................................................................................................. 13 E-3 When starting switch is turned to ON position, machine monitor displays nothing .............................. 17 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up. . 20 E-5 Precaution monitor lights up while engine is running ........................................................................... 21 E-6 Emergency stop monitor lights up while engine is running .................................................................. 23 E-7 Fuel level gauge does not indicate properly......................................................................................... 24 E-8 Engine coolant temperature gauge does not indicate properly ............................................................ 26 E-9 Hydraulic oil temperature gauge does not indicate properly ................................................................ 27 E-10 Displays on machine monitor are different from those for actual machine......................................... 30 E-11 Some areas of machine monitor screen are not displayed ................................................................ 31 E-12 Function switch does not operate....................................................................................................... 31 E-13 Automatic warm-up system does not operate (in cold season).......................................................... 32 E-14 Auto-decelerator does not operate properly....................................................................................... 33 E-15 Working mode does not change......................................................................................................... 34 E-16 Travel speed does not change ........................................................................................................... 35
PC200, 200LC, 220, 220LC-8M0
40-400
1
SEN06138-00
400 Troubleshooting of electrical system (E-mode)
E-17 Alarm buzzer cannot be canceled ...................................................................................................... 36 E-18 When starting switch is turned OFF, service meter is not displayed .................................................. 36 E-19 Service mode cannot be selected ...................................................................................................... 36 E-20 Any of work equipment, swing and travel do not operate or cannot be locked .................................. 37 E-21 Swing holding brake does not operate properly ................................................................................. 39 E-22 One-touch power maximizing function does not operate properly ..................................................... 42 E-23 Travel alarm does not sound or does not stop sounding.................................................................... 45 E-24 Horn does not sound or does not stop ............................................................................................... 46 E-25 Windshield wiper and window washer do not operate........................................................................ 48 E-26 BOOM DOWN indicator is not displayed properly with monitoring function ....................................... 50 E-27 ARM DUMP indicator is not displayed properly with monitoring function........................................... 50 E-28 ARM IN indicator is not displayed properly with monitoring function.................................................. 50 E-29 BOOM RAISE indicator is not displayed properly with monitoring function........................................ 51 E-30 BUCKET CURL indicator is not displayed properly with monitoring function ..................................... 51 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function .................................... 51 E-32 SWING indicator is not displayed properly with monitoring function .................................................. 52 E-33 TRAVEL indicator is not displayed properly with monitoring function................................................. 52 E-34 ATTACHMENT indicator is not displayed properly with monitoring function ...................................... 53 E-35 Attachment hydraulic circuit cannot be changed ................................................................................ 55 E-36 KOMTRAX system does not operate properly ................................................................................... 56
40-400 2
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode)
PC200, 200LC, 220, 220LC-8M0
SEN06138-00
40-400
3
400 Troubleshooting of electrical system (E-mode) Fuse locations
SEN06138-00
Fuse locations Connection table of fuse box a This connection table shows the devices to which power supply from each fuse of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally. Type of power supply
Fusible link
Fuse No.
Fuse capacity
Destination of power Lamp relay, rear lamp relay, cab lamp relay
1
10 A
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve [When pump drive switch is operated in emergency] Swing holding brake solenoid valve [When swing holding brake release switch is operated]
Switch power supply
F04 (60 A)
2
30 A
Pump controller (Solenoid power supply) PPC oil pressure lock solenoid valve
3
10 A
Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal code)
Switch power supply
Switch power supply
Constant power supply
F04 (60 A)
F04 (60 A)
F05 (30 A)
Switch power Starting switch supply ACC
40-400 4
Cigarette lighter
4
10 A
5
10 A
Horn relay, horn
6
10 A
Electrical intake air heater relay
7
10 A
Rotary lamp
8
20 A
Right headlamp, working lamp (boom), working lamp (rear)
9
10 A
10
5A
11
20 A
12
10 A
(Spare)
13
10 A
Headlamp
14
10 A
Optional power supply (1)
15
10 A
16
10 A
17
20 A
Windshield washer motor
Radio Left knob switch (pump controller input) Air conditioner controller supply Air conditioner unit Air conditioner compressor electromagnetic clutch
Travel alarm Optional power supply (2) Radio (backup power supply) Room lamp Starting switch Machine monitor Pump controller
18
5A
Air conditioner controller backup
19
30 A
Engine controller
20
5A
Engine controller (ACC signal)
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) Fuse locations
SEN06138-00
Locations of fusible links
Location of fuse box and fuse Nos.
PC200, 200LC, 220, 220LC-8M0
40-400
5
SEN06138-00
400 Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table
Information contained in troubleshooting table (Rev. 2012/2) a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Failure Problem on machine Related inforInformation related to the detected failure or troubleshooting mation Cause
1
2
3
4
5
6
7
Procedure, measuring location, criteria and remarks q Procedure q Measuring location defectivea "Between A and B" means the measurement of voltage, resistance or others between terminals A and B. a "Between A and ground" means the measurement of voltage, resistance or others between terminal A and the place which has a continuity with chassis frame such as unpainted hexagonal head bolt or bolt hole which has no rust, etc. Open or short circuit in wirq Criteria to judge probable causes (standard value), remarks ing harness q Perform troubleshooting procedures in numerical order. q If the check result does not meet the criteria, the probable cause described on the left column is the actual cause of the failure. Open circuit in wiring harq If the check result shows no failure, and unless otherwise specified, proceed to the ness next step (next cause item). (wire breakage or defective q Check that the failure is fixed after the failure was found and repaired. contact of connector) q Open circuit in wiring The connector connection is defective or the wire is broken. q Ground fault Ground fault in wiring harA harness not connected to the ground circuit contacts with the ground wiring or ness machine. (contact with ground circuit) q Hot short circuit A harness not connected to the power (24 V) circuit contacts with the power (24 V) circuit. q Short circuit Hot short circuit An independent wire in the wiring harness contacts with other wire. (contact with 24 V circuit) (poor insulation at connector and others) (1) Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapter as follows unless otherwise specified. q When "male" or "female" is not indicated with a connector number, disconnect Short circuit in wiring harthe connector, and insert T-adapter between the male and female connectors. ness q When "male" or "female" is indicated with a connector number, disconnect the connector, and connect T-adapter only to either male or female connector. (2) Description sequence of pin number and handling of tester lead For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless otherwise specified. Defective controller q Connect the positive (+) lead to pin or wire indicated first. q Connect the negative (-) lead to a pin or wire indicated second.
40-400 6
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table
SEN06138-00
Circuit diagram related to troubleshooting
This is the excerpted circuit diagram related to troubleshooting q The circuit diagram contains the connector Nos., pin Nos., and connector colors related to the failure. q The "/" in a connector number is either: 1) An abbreviation (of more than three letters) Example: T/C (Torque Converter) 2) Different connector number at male and female sides Example: BREAK OUT/ E24 q The circuit diagram contains the destination or source of the branch line in a wiring harness. q Arrow (io): Roughly shows the location on the machine. q NO: Normally Open q NC: Normally Closed
PC200, 200LC, 220, 220LC-8M0
40-400
7
400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
SEN06138-00
E-1 Engine does not start (Engine does not crank) Failure Related information
q
Engine does not start (engine does not crank)
q
Engine starting circuit has following two start lock mechanisms. 1) Start lock by password protection of machine monitor 2) Start lock by lock lever position If failure symptom "Battery relay operation sound is not heard" appears when starting switch is turned to ON position, perform troubleshooting for E-1 also.
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 1 Defective fusible links F04 or F05 2. Remove fusible links F04 and F05 Between terminals F04 and F05
Resistance
Max. 1 z
2
Defective fuses Nos. 3 and 17 in fuse box F01
3
1. Turn starting switch to OFF position. Loose terminal connection or open Check terminals of starting motor, alternator, battery relay, grounds T04, T07 circuit at terminal and T08, etc.
If fuse is broken, circuit probably has ground fault. (See Cause 16.)
1. Turn starting switch to OFF position. Between battery relay (terminal R01) and ground Resistance Max. 1 z a Use machine frame as ground. a Perform followings when the above check result is abnormal (grounding is defective). a See figure. Defective contact (ground) 1. Disconnect battery ground cable. 4 between battery relay bracket and 2. Remove battery relay (BAT RL) frame 3. Remove battery bracket (BKT) q Check contact faces of battery relay bracket (BKT) and frame for rust and dirt (Check frame side, too). a If there is rust etc., remove it. q Check mounting bolt (B) for rust. a If mounting bolt (B) is rusted, be sure to replace it with plated one. q Tighten mounting bolt (B) to specified torque. a Be ready with starting switch at OFF, then perform troubleshooting without turning starting switch to ON position. 5 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V Electrolyte specific gravity (each) q
Min. 1.26
Battery relay bracket (BKT), Battery relay (BAT RL)
40-400 8
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Cause
SEN06138-00
Procedure, measuring location, criteria and remarks
Engine controller power supply and ACC signal are diagnosed with proce6 Defective engine controller system dures for failure code [DB2QKR], If failure code [DB2QKR] is displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Remove fuse No.19 (30 A) in fuse box F01. (to prevent engine from starting during check) Defective starting switch, starter 3. Insert T-adapters into connector E10. 7 cut relay R06, personal code relay 4. Turn starting switch to START position and hold (two persons required for this check). R07, battery relay, wiring harness Voltage
Between E10 (1) and ground
20 to 30 V
a If voltage is normal, proceed to cause 14.
8
9
10
Defective starting switch (Internal open circuit)
Defective lock lever switch (Internal open circuit)
Defective starter cut relay (Internal open circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector H15 and connect T-adapters to male side. 3. After troubleshooting, perform troubleshooting again with starting switch at ON and START positions. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (2) Resistance Max. 1 z ON position. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (5) Resistance Max. 1 z ON position. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. and (4) Starting switch: START Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connector S14 and connect T-adapters to female side. Between S14 (female) (1) and (3)
Lock lever: FREE
Resistance Min. 1 Mz
Lock lever: LOCK
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Replace starter cut relay (R06) with horn relay (R08). 3. Start engine. If engine starts, original starter cut relay (R06) is defective.
11
Defective personal code relay (internal open or short circuit)
a 1. 2. 3.
If no failure is found by check on causell, this check is not. Turn starting switch to OFF position. Replace personal code relay (R07) with horn relay (R08). Start engine.
If engine starts, original personal code relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector D01 and connect T-adapters to diode. a Check by using multimeter in diode range. 12
Defective diode D01 (internal open or short circuit)
PC200, 200LC, 220, 220LC-8M0
Between D01 (male) (1) (+) and (5) (-)
No continuity
Between D01 (male) (5) (+) and (1) (-)
Continuity
Between D01 (male) (2) (+) and (6) (-)
No continuity
Between D01 (male) (6) (+) and (2) (-)
Continuity
40-400
9
400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
SEN06138-00
Cause
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Defective starting motor safety 13 relay (internal defect)
14
Defective starting motor (internal defect)
15
Defective alternator (Internal short circuit)
Open circuit in wiring harness 16 (wire breakage or defective contact of connector)
40-400 10
Turn starting switch to OFF position. Disconnect cable only from C terminal on starting motor safety relay. Insert T-adapter between male and female sides of connector R17. Turn starting switch to START position and perform troubleshooting. Power supBetween safety relay terminal B and E Voltage 20 to 30 V ply Input from Between safety relay terminal R alternator Voltage Max. 1 V (R17-2) and safety relay terminal E generation Starting Between safety relay terminal S input to Voltage 20 to 30 V (R17-1) and safety relay terminal E starting motor Starting outBetween safety relay terminal C (R28) put to start- Voltage 20 to 30 V and safety relay terminal E ing motor If power supply, input from alternator generation, and starting input to starting motor normal but starting output to starting motor is abnormal, starting motor safety relay is defective. 1. Turn starting switch to OFF position. 2. Turn starting switch to START position and perform troubleshooting. Between starting motor terminal B Power supVoltage 20 to 30 V (SB) and ground ply Starting Between starting motor terminal C input to Voltage 20 to 30 V (SC) and ground starting motor If power supply and starting input to starting motor are normal but starting motor does not rotate, starting motor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connector E12. 3. Turn starting switch to ON position. Input from Voltage Between E12 (1) and ground alternator Max. 1 V generation q Battery relay 1. Turn starting switch to OFF position. Between terminal R01 and ground (T08) Resistance Max. 1 z q Battery relay 1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. a To check to where 24 V is supplied to locate open section Between terminals R04 and R01 Voltage 20 to 30 V Between terminals R02 and R01 Voltage 20 to 30 V Between terminals R03 and R01 Voltage 20 to 30 V Between terminal R01 and ground Voltage Max. 1 V q Alternator and starting motor 1. Turn starting switch to OFF position. 2. Disconnect battery ground cable. 3. Insert T-adapters into connectors H15, S14, R07, R17, E10, and E12. 4. Connect battery ground cable. 5. Turn starting switch to START position and perform troubleshooting. a Check to where 24 V power is supplied to isolate open section. Between H15 (4) and ground Voltage 20 to 30 V Between S14 (1) and ground Voltage 20 to 30 V Between S14 (3) and ground Voltage 20 to 30 V Between R07 (4) and ground Voltage 20 to 30 V Between R17 (1) and ground Voltage 20 to 30 V Between E10 (1) and ground Voltage 20 to 30 V Between alternator B terminal and ground Voltage 20 to 30 V Between starting motor terminal B and ground Voltage 20 to 30 V
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Cause
SEN06138-00
Procedure, measuring location, criteria and remarks a 1. 2. 3.
Open circuit in wiring harness 16 (wire breakage or defective contact of connector)
17
Defective battery relay (Does not work)
18
Ground fault in wiring harness (contact with ground circuit)
If fuse or fusible link is broken, replace it. Turn starting switch to OFF position. Disconnect H15, S14, R06 and R07. Connect T-adapters to female sides of H15, R06 and R07, and to male side of S14. 4. Remove fuse F01-3. Between H15 (female) (4) and R06 (female) (5) Resistance Max. 1 z Between R06 (female) (3) and R07 (female) (4) Resistance Max. 1 z Between R07 (female) (1) and S14 (male) (1) Resistance Max. 1 z Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z Between R07 (female) (3) and starting motor safety Resistance Max. 1 z relay terminal S Between alternator terminal B and starting motor Resistance Max. 1 z terminal B Between starting motor B and battery relay R03 Resistance Max. 1 z Between starting motor safety relay R terminal and Resistance Max. 1 z alternator L terminal Between alternator terminal L and D01 (female) (6) Resistance Max. 1 z Between F01-3 and S14 (male) (1) Resistance Max. 1 z Between S14 (male) (3) and R06 (male) (1) Resistance Max. 1 z Between R06 (male) (2) and ground (T04) Resistance Max. 1 z If only terminal R03 voltage is abnormal during battery relay check for cause 16, battery relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect H15, S14, R06 and R07. 3. Connect T-adapters to female sides of H15, R06 and R07, and to male side of S14. 4. Remove fuse F01-3. Between H15 (female) (4) and ground, or between Resistance Min. 1 Mz R06 (female) (5) and ground Between R06 (female) (3) and ground, or between Resistance Min. 1 Mz R07 (female) (4) and ground Between R07 (female) (3), or R17 (female) (1) and Resistance Min. 1 Mz ground Between starting motor safety relay B or battery Resistance Min. 1 Mz relay R03 and ground Between starting motor safety relay C or starting motor C (SC) and ground
Resistance Min. 1 Mz
Between ground and F01-3 or S14 (male) (1)
Resistance Min. 1 Mz
Between ground and S14 (male) (3) or R06 (female) Resistance Min. 1 Mz (1) 1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Insert T-adapter between male and female sides of connector R17 or E08. 19 3. Turn starting switch to ON position. (contact with 24 V circuit) Between R17 (female) (2) or E08 (1) and ground Voltage Max. 1 V
PC200, 200LC, 220, 220LC-8M0
40-400
11
SEN06138-00
400 Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Circuit diagram related to engine start circuit
40-400 12
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
SEN06138-00
E-2 Preheater does not operate Failure
1) Manual preheating does not function.
a This troubleshooting describes procedures to be followed when manual preheating does not function to heat electrical intake air heater (ribbon heater) mounting section. q “Automatic preheating” and “Manual preheating” functions are available. When either function is operated, preheating monitor lights up. (When only preheating monitor does not light up, perform troubleshooting "3) While preheater is operating, preheating monitor does not light Related information up") q If "Machine monitor displays nothing" or "Battery relay operation sound is not heard" when turning starting switch to ON position, main electric power supply system may be defective. So, perform troubleshooting for E-3 and E-1. q Before performing troubleshooting, check that no related failure code is displayed. (If failure codes [D110KB] is displayed, troubleshoot it first.) Cause 1
Defective fuse No. 17 in fuse box F01
2
Loose terminal or open circuit at terminal
Procedure, measuring location, criteria and remarks If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 8 first. 1. Turn starting switch to OFF position.
Check terminals of heater relay, battery relay, electrical intake air heater (ribbon heater), etc. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and H15, and connect T-adapter to female side of H15. a Heater relay coil resistance Approx. Resistance Between H15 (female) (3) and ground 20 z 1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. Open circuit or ground fault in wirBetween input terminal on contact side of heater 3 Voltage 20 to 30 V ing harness relay and ground 1. Turn starting switch to OFF position. 2. Disconnect heater relay terminal R16. a To prevent current from flowing through heater when starting switch is turned to HEAT position 3. Turn starting switch to HEAT position (Connect R1). Between heater relay terminal R15 and ground 4
5
Defective heater relay (Does not work) (Terminal R16)
Defective diode D02 (internal open or short circuit)
Defective electrical intake air 6 heater (ribbon heater) (Internal open circuit)
7 Defective starting switch
20 to 30 V
If no failure is found by check on cause 3 and heater relay operation sound is not heard, heater relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector D02 and connect T-adapters to diode. a Check by using multimeter in diode range. Between D02 (male) (1) (+) and (5) (-)
No continuity
Between D02 (male) (5) (+) and (1) (-)
Continuity
1. Turn starting switch to OFF position. 2. Disconnect terminal E01. Between E01 terminal and ground 1. 2. 3. 4.
Continuity
Turn starting switch to OFF position. Disconnect battery ground cable. Disconnect connector H15 and connect T-adapters to male side. Turn starting switch to OFF/HEAT position and perform troubleshooting.
Between H15 (male) (1) and (3)
PC200, 200LC, 220, 220LC-8M0
Voltage
OFF
Resistance
Min. 1 Mz
HEAT
Resistance
Min. 1 Mz
40-400
13
400 Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
SEN06138-00
8
Cause
Procedure, measuring location, criteria and remarks
Ground fault in wiring harness (contact with ground circuit)
a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors H15 and CM01, terminals R15 and E01, and starting motor terminal B. Between heater relay terminal R15 (wiring harness Resistance Min. 1 Mz side) and ground Between input terminal on contact side of heater Resistance Min. 1 Mz relay and ground Between heater relay terminal E01 (wiring harness Resistance Min. 1 Mz side) and ground
Failure
2) Automatic preheating does not function. q
Related information
q q q
Automatic preheating starts when boost temperature is below -4 °C. (Monitoring code Boost temperature: 18500) If automatic preheating does not function, check if manual preheating functions. Engine controller checks primary (coil) side of preheater relay (connector R18) and generates failure codes [CA2555] and [CA2556] if it is defective. Engine controller checks boost temperature sensor and generates failure codes [CA153] and [CA154] if it is defective.
Cause 1
Defective fuse No. 6 in fuse box F01
Procedure, measuring location, criteria and remarks If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 5 first.
1. Turn starting switch to OFF position. 2. Replace auto preheater relay (connector R18) with horn relay (connector R08), Defective auto preheater for example. 2 relay R18 (open or short cir- 3. Turn starting switch to ON position. cuit in internal wiring) If automatic preheater operates when charged (boosted) air temperature is below -4 °C, original auto preheater relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and R18, and connect T-adapter to female side of R18. Open circuit or ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is be3 wiring harness low 1 z, wiring harness has short circuit. a Heater relay coil resistance Between R18 (female) (5) and ground
Open circuit in wiring harness 4 (Wire breakage or defective contact)
Ground fault in wiring har5 ness (contact with ground circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors R18 and CM01, and connect T-adapters to female side of R18. 3. Remove fuse No. 6 in fuse box F01. Between R18 (female) (3) and F01-6
Resistance
Max. 1 z
Between R18 (female) (5) and heater relay terminal Resistance Max. 1 z R15 If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01, R18, and starting motor terminal B, and connect T-adapter to female side of R18. Between R18 (female) (3) and ground
40-400 14
Resistance Approx. 20 z
Resistance
Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Failure
SEN06138-00
3) While preheater is operating, preheating monitor does not light up.
Related information
q q
"Automatic preheating" and "Manual preheating" functions are available. When either function is operated, preheating monitor lights up. Check if manual preheating functions first.
Cause Open circuit in wiring harness 1 (Wire breakage or defective contact)
2 Defective machine monitor
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to each female side. Between H15 (female) (3) and CM01 (female) (16)
Resistance
Max. 1 z
Between R18 (female) (5) and CM01 (female) (16)
Resistance
Max. 1 z
If no failure is found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Disconnect heater relay terminal R16. a To prevent current from flowing through heater when starting switch is turned to HEAT position 4. Turn the starting switch to HEAT position. Between CM01 (16) and (3) Resistance 20 to 30 V a Between CM01(3) is ground
PC200, 200LC, 220, 220LC-8M0
40-400
15
SEN06138-00
400 Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Circuit diagram related to preheating of engine
40-400 16
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
SEN06138-00
E-3 When starting switch is turned to ON position, machine monitor displays nothing Failure
Related information
q
When starting switch is turned to ON position, machine monitor displays nothing.
q
When starting switch is turned to ON position, machine monitor displays KOMATSU logo screen, password input screen (if set), breaker mode confirmation screen (if selected), check before starting screen, working mode and travel speed confirmation screen, and standard screen in order. When engine is started, battery voltage may lower suddenly, depending on ambient temperature and condition of the battery. In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.
q
Cause 1
Defective connection of battery ground terminal
2 Insufficient battery capacity
3
Defective fusible link F05 Defective fuse F01-17
Procedure, measuring location, criteria and remarks Check battery ground terminal (60B) connection. a Be ready with starting switch at OFF position, then perform troubleshooting without turning starting switch to ON position. Battery voltage (two pieces)
Min. 24 V
Electrolyte specific gravity (each)
Min. 1.26
If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 7.)
1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter into connector CM01. 3. Connect battery ground cable, and turn starting switch to ON position (to connect ACC). Defective wiring harness, starting 4 Between CM01 (1) and (3) Voltage 20 to 30 V switch, or machine monitor
5
Defective starting switch (Internal open circuit)
Open circuit in wiring harness 6 (wire breakage or defective contact of connector)
PC200, 200LC, 220, 220LC-8M0
Between CM01 (2) and (4)
Voltage
20 to 30 V
Between CM01 (10) and (4)
Voltage
20 to 30 V
1. Turn starting switch to OFF position. 2. Disconnect connector H15 and connect T-adapters to male side. 3. Turn starting switch to ON position and perform troubleshooting again. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (5) Resistance Max. 1 z ON position. If check result on cause 4 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect fusible link F05, No. 17 of fuse F01, and connectors H15 and CM01. 3. Connect T-adapters to male side of connector F05 and female side of H15 and CM01. Between battery (-) and ground
Resistance
Max. 1 z
Between battery (+) and F05 (male) (1)
Resistance
Max. 1 z
Between F05 (male) (2) and F01-16E
Resistance
Max. 1 z
Between F01-17 and each of CM01 (female) (1) and (2)
Resistance
Max. 1 z
Between CM01 (female) (3), (4) and ground (T05)
Resistance
Max. 1 z
Between F01-17 and H15 (female) (1)
Resistance
Max. 1 z
Between H15 (female) (5) and CM01(female)(10)
Resistance
Max. 1 z
40-400
17
SEN06138-00
Cause
400 Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
Procedure, measuring location, criteria and remarks If check result on cause 4 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 20E, and connectors H15, CM01, and C01. 3. Connect T-adapters to male side of connector F05 and female side of H15 and CM01.
7
Ground fault in wiring harness (contact with ground circuit)
8 Defective machine monitor
40-400 18
Between battery (+) or F05 (male) (1) and ground
Resistance
Min. 1 Mz
Between F05 (male) (2) and ground, or between Resistance Min. 1 Mz F01-16E and ground Between F01-17 and ground, or between CM01 (female) (1), (2) and ground, or between H15 Resistance Min. 1 Mz (female) (1) and ground Between H15 (female) (5) and ground, or between Resistance Min. 1 Mz CM01 (female) (14) and ground If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
SEN06138-00
Circuit diagram related to machine monitor power supply
PC200, 200LC, 220, 220LC-8M0
40-400
19
SEN06138-00
400 Troubleshooting of electrical system (E-mode) E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up. 1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow.
Failure Related information
Cause 1
Procedure, measuring location, criteria and remarks
Defective engine oil level switch Perform troubleshooting for failure code [B@BAZK]. system (machine monitor system) Failure
2) Radiator coolant level monitor lights up in yellow.
Related information Cause 1
Radiator sub tank coolant level switch system
40-400 20
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [B@BCZK].
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-5 Precaution monitor lights up while engine is running
SEN06138-00
E-5 Precaution monitor lights up while engine is running Failure
1) Engine coolant temperature monitor lights up in white. q
Related information
q
Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in white, engine coolant temperature may be low (below approximately 30 °C). Warm up engine. q Lighting up in white: Engine coolant temperature is low. q Lighting up in blue: Engine coolant temperature is proper. If no failure is found by check on cause 1, engine coolant temperature gauge Defective engine coolant tempera2 system may be defective. Perform troubleshooting for "E-8 Engine coolant ture gauge system temperature gauge does not indicate properly". Insufficient warm-up of machine 1 (when system works properly)
Failure
2) Hydraulic oil temperature monitor lights up in white. q
Related information
q
Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in white, hydraulic oil temperature may be low (below approximately 20 °C). Warm up engine. q Lighting up in white: Hydraulic oil temperature is low. q Lighting up in blue: Hydraulic oil temperature is proper. If no failure is found by check on cause 1, hydraulic oil temperature gauge sysDefective hydraulic oil temperature 2 tem may be defective. Perform troubleshooting for "E-9 hydraulic oil temperagauge system ture gauge does not indicate properly". Insufficient warm-up of machine 1 (when system works properly)
Failure
3) Charge level monitor lights up while engine is running.
Related information
q
Power generation signal of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
Cause
Procedure, measuring location, criteria and remarks
1 Defective alternator system
Failure
Perform troubleshooting for failure code [AB00KE].
4) Fuel level monitor lights up in red.
Related information
q
Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause
Procedure, measuring location, criteria and remarks
Low fuel level (when system works Fuel level may be low. Check it and add fuel if necessary. properly) If no failure is found by check on cause 1, fuel level gauge system may be 2 Defective fuel level gauge system defective. Perform troubleshooting for "E-7 Fuel level gauge does not indicate properly". 1
PC200, 200LC, 220, 220LC-8M0
40-400
21
400 Troubleshooting of electrical system (E-mode) E-5 Precaution monitor lights up while engine is running
SEN06138-00
Failure
5) Air cleaner clogging monitor lights up in yellow.
Related information
q
Air cleaner clogging switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2)
Cause Clogging of air cleaner (when system works properly) Defective air cleaner clogging 2 switch system 1
Procedure, measuring location, criteria and remarks Air cleaner may be clogged. Check it, then clean or replace if necessary. Perform troubleshooting for failure code [AA10NX].
6) Engine state monitor light up in yellow because of water separator sensor detection. (high water level in water separator) q Signal of water detection by fuel filter sensor can be checked with monitoring function. Related information (Code: 18800 Condition of WIF sensor) Failure
Cause
Procedure, measuring location, criteria and remarks
1
High water level in water separator Full of water is detected in water separator. Check and drain water separator. (when system works properly)
2
Defective water-in-fuel sensor system (engine controller circuit)
3 Defective machine monitor
40-400 22
If no failure is found by check on cause 1, water-in-fuel sensor system may be defective. Perform troubleshooting for failure codes [CA428] and [CA429] If no failure is found by checks on causes 1 and 2, machine monitor may be defective (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-6 Emergency stop monitor lights up while engine is running
SEN06138-00
E-6 Emergency stop monitor lights up while engine is running Failure
1) Engine coolant temperature monitor lights up in red. q
Related information
q
Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in red, engine coolant temperature may be high (above approximately 102 °C). Cool down engine coolant (run engine at low idle). Overheating of engine coolq Lighting up in red: Engine coolant temperature is high (overheating). 1 ant (when system works q Lighting up in blue: Engine coolant temperature is proper. properly) Perform troubleshooting for "S-14 Coolant temperature becomes too high (overheating)". If no failure is found by check on cause 1, engine coolant temperature gauge sysDefective engine coolant 2 tem may be defective. Perform troubleshooting for "E-8 Engine coolant temperature temperature gauge system gauge does not indicate properly".
Failure
2) Hydraulic oil temperature monitor lights up in red. q
Related information
q
Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature)
Cause
Procedure, measuring location, criteria and remarks
Overheating of hydraulic oil 1 (when system works properly) 2
Defective hydraulic oil temperature gauge system
Failure
If monitor lights up in red, hydraulic oil temperature may be high (above approximately 102 °C). Cool down hydraulic oil (run engine at low idle or stop engine). q Lighting up in red: Hydraulic oil temperature is high (overheating). q Lighting up in blue: Hydraulic oil temperature is proper. If no failure is found by check on cause 1, hydraulic oil temperature gauge system may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge does not indicate properly".
3) Engine oil pressure monitor lights up in red.
Related information
q
Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller to machine monitor through CAN communication.
Cause Low engine oil pressure 1 (when system works properly) Defective engine oil pres2 sure switch system
Procedure, measuring location, criteria and remarks Engine oil pressure may be low. Check it. If it is low, perform troubleshooting for "S-12 Oil pressure decreases". If no failure is found by check on cause 1, engine oil pressure switch system may be defective. Perform troubleshooting for failure code [CA435].
PC200, 200LC, 220, 220LC-8M0
40-400
23
400 Troubleshooting of electrical system (E-mode) E-7 Fuel level gauge does not indicate properly
SEN06138-00
E-7 Fuel level gauge does not indicate properly 1) While fuel is added, fuel level gauge indicator does not rise above red range (E). 2) While fuel level is low, fuel level gauge indicator does not lower below green range top (F).
Failure Related information
q
Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause Defective fuel level sensor 1 (internal open or short circuit)
2
Open circuit or ground fault in wiring harness
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector P21 and connect T-adapters to male side. Between P21 (male) (1) and ground
Fuel level: FULL
Resistance
7 to 11 z
Fuel level: EMPTY
Resistance
85 to 95 z
1. Turn starting switch to OFF position. 2. Disconnect connector CM01 and connect T-adapter to female side. Between CM01(female) (15) and ground
Fuel level: FULL
Resistance
7 to 11 z
Fuel level: EMPTY
Resistance
85 to 95 z
a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and P21, and connect T-adapters to each female side. Between CM01(female) (15) and P21(female) (1)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors CM01 and P21, and connect T-adapters to either female 4 ness side. (contact with ground circuit) Between CM01(female) (15) and ground, or between Resistance Min. 1 Mz P21(female) (1) and ground 1. Turn starting switch to OFF position. 2. Disconnect connector P21. Hot short circuit in wiring 3. Insert T-adapters into connector CM01 or connect T-adapters to female side of 5 harness connector P21. (Contact with 24 V circuit) 4. Turn starting switch to ON position. Between CM01(15) and ground, or between P21 Approx. 3.3 Voltage (female) (1) and ground V If no failure is found by above checks, machine monitor is defective. (Since this is 6 Defective machine monitor an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to fuel level sensor
40-400 24
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-7 Fuel level gauge does not indicate properly
SEN06138-00
3) Indication of fuel level gauge is different from actual fuel level. 4) Indication of fuel level gauge is different from display of fuel level monitor.
Failure Related information
q
Signal voltage of fuel level sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Fuel level
1 Defective machine monitor
Reading of fuel level gauge Color of monitor light (a)
289 l
6
244.5 l
5
200 l
4
100 l
3
60 l
2
41 l
1
Blue
Red
Fuel level gauge and fuel level monitor
PC200, 200LC, 220, 220LC-8M0
40-400
25
400 Troubleshooting of electrical system (E-mode) E-8 Engine coolant temperature gauge does not indicate properly
SEN06138-00
E-8 Engine coolant temperature gauge does not indicate properly 1) While engine coolant temperature is rising properly, temperature gauge indicator does not rise above white range (C). Failure 2) While engine coolant temperature remains in normal range, temperature gauge indicator rises to red range (H). q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is Related infortransmitted to machine monitor through CAN communication system. q Engine coolant temperature can be checked with monitoring function mation (Code: 04107 Engine coolant temperature) Cause 1
Defective engine coolant temperature sensor system
2 Defective machine monitor
Procedure, measuring location, criteria and remarks Engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145]. If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3) Indication of engine coolant temperature gauge is different from actual engine coolant temperature. Failure 4) Indication of engine coolant temperature gauge is different from display of engine coolant temperature monitor. q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is Related infortransmitted to machine monitor through CAN communication system. q Engine coolant temperature can be checked with monitoring function mation (Code: 04107 Engine coolant temperature) Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting.
1 Defective machine monitor
Engine coolant temperature
Coolant temperature gauge level
105 °C
6
102 °C
5
100°C
4
85 °C
3
60 °C
2
30°C
1
Color of monitor light (a) Red
Blue
White
Engine coolant temperature gauge and coolant temperature monitor
40-400 26
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate properly
SEN06138-00
E-9 Hydraulic oil temperature gauge does not indicate properly 1) While hydraulic oil temperature is rising properdy, temperature gauge does not rise from white range (C). 2) While hydraulic oil temperature is stabilized properly, temperature gauge rises to red range (H). q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitRelated inforted to machine monitor through CAN communication system. mation q Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) Failure
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector P22 and connect T-adapters to male side.
Defective hydraulic oil temperature sensor 1 (internal open or short circuit)
Between P22 (male) (1) and (2) a Temperature characteristics of oil temperature sensor
Between P22 (male) (2) and ground
2
Open circuit or ground fault in wiring harness
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
10°C
Resistance
30°C
Resistance
80°C
Resistance
100°C
Resistance Resistance
Approx. 90 kz Approx. 35 kz Approx. 6.5 kz Approx. 3.5 kz Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. Between C01 (female) (29) and (46) a Resistance accords with temperature characteristics Resistance 3.5 to 90 kz table in cause 1. Between C01 (female) (29) and ground Resistance Min. 1 Mz a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P22, and connect T-adapters to each female side. Between C01 (female) (29) and P22 (female) (2) Resistance Max. 1 z
Between C01 (female) (46) and P22 (female) (1) Resistance Max. 1 z a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C01 and P22, and connect T-adapters to either female 4 ness side. (contact with ground circuit) Between C01 (female) (29) and ground, or between Resistance Min. 1 Mz P22 (female) (2) and ground 1. Turn starting switch to OFF position. 2. Disconnect connector P22. Hot short circuit in wiring har- 3. Insert T-adapters into connector C01 or connect T-adapters to female side of 5 ness connector P22. (contact with 24 V circuit) 4. Turn starting switch to ON position. Between C01 (29) and ground, or between P22 Voltage Approx. 5 V (female) (2) and ground If no failure is found by above checks, the pump controller is defective. (Since this is 6 Defective pump controller an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
40-400
27
SEN06138-00
400 Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate properly
Circuit diagram related to hydraulic oil temperature sensor
40-400 28
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate properly
SEN06138-00
3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. 4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitted to machine monitor through CAN communication system. Related inforq Hydraulic oil temperature can be checked with monitoring function mation (Code: 04401 Hydraulic oil temperature) Failure
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Hydraulic oil temperature
Reading of hydraulic oil temperature gauge
105 °C
6
102 °C
5
100°C
4
85 °C
3
40°C
2
20°C
1
1 Defective machine monitor
Color of monitor light (a) Red
Blue
White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
PC200, 200LC, 220, 220LC-8M0
40-400
29
400 Troubleshooting of electrical system (E-mode) E-10 Displays on machine monitor are different from those for actual machine
SEN06138-00
E-10 Displays on machine monitor are different from those for actual machine Failure
q
Displays on machine monitor are different from those for actual machine
Related information q
PC200-8M0, PC200LC-8M0 Cause
q
Procedure, measuring location, criteria and remarks
1 Defective model code signal
a Turn starting switch to ON position and perform troubleshooting (with monitoring function). Model selection 1 = OFF Model selection 2 = OFF 00201 Switch Input Model selection 3 Monitoring code Monitoring display 2 = ON Model selection 4 = OFF Model selection 5 = OFF If display on monitor is incorrect, perform troubleshooting for failure code [DA29KQ].
2 Defective machine monitor
If no failure is found by check on cause 1, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC220-8M0, PC220LC-8M0 Cause
Procedure, measuring location, criteria and remarks
1 Defective model code signal
a Turn starting switch to ON position and perform troubleshooting (with monitoring function). Model selection 1 = ON Model selection 2 = OFF 00201 Switch Input Model selection 3 Monitoring code Monitoring display 2 = ON Model selection 4 = OFF Model selection 5 = OFF If display on monitor is incorrect, perform troubleshooting for failure code [DA29KQ].
2 Defective machine monitor
If no failure is found by check on cause 1, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-400 30
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-11 Some areas of machine monitor screen are not displayed
SEN06138-00
E-11 Some areas of machine monitor screen are not displayed Failure Related information
q
Machine monitor does not display some items
q
LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If number of bright and black pixels do not exceed ten, it does not indicate failure or defect of LCD panel.
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor 1 (LCD panel)
When following switches are operated, if whole LCD panel is lighted up (whole surface becomes white), LCD panel has no failure. q Operation of switches: [4] and [F2] (Press simultaneously)
Defective machine monitor (body)
If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2
E-12 Function switch does not operate Failure Related information
q
Function switch does not work.
q
Signal of function switch can be checked with monitoring function. (Code: 04503 Monitor function switch)
Cause 1 Defective machine monitor
PC200, 200LC, 220, 220LC-8M0
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-400
31
400 Troubleshooting of electrical system (E-mode) E-13 Automatic warm-up system does not operate (in cold season)
SEN06138-00
E-13 Automatic warm-up system does not operate (in cold season) Failure
q
Automatic warm-up system does not operate (in cold weather)
q
Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant temperature is below 30 °C. With starting switch at ON position or after engine is started, if fuel control dial is kept at 70% throttle position or higher for 3 seconds, automatic warm-up operation is canceled. If machine is equipped with air conditioner, when blower is turned on, ambient temperature is below 5 °C and engine coolant temperature is below 55 °C, automatic warm-up function increases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 °C, automatic warm-up function is canceled. If engine coolant temperature is below 10 °C, turbocharger protection function works to keep engine speed below 1,000 rpm for up to 5 seconds after engine is started.
q
Related information
q
q
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Engine coolant temperaCoolant temperature Monitoring code ture gauge level
04107 Defective engine coolant tempera1 Engine coolant temperature signal system ture
2 Defective engine controller
105 °C
6 (a: Red)
102 °C
5 (a: Red)
100 °C
4 (a: Blue)
85 °C
3 (a: Blue)
60 °C
2 (a: Blue)
30 °C
1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge level, perform troubleshooting for "E-8 Engine coolant temperature gauge does not indiate properly". If no failure is found by cause 1, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Engine coolant temperature gauge and engine coolant temperature monitor
40-400 32
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-14 Auto-decelerator does not operate properly
SEN06138-00
E-14 Auto-decelerator does not operate properly 1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off. q Condition of signal of auto-decelerator switch can be checked with monitoring function. Related information (Code: 04504 Monitor 1st, 2nd line switches) Failure
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor Failure
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2) Auto-decelerator is not operated or canceled with lever. q
Related information q
Since set speed of auto-decelerator is 1,050 rpm, it is not operated or canceled if fuel control dial is set below this speed. Auto-deceleration does not function in arm crane mode (L) for machines with arm crane.
Cause
Procedure, measuring location, criteria and remarks a Start engine and perform troubleshooting (with monitoring function). Monitoring code
Item
Correct display
Swing Travel 01900 Pressure switch 1 1 Defective PPC oil pressure signal
Boom LOWER Boom RAISE Arm IN
When lever is operated: ON When lever is in neutral: OFF
Arm OUT Bucket CURL 01901 Pressure Switch 2
Bucket DUMP Service
When lever is operated: ON When lever is in neutral: OFF
If display of monitor is incorrect, perform troubleshooting for "E-26 - 34 Monitoring function does not display *** properly". 2 Defective machine monitor 3 Defective pump controller 4 Defective engine controller
PC200, 200LC, 220, 220LC-8M0
If no problem is found in check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no problem is found in checks on causes 1 and 2, pump controller may be defective (Since this is an internal defect, troubleshooting cannot be performed.) If no problem is found in checks on causes 1 and 3, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-400
33
400 Troubleshooting of electrical system (E-mode) E-15 Working mode does not change
SEN06138-00
E-15 Working mode does not change Failure
1) When working mode switch is operated, working mode selection screen is not displayed.
Related information
q
Signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause 1 Defective machine monitor
Failure
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2 Defective pump controller
Pump controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-400 34
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-16 Travel speed does not change
SEN06138-00
E-16 Travel speed does not change 1) When travel speed selector switch is operated, display of travel speed monitor does not change. q Signal of travel speed selector switch can be checked with monitoring function. Related information (Code: 04504 Monitor 1st, 2nd line switches) Failure
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Failure
2) When selection of travel speed is changed, actual travel speed does not change. q
Related information
q
When failure due to cause 1 occurs, actual travel speed does not decrease when travel speed setting is changed to "Lo". As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector.
Cause
1
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Hot short circuit in wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04 and connect T-adapters to female side. 3. Turn starting switch to ON position. Between V04 (female) (2) and ground
2 Defective machine monitor 3 Defective pump controller
Voltage
Max. 3 V
If no problem is found in check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no problem is found in checks on causes 1 and 2, pump controller may be defective (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to travel speed solenoid
PC200, 200LC, 220, 220LC-8M0
40-400
35
400 Troubleshooting of electrical system (E-mode) E-17 Alarm buzzer cannot be canceled
SEN06138-00
E-17 Alarm buzzer cannot be canceled Failure Related information
q
Alarm buzzer does not stop sounding.
q
Signal of alarm buzzer cancel switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
E-18 When starting switch is turned OFF, service meter is not displayed Failure
q
When starting switch is at OFF position, service meter is not displayed.
q
While starting switch is at OFF position, if following switches are operated, service meter is displayed at top center of screen. Operation of switches: [4] and [1] (Press simultaneously)
Related information
Cause
Procedure, measuring location, criteria and remarks
Defective backup power supply 1 system
When starting switch is turned to ON position, if machine monitor displays nothing, backup power supply system may be defective. In this case, perform troubleshooting for "E-3 When starting switch is turned to ON position, machine monitor displays nothing".
2 Defective machine monitor
If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
E-19 Service mode cannot be selected Failure Related information
q
Machine monitor cannot be set in service mode
q
Following switch operation sets machine monitor in service mode. Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
Cause 1 Defective machine monitor
40-400 36
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-20 Any of work equipment, swing and travel do not operate or cannot be locked
SEN06138-00
E-20 Any of work equipment, swing and travel do not operate or cannot be locked Failure
1) All of work equipment, swing, and travel mechanism do not move.
Related information Cause 1 Defective fuse F01-3
Defective lock lever 2 switch (internal open circuit)
Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has grounding fault. (See Cause 6.) 1. Turn starting switch to OFF position. 2. Disconnect connector S14 and connect T-adapters to female side. Between S14 (male) (1) and (2)
Lock lever: LOCK
Resistance
Min. 1 Mz
Lock lever: FREE
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapters to male side. 3 noid (open or short circuit Between V01 (male) (1) and (2) Resistance in internal wiring) Between V01 (male) (1) and ground Resistance
20 – 60 z Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove diode array D01 and connect T-adapters to male side. Defective diode array D01 a Check the continuity in diode range. 4 (Internal short circuit) Between D01 (male) (8) (+) and (4) (-) Continuity Between D01 (male) (4) (+) and (8) (-)
No continuity
1. Turn starting switch to OFF position. 2. Set lock lever to FREE position. 3. Remove fuse F01-3. Between F01-3 and ground (coil resistance of PPC lock Resistance 20 – 60 z solenoid) Open circuit in wiring har- a If no failure is found by above check, this check is not required. 1. Turn starting switch to OFF position. ness 5 (wire breakage or defec- 2. Remove fuse F01-3. tive contact of connector) 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side of S14 and female side of V01. Between F01-3 and S14 (male) (1)
Resistance
Max. 1 z
Between S14 (male) (2) and V01 (female) (1)
Resistance
Max. 1 z
Between V01 (female) (2) and ground (T09)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Remove fuse F01-3. Ground fault in wiring har- 3. Disconnect connectors S14, V01, and D01, and then connect T-adapters to male ness side of S14 or female side of V01 or D01. 6 (contact with ground cir- Between ground and F01-3 or S14 (male) (1) Resistance Min. 1 Mz cuit) Between ground and S14 (male) (2), V01 (female) (1) or Resistance Min. 1 Mz D01 (female) (4)
PC200, 200LC, 220, 220LC-8M0
40-400
37
400 Troubleshooting of electrical system (E-mode) E-20 Any of work equipment, swing and travel do not operate or cannot be locked
SEN06138-00
Failure
2) All of work equipment, swing, and travel mechanism are not locked.
Related information Cause
1
Defective lock lever switch (Internal short circuit)
Hot short circuit in wiring 2 harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S14, and connect T-adapters to male side. Between S14 (male) (1) and (2)
Lock lever: LOCK
Resistance
Min. 1 Mz
Lock lever: FREE
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector V01 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between V01 (male) (1) and (2)
Voltage
Max. 1 V
Circuit diagram related to troubleshooting
40-400 38
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-21 Swing holding brake does not operate properly
SEN06138-00
E-21 Swing holding brake does not operate properly Failure
1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related information
q
Signal of swing lock switch can be checked with monitoring function. (Pump controller system code: 02200 Switch input 1)
Cause 1 Defective fuse F01-1
Procedure, measuring location, criteria and remarks If fuse F01-1 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side.
Defective swing brake can2 cel switch (internal short circuit)
swing brake cancel switch: Between S25 (male) (13) Normal and (14) swing brake cancel switch: FREE
Resistance
Min. 1 Mz
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to male side. a Check the continuity in diode range. 3
Defective diode array D01 or Between D01 (male) (7) (+) and (3) (-) D03 (internal short circuit) Between D01 (male) (3) (+) and (7) (-)
Continuity No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
1. Turn starting switch to OFF position. 2. Disconnect connector V03 and connect T-adapters to female side. 3. Turn starting switch to ON position. 4 Defective wiring harness
Open circuit in wiring harness 5 (wire breakage or defective contact of connector)
swing brake cancel switch: Between V03 (female) (1) FREE and (2) swing brake cancel switch: Normal
Voltage
20 to 30 V
Voltage
Max. 1 V
a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors V03 and S25 and connect T-adapters to each male side. Between V03 (female) (1) and S25 (female) (14)
Resistance
Max. 1 z
Between V03 (female) (2) and C02 (female) (115)
Resistance
Max. 1 z
a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors S25, V03, D01 and D03, and connect T-adapters to 6 ness female side of V03. (contact with ground circuit) Between V03 (female) (1) and ground Resistance Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0
40-400
39
400 Troubleshooting of electrical system (E-mode) E-21 Swing holding brake does not operate properly
SEN06138-00
Failure
2) When swing brake cancel switch is set to Normal position, swing holding brake does not operate.
Related information Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S25 and connect T-adapters to male side.
Defective swing brake can1 cel switch (internal short circuit)
Hot short circuit in wiring 2 harness (contact with 24 V circuit)
swing brake cancel switch: Between S25 (male) (13) Normal and (14) swing brake cancel switch: FREE 1. 2. 3. 4.
Min. 1 Mz
Resistance
Max. 1 z
Turn starting switch to OFF position. Disconnect connector V03 and connect T-adapters to female side. Turn starting switch to ON position. Set swing lock switch to ON position.
Between V03 (female) (1) and ground
40-400 40
Resistance
Voltage
Max. 1 V
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-21 Swing holding brake does not operate properly
SEN06138-00
Circuit diagram related to swing brake solenoid
PC200, 200LC, 220, 220LC-8M0
40-400
41
400 Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
SEN06138-00
E-22 One-touch power maximizing function does not operate properly 1) When L.H. knob switch is pressed, one-touch power max. monitor is not displayed. 2) When L.H. knob switch is pressed, work equipment power is not increased.
Failure
q
Related information
q
One-touch power max. function does not operate when selected working mode is not power mode (P) or economy mode (E). Signal of L.H. knob switch can be checked with monitoring function. (Code: 02200 Switch Input 1)
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
When L.H. knob switch is pressed, if work equipment power is increased but one-touch power max. monitor is not displayed on machine monitor, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
2 Defective fuse No. 9
If fuse is blown, circuit probably has grounding fault. (See Cause 6.)
1. Turn starting switch to OFF position. 2. Disconnect connector S11, and connect T-adapters to male side. Defective left knob switch L.H. knob switch: 3 Resistance Min. 1 Mz (Internal open circuit) Between S11 (female) (1) Released L.H. knob switch: and (2) Resistance Max. 1 z Pressed 1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. 3. Turn starting switch to ON position. Open circuit or ground fault in wir- a Ignore displayed failure code. 4 ing harness L.H. knob switch: Voltage Max. 1 V Between C01 (female) Released L.H. knob switch: (41) and ground Voltage 20 to 30 z Pressed a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01-9. Open circuit in wiring harness 3. Disconnect connectors C01 and S11 and connect T-adapters to each female 5 (wire breakage or defective conside. tact of connector) Between F01-9 and S11 (female) (1) Resistance Max. 1 z Between S11 (female) (2) and C01 (female) (41)
6
Ground fault in wiring harness (contact with ground circuit)
a 1. 2. 3.
Between F01-9 or S11 (female) (1) and ground
7 Defective pump controller
40-400 42
Resistance
Max. 1 z
If no failure is found by check on cause 4, this check is not required. Turn starting switch to OFF position. Remove fuse F01-9. Disconnect connectors C01 and S11 and connect T-adapters to female side of S11. Resistance
Min. 1 Mz
Between S11 (female) (2) or C01 (female) (41) and Resistance Min. 1 Mz ground If no failure is found by above checks, the pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
SEN06138-00
Circuit diagram related to one-touch power maximizing switch
PC200, 200LC, 220, 220LC-8M0
40-400
43
400 Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
SEN06138-00
Failure
3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related information
q
Signal of L.H. knob switch can be checked with monitoring function. (Code: 02200 Switch Input 1)
Cause Hot short circuit in wiring 1 harness (contact with 24 V circuit) 2 Defective pump controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V02 and connect T-adapters to female side. 3. Turn starting switch to ON position. Between V02 (female) (1) and (2)
Voltage
Max. 3 V
If no failure is found by check on cause 1, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to 2-stage relief solenoid
40-400 44
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-23 Travel alarm does not sound or does not stop sounding
SEN06138-00
E-23 Travel alarm does not sound or does not stop sounding Failure
1) Alarm does not sound during travel.
Related information
q
Output to travel alarm can be checked with monitoring function. (Code: 03701 Controller output 2)
Cause 1
Defective travel alarm (internal defect)
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M14 and connect T-adapters to male side. Between M14 (male) (1) and (2)
Continuity
1. Turn starting switch to OFF position. 2. Disconnect connectors M14 and C02 and connect T-adapters to each female side. Between C02 (female) (107) and M14 (female) (1)
Resistance
Max. 1 z
Between C02 (female) (115) and M14 (female) (2)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C02 and M14, and connect T-adapters to either female 3 ness side. (contact with ground circuit) Between C02 (female) (107) and ground, or between Resistance Min. 1 Mz M14 (female) (1) and ground
Failure
2) Alarm does not stop sounding while machine is stopped.
Related information Cause Hot short circuit in wiring 1 harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M14 and connect T-adapters to female side. 3. Turn starting switch to ON position. Between M14 (female) (1) and ground
Voltage
Max. 3 V
Circuit diagram related to travel alarm
PC200, 200LC, 220, 220LC-8M0
40-400
45
400 Troubleshooting of electrical system (E-mode) E-24 Horn does not sound or does not stop
SEN06138-00
E-24 Horn does not sound or does not stop Failure
1) Horn does not sound.
Related information Cause 1 Defective fuse F01-5
2
Defective horn relay (internal open or short circuit)
Procedure, measuring location, criteria and remarks If fuse F01(5) is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 7 first. 1. 2. 3. 4.
Turn starting switch to OFF position. Replace horn relay (connector: R08) with another relay. Turn starting switch to ON position. Press L.H. knob switch.
If horn sounds, original horn relay is defective.
3
Defective horn switch (internal open or short circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector S10 and connect T-adapters to male side. Between S10 (male) (1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors M07 and M08, and connect T-adapters to each male Defective high-tone horn (M07) side. 4 or low-tone horn (M08) (internal Between M07 (male) (1) and (2) Continuity open or short circuit) Between M08 (male) (1) and (2)
5 Defective wiring harness
1. 2. 3. 4.
Continuity
Turn starting switch to OFF position. Disconnect connector R08 and connect T-adapters to female side. Turn starting switch to ON position. Press L.H. knob switch.
Between R08 (female) (1) and (2)
Voltage
20 to 30 V
Between R08 (female) (3) and (2)
Voltage
20 to 30 V
1. Turn starting switch to OFF position. 2. Disconnect connector R08 and connect T-adapters to female side. Between R08 (female) (5) and ground
Continuity
Between R08 (female) (1) and ground
Continuity
a 1. Open circuit in wiring harness 6 (Wire breakage or defective con- 2. 3. tact)
7
Ground fault in wiring harness (contact with ground circuit)
40-400 46
If no failure is found by above checks, this check is not required. Turn starting switch to OFF position. Remove fuse F01-5. Disconnect connectors R08 and S10, and connect T-adapters to each female side.
Between F01-5 and S10 (female) (1)
Resistance
Max. 1 z
Between S10 (female) (2) and R08 (female) (1)
Resistance
Max. 1 z
Between R08 (female) (2) and ground
Resistance
Max. 1 z
Between R08 (female) (3) and F01(5)
Resistance
Max. 1 z
a 1. 2. 3.
If fuse is not blown, this check is not required. Turn starting switch to OFF position. Remove fuse F01-5. Disconnect connectors R08, M07, and M08, and connect T-adapters to female side of R08.
Between R08 (female) (1) and ground
Resistance
Min. 1 Mz
Between R08 (female) (3) and ground
Resistance
Min. 1 Mz
Between R08 (female) (5) and ground
Resistance
Min. 1 Mz
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-24 Horn does not sound or does not stop
Cause 8
Defective horn (internal defect)
Failure
SEN06138-00
Procedure, measuring location, criteria and remarks If no failure is found by above checks, horn may be defective.
2) Horn does not stop sounding.
Related information Cause
1
Defective horn relay (R08) (internal open or short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove horn relay (connector R08). 3. Turn starting switch to ON position. If horn stops sounding, original horn relay is defective.
2
Hot short circuit in wiring harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors M07 and M08, and connect T-adapters to each female side. 3. Turn starting switch to ON position. Between M07 (female) (2) and (1)
Voltage
Max. 1 V
Between M08 (female) (2) and (1)
Voltage
Max. 1 V
Circuit diagram related to horn
PC200, 200LC, 220, 220LC-8M0
40-400
47
400 Troubleshooting of electrical system (E-mode) E-25 Windshield wiper and window washer do not operate
SEN06138-00
E-25 Windshield wiper and window washer do not operate Failure
1) When wiper switch is operated, wiper monitor does not light up or go off.
Related information
q
Signal of wiper switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Failure
2) When wiper switch is operated, windshield wiper does not operate. q
Related information
q
Signal of window rear limit switch can be checked with monitoring function. (Code: 02204 Switch input 5) Wiper motor is checked and its failure is expressed in failure code [DY20KA], [DY20MA], [DY2DKB], or [DY2EKB].
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector W03.
1
2
Defective window rear limit switch (Internal short circuit) Between W03 (male) (1) and (2)
Defective wiper motor (Internal open circuit)
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
Front window: when set in position
Resistance
Min. 1 Mz
Front window: when pulled up
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapters to female side. Between M05 (female) (1) and (3)
Continuity
a Wiper motor system See troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB]. a Wiper rear limit switch system 1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapters to female side. 3. Pull up front window. Between C01 (female) (57) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connector C01 and connect T-adapters to female side. 4 ness 3. Set front window in position. (contact with ground circuit) Between C01 (female) (57) and ground Resistance Min. 1 Mz 5 Defective pump controller
Failure
If no failure is found by above checks, the pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
3) When window washer switch is operated, window washer does not operate.
Related information
q q
Signal of window washer switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Window washer is checked and its failure is expressed in failure codes [DY2CKA] or [DY2CKB].
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)
40-400 48
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-25 Windshield wiper and window washer do not operate
SEN06138-00
Circuit diagram related to wiper
PC200, 200LC, 220, 220LC-8M0
40-400
49
400 Troubleshooting of electrical system (E-mode) E-26 BOOM DOWN indicator is not displayed properly with monitoring function
SEN06138-00
E-26 BOOM DOWN indicator is not displayed properly with monitoring function Failure
"Boom DOWN" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective boom DOWN PPC oil 1 pressure sensor system (internal open circuit or short circuit)
Perform troubleshooting for failure code [DHS9MA].
E-27 ARM DUMP indicator is not displayed properly with monitoring function Failure
"Arm DUMP" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective arm DUMP PPC oil 1 pressure sensor system (internal open circuit or short circuit)
Perform troubleshooting for failure code [DHSCMA].
E-28 ARM IN indicator is not displayed properly with monitoring function Failure
"Arm IN" operation signal is not displayed properly on monitoring sceen.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause Defective arm IN PPC pressure 1 sensor system (internal open or short circuit)
40-400 50
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DHS3MA].
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-29 BOOM RAISE indicator is not displayed properly with monitoring function
SEN06138-00
E-29 BOOM RAISE indicator is not displayed properly with monitoring function Failure
"Boom RAISE" operation signal is not displayed properly on monitoring screen.
Related information
Monitoring code: 01900 Pressure switch 1
q
Cause
Procedure, measuring location, criteria and remarks
Defective boom RAISE PPC pressure sensor system 1 Perform troubleshooting for failure code [DHS8MA]. (internal open or short circuit)
E-30 BUCKET CURL indicator is not displayed properly with monitoring function Failure
"Bucket CURL" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause 1
Procedure, measuring location, criteria and remarks
Defective bucket CURL PPC presPerform troubleshooting for failure code [DHS4MA]. sure sensor system
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function Failure
"Bucket DUMP" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause 1
Procedure, measuring location, criteria and remarks
Defective bucket DUMP PPC presPerform troubleshooting for failure code [DHSDMA]. sure sensor system
PC200, 200LC, 220, 220LC-8M0
40-400
51
400 Troubleshooting of electrical system (E-mode) E-32 SWING indicator is not displayed properly with monitoring function
SEN06138-00
E-32 SWING indicator is not displayed properly with monitoring function Failure
"Swing" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective swing PPC pressure 1 sensor system (internal open or short circuit)
Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
E-33 TRAVEL indicator is not displayed properly with monitoring function Failure
"Travel" operation signal is not displayed properly on monitoring screen.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective travel PPC oil pressure 1 sensor system (internal open or short circuit)
Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA] and [DHSJMA].
40-400 52
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-34 ATTACHMENT indicator is not displayed properly with monitoring function
SEN06138-00
E-34 ATTACHMENT indicator is not displayed properly with monitoring function Failure
"Attachment" operation signal is not displayed properly on monitoring screen. q
Related information
q k
Monitoring code: 01901 Pressure switch 2 For safety, use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause 1 and 2. Do not check pressure switch connector while engine is running.
Cause
Procedure, measuring location, criteria and remarks
A. If "Service" operation signal displayed on monitoring screen is not "ON" when engine is started and attachment control pedal is depressed at front end 1. Turn starting switch to OFF position. 2. Disconnect connector P14 and connect "short connector" to male side. 3. Turn starting switch to ON position. a After finishing troubleshooting, return connectors as they were. Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON", 1 (P14) for front end of attachment front service PPC pressure switch (P14) is defective (Note 1). B. If "Service" operation signal displayed on monitoring screen is ON" when control pedal starting switch is turned to ON position 1. Turn starting switch to OFF position. 2. Disconnect connector P14. 3. Turn starting switch to ON position. If "Service" operation signal displayed on monitoring screen changes to "OFF", front service PPC pressure switch (P14) is defective (Note 2). A. If "Service" operation signal displayed on monitoring screen is not "ON" when engine is started and attachment control pedal is depressed at rear end 1. Turn starting switch to OFF position. 2. Disconnect connector P15 and connect "short connector" to male side. 3. Turn starting switch to ON position. a After finishing troubleshooting, return connectors as they were. Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON", 2 (P15) for rear end of attachment rear service PPC pressure switch (P15) is defective (Note 1). B. If "Service" operation signal displayed on monitoring screen is ON" when control pedal starting switch is turned to ON position 1. Turn starting switch to OFF position. 2. Disconnect connector P15. 3. Turn starting switch to ON position. If "Service" operation signal displayed on monitoring screen changes to "OFF", rear service PPC pressure switch (P15) is defective (Note 2). 1. Turn starting switch to OFF position. 2. Insert T-adapters into P13. 3. Start engine. 4. Operate attachment control pedal, and perform troubleshooting. Defective wiring harness or pump 3 attachment control pedal: controller Between P13 (1) and (2) Voltage Approx. 7 V Neutral attachment control pedal: Between P13 (1) and (2) front end or rear end Voltage Max. 1 V depressed
PC200, 200LC, 220, 220LC-8M0
40-400
53
SEN06138-00
Cause
400 Troubleshooting of electrical system (E-mode) E-34 ATTACHMENT indicator is not displayed properly with monitoring function
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P14, and P15, and connect T-adapters to each female side.
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
6 Short circuit in wiring harness
7 Defective pump controller
Between C01(female) (76) and P14(female) (1)
Resistance
Max. 1 z
Between C01(female) (76) and P15(female) (1)
Resistance
Max. 1 z
Between P14 (female) (2) and ground (T06)
Resistance
Max. 1 z
Between P15 (female) (2) and ground (T06)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P14, and P15, and connect T-adapters to either female side. Between ground C01 (female) (76), P14 (female) Resistance Min. 1 Mz (1) or P15 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors P14 and P15, and connect T-adapters to either female side. 3. Turn starting switch to ON position. Between P14 (female) (1) and ground, or between Voltage Approx. 7 V P15 (female) (1) and ground If no failure is found by above checks, pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Note 1: If "Service" operation signal displayed on monitoring screen is "OFF" while voltage between C01 (52) and ground is below 1 V, pump controller is defective. Note 2: If "Service" operation signal displayed on monitoring screen is "ON" while voltage between C01 (52) and ground is approximately 7 V, pump controller is defective. Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)
40-400 54
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-35 Attachment hydraulic circuit cannot be changed
SEN06138-00
E-35 Attachment hydraulic circuit cannot be changed Failure Related information
q Attachment circuit is not changed 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected. 2) When working mode B is selected, breaker circuit (one-way circuit) is not selected. q
Failures (open circuit, short circuit) of attachment oil return selector solenoid are troubleshot for failure codes [DWA2KA] and [DWA2KB].
Cause Defective attachment oil return 1 selector solenoid (internal short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V06 and connect T-adapter to male side. Between V06 (male) (1) and (2)
Resistance
20 – 60 z
Between V06 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Disconnect connector V06 and connect T-adapters to female side. 2 3. Turn starting switch to ON position. (contact with 24 V circuit) Between V06 (female) (1) and ground Voltage Max. 3 V
Circuit diagram related to attachment oil return selector solenoid
PC200, 200LC, 220, 220LC-8M0
40-400
55
400 Troubleshooting of electrical system (E-mode) E-36 KOMTRAX system does not operate properly
SEN06138-00
E-36 KOMTRAX system does not operate properly Failure Related information
q
KOMTRAX system does not operate properly.
q
Perform following troubleshooting if administrator of KOMTRAX system requests to check whether failure is occurring in system on machine. Even when KOMTRAX system is defective, no problem appears on machine. Check all of results of troubleshooting on service menu display of machine monitor.
q q
No.
Cause
1 Defective communication 1
Procedure, measuring location, criteria and remarks 1. Turn starting switch to ON position. 2. Display “Terminal status” screen. Monitoring Check item: To be completed display Station set-up check 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. N ###.##.## (Latitude)
2 Defective positioning by GPS
Monitoring display
Check item: Positioning
E ###.##.## (Longitude) In positioning
If latitude and longitude are not displayed within 5 minutes with machine stayed outdoor where opens clearly for sky, contact KOMTRAX service hot line. 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. Monitoring Check item: Satellite in View or No Satellite in View Defective communication environdisplay Communication 3 ment If Communication Status does never display “Satellite in View” within 15 minutes with machine stayed outdoor where opens clearly for sky, check if connector of TC330 or antenna on top of cab are properly connected. 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. Check item: 4 Defective communication 2 Monitoring Number of message not 0 to 60 (normally 0) display yet sent
a Select “01 Terminal Status” from “11 KOMTRAX settings” in service menu of machine monitor.
40-400 56
a Select “02 GPS & Communication Status” from “11 KOMTRAX settings” in service menu of machine monitor.
PC200, 200LC, 220, 220LC-8M0
400 Troubleshooting of electrical system (E-mode) E-36 KOMTRAX system does not operate properly
PC200, 200LC, 220, 220LC-8M0
SEN06138-00
40-400
57
SEN06138-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06138-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-400
58
SEN06139-00 SEN05990-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 500 Troubleshooting of hydraulic and mechanical system (H-mode) System diagram of hydraulic and mechanical system ................................................................................
4
Failure mode and cause table.....................................................................................................................
6
Information in troubleshooting table ............................................................................................................
8
H-1 Speed or power of whole work equipment, swing, and travel is low ....................................................
9
H-2 Engine speed lowers significantly or engine stalls ............................................................................... 11 H-3 Work equipment, swing, and travel systems do not work .................................................................... 12 H-4 Unusual noise comes out from around hydraulic pump ....................................................................... 13 H-5 Fine control performance or response is low ....................................................................................... 14 H-6 Speed or power of boom is low ............................................................................................................ 15 H-7 Speed or power of arm is low............................................................................................................... 16 H-8 Speed or power of bucket is low .......................................................................................................... 17 H-9 Work equipment does not move in its single operation........................................................................ 18 H-10 Hydraulic drift of work equipment is large .......................................................................................... 19 H-11 Time lag of work equipment is large................................................................................................... 21 H-12 Other work equipment moves when one of work equipment is relieved ............................................ 22 H-13 One-touch power maximizing function does not work........................................................................ 23 H-14 In combined operation of work equipment, equipment having heavier load moves slower. .............. 24 H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................................... 25
PC200, 200LC, 220, 220LC-8M0
40-500
1
SEN06139-00
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-16 Travel speed drops largely in combined operation of swing and travel.............................................. 26 H-17 Machine does not travel straight ........................................................................................................ 27 H-18 Travel speed is low............................................................................................................................. 28 H-19 Machine is hard to steer or travel power is low .................................................................................. 29 H-20 Travel speed does not change or travel speed is low/high................................................................. 30 H-21 One of tracks does not run ................................................................................................................. 31 H-22 Upper structure does not swing.......................................................................................................... 32 H-23 Swing acceleration is poor or swing speed is low .............................................................................. 34 H-24 Upper structure overruns remarkably when it stops swinging ............................................................ 36 H-25 Shock is large when upper structure stops swinging ......................................................................... 37 H-26 Large sound is made when upper structure stops swinging .............................................................. 38 H-27 Hydraulic drift of swing is large........................................................................................................... 39 H-28 Attachment circuit cannot be changed ............................................................................................... 40 H-29 Oil flow in attachment circuit cannot be controlled ............................................................................. 41
40-500 2
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode)
PC200, 200LC, 220, 220LC-8M0
SEN06139-00
40-500
3
SEN06139-00
500 Troubleshooting of hydraulic and mechanical system (H-mode) System diagram of hydraulic and mechanical system
System diagram of hydraulic and mechanical system
40-500 4
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) System diagram of hydraulic and mechanical system
SEN06139-00
a This system diagram is a rough general hydraulic circuit diagram made as reference material for troubleshooting of the hydraulic and mechanical systems.
PC200, 200LC, 220, 220LC-8M0
40-500
5
500 Troubleshooting of hydraulic and mechanical system (H-mode) Failure mode and cause table
SEN06139-00
Failure mode and cause table
Any of work equipment, swing and travel
Failure mode All of work equipment, swing and travel work slow or lack power Engine speed lowers extremely or engine stalls All work equipment, travel, and swing systems do not work. Unusual sound is heard from around hydraulic pump Fine control performance or response is poor
Tank
Hydraulic pump
q q
q q q q q q q q
q
Work equipment Swing Swing and and travel boom Travel Swing
q
q q
q
q q q q q
q q
q q q q q q q q
Speed or power of arm is low Speed or power of bucket is low
Attach -ment
q q
q q q q q q q
Speed or power of boom is low
Work equipment does not move in single operation Boom Hydraulic drift of work Arm equipment is large Bucket Time lag of work equipment operation is large Other wok equipment moves when one of work equipment is relieved One-touch power maximizing function does not work. In combined operation of work equipment, equipment having heavier load moves slower
Control valve
Engine system Damper Hydraulic oil Cap stainer Piston pump Servo piston Pump swash plate sensor PC-EPC valve PC valve LS-EPC valve LS valve Spool Unload valve Main relief valve Pressure compensation valve Self-pressure reducing valve LS line throttle Pump merge-divider main EPC valve Pump merge-divider LS-EPC valve Pump merge-divider main valve Pump merge-divider LS valve Boom throttle EPC solenoid Boom regeneration valve Boom lock valve
Failed parts
q q q
q q q q q q q q q q q
q q q q
q
q
q q q
In combined operations of swing and boom RAISE, boom rising speed is low Travel speed drops largely in combined operation of swing and travel Machine does not travel straight Travel speed is low. Machine is hard to steer or travel power is low Travel speed does not change or travel speed is too low or high One of tracks does not run Upper structure swings Upper structure does not neither to the right nor left Upper structure does not swing swing in only one direction Poor or low for both of the Swing acceleration is poor right and left Poor or low for only in one or swing speed is low direction Largely for both of the right Upper structure overruns and left considerably when it stops Largely for only in one swinging direction Shock is larger when upper structure stops swinging Large unsual noise is heard when upper structure stops swinging Swing drift on a slope is When swing brake works When swing brake works large Attachment circuit is not changed
q
q q q q
q q q q
q
q
q q q q
q
q q q q
q
q
q
q
Oil flow in attachment circuit cannot be changed
40-500 6
PC200, 200LC, 220, 220LC-8M0
q q q q
q q q q
q q q q q q q q q q q q
q
q
PC200, 200LC, 220, 220LC-8M0
q
Control valve
q
q
q
q
q q q
q
q q
q
q
q
q
q
q
q q
q q
q
q q q q
q
q
q
q q
q q q
q q
q q
q q
q q
q q
q
q q
q q q q q q q q q
q
q q
q q q q q q
q
q q
q
q
q q
q
q q q q
Diagnosis codes
Final drive Hydraulic cylinder
Parking brake
Safety valve
Check valve
Swing motor
Counterbalance valve
Piston motor
Center swivel joint
Swing machinery
Parking brake
Shockless valve
Suction valve
Check valve
Solenoid valve
Safety valve
Piston motor
ATT return selector solenoid
Swing holding brake solenoid
Travel speed selector solenoid
Travel interconnection solenoid
2-stage relief solenoid
Work equipment lock solenoid
Oil flow adjuster EPC valve for attachment
Swing PPC slow return valve
PPC valve (service)
PPC valve (travel lever)
PPC valve (left lever)
PPC valve (right lever)
Service valve (safety valve)
Back pressure valve
Travel junction valve
Swing LS select valve
Arm lock valve
Arm quick return valve
Arm regeneration valve
LS shuttle valve
Suction valve
Safety valve
500 Troubleshooting of hydraulic and mechanical system (H-mode) Failure mode and cause table
SEN06139-00
Travel motor
H-1
H-2
H-3 H-4
H-5
H-6 H-7 H-8 H-9
q q H-10 q H-11 H-12
H-13
H-14
H-15
H-16
H-17 H-18 H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
H-29
40-500
7
500 Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table
SEN06139-00
Information in troubleshooting table a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully. Failure
Description of failure code
Related inforInformation related to detected failure or troubleshooting mation Cause
Criteria and troubleshooting procedure
1
Probable causes and criteria
2
3
Probable causes of trouble (Given numbers are refer- q Standard value in normal condition to judge probable causes ence numbers, which do q Remarks on judgment not indicate priority)
4
40-500 8
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Speed or power of whole work equipment, swing, and travel is low
SEN06139-00
H-1 Speed or power of whole work equipment, swing, and travel is low Failure
q
Speed or power of all work equipment, swing, and travel is low.
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle.
1 Malfunction of unload valve
Control lever
Unload pressure
3.5 ± 1.0 MPa {36 ± 10 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control Main relief pressure lever Defective adjustment or mal33.3 to 37.2 MPa Arm IN relief function of main relief valve {340 to 380 kg/cm2} If normal oil pressure is not obtained by adjustment, main relief valve may malfunction or have internal defect. Check main relief valve. a Be ready with engine stopped, then troubleshoot with engine high idle. Malfunction of self-pressure Control lever Control circuit source pressure reducing valve 2.84 to 3.43 MPa All levers in the neutral position {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine at low speed and engine high idle. PC-EPC valve outEngine Control lever put pressure Malfunction of PC-EPC Approx. 2.9 MPa valve Low idle All levers in the neu- {Approx. 30 kg/cm2} 0.52 to 0.91 MPa tral position High idle {5.3 to 9.3 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine at full speed. Measured oil pres- Measurement condiRatio of oil pressures sure tions Defective adjustment or malPump discharge Swing lock 1 function of PC valve pressure Switch: ON PC valve output presApprox. 0.6 (Approx. Arm IN relief sure 3/5) If normal oil pressure is not obtained after adjustment, PC valve may malfunction or have internal defect. Check PC valve. a Be ready with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve Travel speed Travel lever output pressure Malfunction of LS-EPC valve Approx. 2.9 MPa Lo Neutral {30 kg/cm2} 0 MPa Hi Operation {0 kg/cm2} All levers in the neutral position
2
3
Probable causes and criteria 4
5
6
PC200, 200LC, 220, 220LC-8M0
40-500
9
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Speed or power of whole work equipment, swing, and travel is low
SEN06139-00
Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Operation of levers and oil pressure ratio Measured oil pressure
Probable causes and criteria
40-500 10
7
Defective adjustment or malfunction of LS valve
All levers in the neutral position
Run the track off ground. (lever at half stroke)
Pump discharge 1 Almost same prespressure PC valve output presApprox. 0.6 (Approx. sure sure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve.
8 Malfunction of servo piston
Servo piston may malfunction. Check it.
9 Defective piston pump
Piston pump may have performance deterioration, malfunction or internal defect.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Engine speed lowers significantly or engine stalls
SEN06139-00
H-2 Engine speed lowers significantly or engine stalls Failure
q
Engine speed lowers significantly or engine stalls
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
Criteria and troubleshooting procedure
a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control Main relief pressure lever Defective adjustment or mal33.3 to 37.2 MPa 1 Arm IN relief function of main relief valve {340 to 380 kg/cm2} If normal oil pressure is not obtained by adjustment, main relief valve may malfunction or have internal defect. Check main relief valve. a Be ready with engine stopped, then troubleshoot with engine at low speed and engine high idle. PC-EPC valve outEngine Control lever put pressure Malfunction of PC-EPC 2 Approx. 2.9 MPa valve Low idle All levers in the neu- {Approx. 30 kg/cm2} 0.52 to 0.91 MPa tral position High idle {5.3 to 9.3 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Measured oil pres- Measurement condiRatio of oil pressures sure tions Defective adjustment or malPump discharge Swing lock 3 1 function of PC valve pressure Switch: ON PC valve output presApprox. 0.6 (Approx. Arm IN relief sure 3/5) If normal oil pressure is not obtained after adjustment, PC valve may malfunction or have internal defect. Check PC valve. a Be ready with engine stopped, then troubleshoot with engine high idle. Operation of levers and oil pressure ratio Measured oil pressure 4
Defective adjustment or malfunction of LS valve
All levers in the neutral position
Run the track off ground. (lever at half stroke)
Pump discharge 1 Almost same prespressure PC valve output presApprox. 0.6 (Approx. sure sure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check 5 serve device them. 6 Malfunction of servo piston
PC200, 200LC, 220, 220LC-8M0
Servo piston may malfunction. Check it.
40-500
11
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-3 Work equipment, swing, and travel systems do not work
SEN06139-00
H-3 Work equipment, swing, and travel systems do not work Failure
q
All work equipment, swing, and travel do not work
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
1
Malfunction of PPC lock solenoid valve
2
Malfunction of self-pressure reducing valve
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. PPC lock solenoid valve Lock lever output pressure 0 MPa LOCK {0 kg/cm2} Approx. 2.9 MPa FREE {Approx. 30 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Control lever
Control circuit source pressure
2.84 to 3.43 MPa {29 to 35 kg/cm2} Piston pump may malfunction or have internal defect. Check it by following method. 1) Remove pump discharge pressure pickup plugs (F and R). 2) Crank engine at flywheel (manually). 3) If the oil flows out of the pump discharge pressure pickup ports, it is normal. Pump shaft may not revolve because of internal defect of damper. Check damper. All levers in the neutral position
3 Defective piston pump
4 Defective damper
40-500 12
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Unusual noise comes out from around hydraulic pump
SEN06139-00
H-4 Unusual noise comes out from around hydraulic pump Failure
q
Unusual sound is heard from around hydraulic pump
Related information Cause
Probable causes and criteria
Criteria and troubleshooting procedure
Lowering of hydraulic oil 1 level
Hydraulic oil level may be low. Check it.
2 Defective hydraulic oil
Air may be mixed in hydraulic oil. Check oil.
Clogging of hydraulic tank cap Clogging of hydraulic tank 4 strainer
Negative pressure may be generated in hydraulic tank because of clogged hydraulic tank cap. Check cap. Negative pressure may be generated in suction circuit because of clogged hydraulic tank strainer. Check strainer.
5 Defective piston pump
Piston pump may have internal defect. Check it.
3
PC200, 200LC, 220, 220LC-8M0
40-500
13
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-5 Fine control performance or response is low
SEN06139-00
H-5 Fine control performance or response is low Failure
q
Fine control performance or response is low.
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve Travel speed Travel lever output pressure
1 Malfunction of LS-EPC valve
Probable causes and criteria
2 Clogging of LS circuit orifice
Lo
Neutral
Hi
Operation
Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa {0 kg/cm2}
Orifice of LS circuit (pump – piping – control valve) may be clogged. Check it. a Be ready with engine stopped, then troubleshoot with engine at full speed. Operation of levers and oil pressure ratio Measured oil pressure
3
Defective adjustment or malfunction of LS valve
4 Malfunction of servo piston
40-500 14
All levers in the neutral position
Run the track off ground. (lever at half stroke)
Pump discharge 1 Almost same prespressure PC valve output presApprox. 0.6 (Approx. sure sure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. Servo piston may malfunction. Check it.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-6 Speed or power of boom is low
SEN06139-00
H-6 Speed or power of boom is low Failure
q
Speed or power of boom is low
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure
1
Malfunction of right PPC valve (boom circuit)
a Be ready with engine stopped, then troubleshoot with engine at full speed. Right work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Boom RAISE Boom LOWER {29 to 35 kg/cm2}
2
Malfunction of merge-divider Merge-divider main EPC valve may malfunction. Check it. main EPC valve
3
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it. LS-EPC valve
4 5 6 Probable causes and criteria
7 8 9
Malfunction of merge-divider main valve Malfunction of merge-divider LS valve Malfunction of boom control valve (spool) Malfunction of boom control valve (pressure compensation valve) Malfunction of boom control valve (regeneration valve)
Merge-divider main valve may malfunction. Check it. Merge-divider LS valve may malfunction. Check it. Spool of boom control valve may malfunction. Check it. Pressure compensation valve of boom control valve may malfunction. Check it. Regeneration valve of boom control valve may malfunction. Check it.
Malfunction of boom control Lock valve of boom control valve may have malfunction. valve (lock valve) Check it.
Malfunction or defective 10 sealing of safety valve for lock valve
Safety valve for lock valve may malfunction or sealing may be defective. Check it.
Malfunction or defective 11 sealing of boom control valve (suction valve)
Suction valve of boom control valve may malfunction or sealing may be defective. Check it.
Malfunction or defective 12 sealing of boom control valve (safety-suction valve)
Safety-suction valve of boom control valve may malfunction or sealing may be defective. Check it.
13
Malfunction of each control valve (LS shuttle valve)
14 Defective boom cylinder
LS shuttle valve of left travel control valve, bucket control valve, or service control valve may malfunction. Check it. a Be ready with engine stopped, then troubleshoot with engine at full speed. Right work equipment control Leakage from boom cylinder lever Boom RAISE relief
PC200, 200LC, 220, 220LC-8M0
20 cc/min
40-500
15
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-7 Speed or power of arm is low
SEN06139-00
H-7 Speed or power of arm is low Failure
q
Speed or power of arm is low
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure
a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control PPC valve output pressure lever Malfunction of left PPC valve 1 0 MPa (arm circuit) Neutral {0 kg/cm2} 2.84 to 3.43 MPa Arm IN Arm OUT {29 to 35 kg/cm2} 2
Malfunction of merge-divider Merge-divider main EPC valve may malfunction. Check it. main EPC valve
3
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it. LS-EPC valve
4 5 6 Probable causes and criteria
7 8
Malfunction of merge-divider main valve Malfunction of merge-divider LS valve Malfunction of arm control valve (spool) Malfunction of arm control valve (pressure compensation valve) Malfunction of arm control valve (regeneration valve)
Merge-divider main valve may malfunction. Check it. Merge-divider LS valve may malfunction. Check it. Spool of arm control valve may malfunction. Check it. Pressure compensation valve of boom control valve may malfunction. Check it. Regeneration valve of arm control valve may malfunction. Check it.
Malfunction of arm control valve (quick return valve)
Quick return valve of arm control valve may have malfunction. Check it.
Malfunction or defective 10 sealing of safety valve for lock valve
Safety valve for lock valve may malfunction or sealing may be defective. Check it.
9
Malfunction or defective 11 sealing of arm control valve Suction valve of arm control valve may malfunction. Check it. (suction valve) Malfunction or defective Safety-suction valve of arm control valve may malfunction or seal12 sealing of arm control valve ing may be deflective. Check it. (safety-suction valve) 13
Malfunction of each control valve (LS shuttle valve)
14 Defective arm cylinder
LS shuttle valve of right travel control valve, boom control valve, left travel control valve, bucket control valve, or service control valve may malfunction. Check it. a Be ready with engine stopped, then troubleshoot with engine at full speed. Left work equipment control Leakage from arm cylinder lever Arm IN relief
40-500 16
20 cc/min
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Speed or power of bucket is low
SEN06139-00
H-8 Speed or power of bucket is low Failure
q
Speed or power of bucket is low
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
1
Malfunction of right PPC valve (bucket circuit)
Malfunction of bucket control valve (spool) Malfunction of bucket control 3 valve (pressure compensation valve) Malfunction or defective 4 sealing of bucket control valve (safety-suction valve) 2
Probable causes and criteria
5
Malfunction of service control valve (LS shuttle valve)
6 Defective bucket cylinder
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Right work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Bucket CURL Bucket DUMP {29 to 35 kg/cm2} Spool of bucket control valve may malfunction. Check it. Pressure compensation valve of bucket control valve may malfunction. Check it. Safety-suction valve of bucket control valve may malfunction or sealing may be defective. Check it. LS shuttle valve of service control valve may malfunction. Check it. a Be ready with engine stopped, then troubleshoot with engine high idle. Right work equipment control Leakage from bucket cylinder lever Bucket CURL relief
PC200, 200LC, 220, 220LC-8M0
20 cc/min
40-500
17
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-9 Work equipment does not move in its single operation
SEN06139-00
H-9 Work equipment does not move in its single operation Failure Related information
(1) Boom does not move independently. (2) Arm does not move independently. (3) Bucket does not move independently. q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle.
Probable causes and criteria
Work equipment control lever 1 Malfunction of PPC valve
Neutral Operation
2
40-500 18
Malfunction of control valve (spool)
PPC valve output pressure 0 MPa {0 kg/cm2} 2.84 to 3.43 MPa {29 to 35 kg/cm2}
Spool of control valve may malfunction. Check it.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-10 Hydraulic drift of work equipment is large
SEN06139-00
H-10 Hydraulic drift of work equipment is large Failure Related information
(1) Hydraulic drift of boom is large. q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
Failure Related information
1 Defective boom cylinder
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Right work equipment control Leakage from boom cylinder lever Boom RAISE relief
2
Defective seal of boom con- Sealing of the lock valve of the boom control valve may be defectrol valve (lock valve) tive. Check it.
3
Defective seal of safety valve for lock valve
Seal of safety valve for lock valve may be defective. Check it.
(2) Hydraulic drift of arm is large. q
Perform all troubleshooting with working mode in power mode (P). Cause
1 Defective arm cylinder
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control Leakage from arm cylinder lever Arm IN relief
Probable causes and criteria
20 cc/min
20 cc/min
Defective seal of arm conSeal of arm control valve spool may be defective. Check it. trol valve (spool) Defective seal of arm conSeal of pressure compensation valve of arm control valve may be 3 trol valve (pressure compendefective. Check it. sation valve) Seal of suction valve of arm control valve may be defective. Check it. Defective seal of arm con4 * Judgment can be made by checking a change of phenomenon trol valve (suction valve) after exchanging suction valve with one for other than the arm control valve. Defective seal of safety 5 Seal of safety valve for lock valve may be defective. Check it. valve for lock valve 2
PC200, 200LC, 220, 220LC-8M0
40-500
19
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-10 Hydraulic drift of work equipment is large
SEN06139-00
Failure Related information
(3) Hydraulic drift of bucket is large. q
Perform all troubleshooting with working mode in power mode (P). Cause
1 Defective bucket cylinder
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control Leakage from bucket cylinder lever Bucket CURL relief
Probable causes and criteria
40-500 20
20 cc/min
Defective seal of bucket conSeal of bucket control valve spool may be defective. Check it. trol valve (spool) Defective seal of bucket con Seal of pressure compensation valve of bucket control valve may 3 trol valve (pressure compenbe defective. Check it. sation valve) Seal of safety-suction valve of bucket control valve may defective. Defective seal of bucket con- Check it. 4 trol valve (safety-suction * You may replace the safety suction valves of the control valves valve) on the bottom side and head side with each other and judge from the change of the phenomenon. 2
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-11 Time lag of work equipment is large
SEN06139-00
H-11 Time lag of work equipment is large Failure
q
Time lag of work equipment operation is large
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. LS-EPC valve Travel speed Travel lever output pressure
1 Malfunction of LS-EPC valve
Probable causes and criteria
Malfunction of control valve 2 (regeneration valve) [Boom and arm only]
3
Malfunction of control valve (safety-suction valve)
Malfunction of control valve 4 (pressure compensation valve)
PC200, 200LC, 220, 220LC-8M0
Lo
Neutral
Hi
Operation
Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa {0 kg/cm2}
Regeneration valve of control valve may malfunction. Check it. Safety-suction valve of control valve may malfunction. Check it. * Judgment can be made by checking a change of phenomenon after exchanging safety-suction valves of control valves with those on a normal control valve. (Set pressure of safety-suction valve for boom head circuit is different, however.) Pressure compensation valve of control valve may malfunction. Check it.
40-500
21
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-12 Other work equipment moves when one of work equipment is relieved
SEN06139-00
H-12 Other work equipment moves when one of work equipment is relieved Failure
q
Other wok equipment moves when one of work equipment is relieved
Related information Probable causes and criteria
40-500 22
Cause Defective seal of control 1 valve (pressure compensation valve) on moving side
Criteria and troubleshooting procedure Seal of pressure compensation valve of control valve on moving side may be defective. Check it.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-13 One-touch power maximizing function does not work
SEN06139-00
H-13 One-touch power maximizing function does not work Failure
q
One-touch power maximizing function does not work.
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
1
Malfunction of 2-stage relief solenoid valve
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. 2-stage relief solenoid valve Swing lock switch output pressure OFF ON
2
Malfunction of main relief valve
PC200, 200LC, 220, 220LC-8M0
0 MPa {0 kg/cm2} Approx. 2.9 MPa {Approx. 30 kg/cm2}
The main relief valve may malfunction. Check it.
40-500
23
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-14 In combined operation of work equipment, equipment having heavier load moves slower.
SEN06139-00
H-14 In combined operation of work equipment, equipment having heavier load moves slower. Failure
q
In combined operation of work equipment, equipment having heavier load moves slower
Related information Cause
Criteria and troubleshooting procedure Pressure compensation valve of control valve on smaller load side may malfunction. Check it.
Probable causes and criteria
40-500 24
Malfunction of control valve 1 (pressure compensation valve) on smaller load side
Combination of combined operation
Larger load side
Smaller load side
Boom RAISE + Arm IN
Boom RAISE
Arm IN
Boom RAISE + Arm OUT
Arm OUT
Boom RAISE
Boom RAISE + Bucket CURL
Boom RAISE
Bucket CURL
Arm OUT + Bucket CURL
Arm OUT
Bucket CURL
Boom LOWER + Arm OUT
Arm OUT
Boom LOWER
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-15 In combined operation of swing and boom RAISE, boom rising speed is low
SEN06139-00
H-15 In combined operation of swing and boom RAISE, boom rising speed is low Failure
q
In combined operations of swing and boom RAISE, boom rising speed is low
Related information
q
If boom RAISE speed is also low when it is operated singly, perform troubleshooting for "H- 6 Boom operation lacks speed or power".
Probable causes and criteria
Cause Malfunction or defective 1 sealing of swing control valve (LS select valve)
PC200, 200LC, 220, 220LC-8M0
Criteria and troubleshooting procedure LS select valve of swing control valve may malfunction or sealing may be defective. Check it.
40-500
25
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-16 Travel speed drops largely in combined operation of swing and travel
SEN06139-00
H-16 Travel speed drops largely in combined operation of swing and travel Failure
q
Travel speed drops largely in combined operation of swing and travel
Related information
q
If speed of single travel operation is also low, carry out troubleshooting for "H-18 Travel speed is low" first.
Probable causes and criteria
40-500 26
Cause 1
Malfunction of each control valve (LS shuttle valve)
Criteria and troubleshooting procedure LS shuttle valve of left travel control valve or swing control valve may malfunction. Check it.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-17 Machine does not travel straight
SEN06139-00
H-17 Machine does not travel straight Failure
q
Machine does not travel straight
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Travel lever
Malfunction of travel PPC 1 valve
2
Malfunction of self-pressure reducing valve
PPC valve output pressure
0 MPa {0 kg/cm2} 2.84 to 3.43 MPa Forward Reverse {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Neutral
Control lever
Control circuit source pressure
2.84 to 3.43 MPa {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. All levers in the neutral position
Operation of levers and oil pressure ratio Measured oil pressure 3
Defective adjustment or malfunction of LS valve
4
Malfunction of travel junction solenoid valve
Probable causes and criteria
All levers in the neutral position
Run the track off ground. (lever at half stroke)
Pump discharge 1 Almost same prespressure PC valve output presApprox. 0.6 (Approx. sure sure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. a Be ready with engine stopped, then troubleshoot with engine high idle. Travel junction solenoid valve Travel lever output pressure Both sides in the NEUTRAL position Either side operated
0 MPa {0 kg/cm2} Approx. 2.9 MPa {Approx. 30 kg/cm2}
Malfunction of travel juncTravel junction valve may malfunction. Check it. tion valve Malfunction of travel control 6 Spool of travel control valve may malfunction. Check it. valve (spool) a Be ready with engine stopped, then troubleshoot with engine high idle. 7 Defective travel motor Travel lever Leakage from travel motor 5
Travel system relief 8 Defective final drive
PC200, 200LC, 220, 220LC-8M0
27.2 l/min
Final drive may have internal defect. Check it. * It may be checked by abnormal sound, abnormal heating,metal chips in drain oil, etc.
40-500
27
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-18 Travel speed is low
SEN06139-00
H-18 Travel speed is low Failure
q
Travel speed is low.
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Travel lever
Malfunction of travel PPC 1 valve
2
Malfunction of self-pressure reducing valve
PPC valve output pressure
0 MPa {0 kg/cm2} 2.84 to 3.43 MPa Forward Reverse {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Neutral
Control lever
Control circuit source pressure
2.84 to 3.43 MPa {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. LS-EPC valve Travel speed Travel lever output pressure All levers in the neutral position
Probable causes and criteria
3 Malfunction of LS-EPC valve
Malfunction of travel control valve (spool) Malfunction of travel control 5 valve (pressure compensation valve) Malfunction of travel control 6 valve (suction valve) 4
Lo
Neutral
Hi
Operation
Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa {0 kg/cm2}
Spool of travel control valve may malfunction. Check it. Pressure compensation valve of travel control valve may malfunction. Check it. Suction valve of travel control valve may malfunction. Check it.
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction. valve (LS shuttle valve) Check it. a Be ready with engine stopped, then troubleshoot with engine high idle. 8 Defective travel motor Travel lever Leakage from travel motor 7
Travel system relief 9 Defective final drive
40-500 28
27.2 l/min
Final drive may have internal defect. Check it. * It may be checked by abnormal sound, abnormal heating,metal chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-19 Machine is hard to steer or travel power is low
SEN06139-00
H-19 Machine is hard to steer or travel power is low Failure
q
Machine is hard to steer or travel power is low
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
1
Malfunction of travel PPC valve (steering spool)
2
Malfunction of travel junction solenoid valve
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. PPC valve output pressure Travel lever (Steering) 0 MPa {0 kg/cm2} 2.84 to 3.43 MPa Either side operated {29 to 35 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Travel junction solenoid valve Travel lever output pressure Both sides in the NEUTRAL position
Both sides in the NEUTRAL position Either side operated
0 MPa {0 kg/cm2} Approx. 2.9 MPa {Approx. 30 kg/cm2}
Malfunction of travel juncTravel junction valve may malfunction. Check it. tion valve Malfunction of merge-divider 4 Merge-divider main EPC valve may malfunction. Check it. main EPC valve 3
Probable causes and criteria
5 6 7 8 9 10 11
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it. LS-EPC valve Malfunction of merge-divider main valve Malfunction of merge-divider LS valve Malfunction of travel control valve (spool) Malfunction of travel control valve (pressure compensation valve) Malfunction of travel control valve (suction valve)
Merge-divider main valve may malfunction. Check it. Merge-divider LS valve may malfunction. Check it. Spool of travel control valve may malfunction. Check it. Pressure compensation valve of travel control valve may malfunction. Check it. Suction valve of travel control valve may malfunction. Check it.
Malfunction of bucket control LS shuttle valve of bucket control valve may malfunction. Check it. valve (LS shuttle valve)
Defective seal of check valve Seal of check valve of LS pressure sensing part (control valve 12 of LS pressure sensing part side) may be defective. Check it. (control valve side) Seal of safety valve of travel motor may malfunction. Check it. * Judgment can be made by checking a change of phenomenon Defective seal of travel 13 after exchanging safety valves between forward and reverse motor (safety valve) circuit of the same motor or between right and left motor circuits. Seal of check valve of travel motor may malfunction. Check it. Defective seal of travel * You may replace the check valves of forward and reverse sec14 motor (check valve) tions of the same motor or those of the right and left motors with each other and judge from the change of the phenomenon.
PC200, 200LC, 220, 220LC-8M0
40-500
29
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-20 Travel speed does not change or travel speed is low/high
SEN06139-00
H-20 Travel speed does not change or travel speed is low/high Failure
q
Travel speed does not change or travel speed is too low or high
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure a Troubleshoot with engine high idle (with monitoring function). Travel speed
Travel lever
Lo Operation Mi 1 Malfunction of LS-EPC valve Hi
Monitoring code: 01500 663 mA(PC200-8M0, PC200LC-8M0) 578 mA(PC220-8M0, PC220LC-8M0) (See *) 424 mA(PC200-8, PC200LC-8M0) 641 mA(PC220-8M0, PC220LC-8M0) 0 mA
a Be ready with engine stopped, then troubleshoot with engine high idle. LS-EPC valve Travel speed Travel lever output pressure
Probable causes and criteria
Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa Hi Operation {0 kg/cm2} a Be ready with engine stopped, then troubleshoot with engine high idle. Travel speed shifting Travel speed Travel lever solenoid valve output pressure 0 MPa Lo Neutral {0 kg/cm2} Approx. 2.9 MPa Hi Operation {Approx. 30 kg/cm2} Lo
2
Malfunction of travel speed shifting solenoid valve
3
Malfunction of travel motor (speed shifting section)
Neutral
Speed shifting section of travel motor may malfunction. Check it.
*: Travel speed Lo can be adjusted with the adjusting function of the machine monitor. Accordingly, if the initial value has been changed, the measured value varies more or less.
40-500 30
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-21 One of tracks does not run
SEN06139-00
H-21 One of tracks does not run Failure
q
One of tracks does not run
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
1
2
Probable causes and criteria
3
4
5
Criteria and troubleshooting procedure
Defective seal of travel conSeal of suction valve of travel motor may malfunction. Check it. trol valve (suction valve) Seal of safety valve of travel motor may malfunction. Check it. Defective seal of travel * You may replace the safety valves of forward and reverse secmotor (safety valve) tions of the same motor or those of the right and left motors with each other and judge from the change of the phenomenon. Seal of check valve of travel motor may malfunction. Check it. Defective seal of travel * You may replace the check valves of forward and reverse secmotor (check valve) tions of the same motor or those of the right and left motors with each other and judge from the change of the phenomenon. Malfunction of travel motor Parking brake of travel motor may malfunction. Check it. (parking brake) a Be ready with engine stopped, then troubleshoot with engine at full speed. Defective travel motor Travel lever Leakage from travel motor Travel system relief
6 Defective final drive
PC200, 200LC, 220, 220LC-8M0
27.2 l/min
Final drive may have internal defect. Check it. * It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.metal chips in drain oil, etc.
40-500
31
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Upper structure does not swing
SEN06139-00
H-22 Upper structure does not swing Failure Related information
(1) Upper structure swings neither to the right nor left q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure
a Be ready with engine stopped, then troubleshoot with engine high idle. Output pressure of swing holding Left work equipment control brake lever Malfunction of swing holding solenoid valve 1 brake solenoid valve 0 MPa Neutral {0 kg/cm2} Approx. 2.9 MPa Left swing Right swing {Approx. 30 kg/cm2}
Probable causes and criteria
2
Malfunction of swing control Spool of swing control valve may malfunction. Check the spool. valve (spool)
3
Malfunction of swing motor (swing holding brake)
a Be ready with engine stopped, then troubleshoot with engine high idle. Swing lock Left work equipment Swing relief pressure Improper adjustment or Malswitch control lever 4 function of swing motor 28.9 to 32.9 MPa Swing to hydraulic ON (safety valve) relief {295 to 335 kg/cm2}
5 Defective swing motor
6 Defective swing machinery
40-500 32
Swing brake may malfunction. Check it.
If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may internal defect. Check it. a Be ready with engine stopped, then troubleshoot with engine high idle. Swing lock Left work equipment Leakage from swing switch control lever motor Swing to hydraulic ON Below 10 l/min relief Swing machinery may have internal defect. Check it. * It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Upper structure does not swing
Failure Related information
(2) Upper structure does not swing in only one direction. q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
SEN06139-00
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Left swing Right swing {29 to 35 kg/cm2}
1
Malfunction of swing PPC valve
2
Malfunction of swing control Spool of swing control valve may malfunction. Check the spool. valve (spool)
Malfunction of swing motor 3 (suction valve)
Suction valve of swing motor may malfunction. Check the valve. * This failure can be checked by interchaning right and left suction valves of swing motor and watching how condition changes.
Malfunction of swing motor 4 (check valve)
Check valve of swing motor may malfunction. Check the valve. * You may replace the check valves of the right and left motorswith each other and judge from the change of the phenomenon.
PC200, 200LC, 220, 220LC-8M0
40-500
33
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-23 Swing acceleration is poor or swing speed is low
SEN06139-00
H-23 Swing acceleration is poor or swing speed is low Failure Related information
(1) Swing acceleration performance is poor or swing speed is slow in both right and left directions. q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
1
Malfunction of swing control Spool of swing control valve may malfunction. Check the spool. valve (spool)
2
Malfunction of all control valves (LS shuttle valves)
LS shuttle valves of all control valves may malfunction. Check them.
3
Malfunction of swing motor (swing holding brake)
Swing brake may malfunction. Check it.
a Be ready with engine stopped, then troubleshoot with engine high idle. Swing lock Left work equipment Swing relief pressure Improper adjustment or Malswitch control lever 4 function of swing motor 28.9 to 32.9 MPa Swing to hydraulic ON (safety valve) relief {295 to 335 kg/cm2}
5 Defective swing motor
6 Defective swing machinery
40-500 34
Criteria and troubleshooting procedure
If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may internal defect. Check it. a Be ready with engine stopped, then troubleshoot with engine high idle. Swing lock Left work equipment Leakage from swing switch control lever motor Swing to hydraulic ON Below 10 l/min relief Swing machinery may have internal defect. Check it. * It may be check by abnormal sound, abnormal heating, metal chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-23 Swing acceleration is poor or swing speed is low
Failure Related information
(2) Swing acceleration performance is poor or swing speed is slow in only one direction. q
Perform all troubleshooting with working mode in power mode (P). Cause
1
Probable causes and criteria
SEN06139-00
Malfunction of swing PPC valve
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Left swing Right swing {29 to 35 kg/cm2}
Malfunction of swing control Spool of swing control valve may malfunction. Check the spool. valve (spool) Malfunction of swing control Pressure compensation valve of swing control valve may malfunc3 valve (pressure compensation. Check it. tion valve) Suction valve of swing motor may malfunction. Check the valve. Malfunction of swing motor * This failure can be checked by interchaning right and left suc4 (suction valve) tion valves of swing motor and watching how condition changes. 2
Malfunction of swing motor 5 (check valve)
PC200, 200LC, 220, 220LC-8M0
Check valve of swing motor may malfunction. Check the valve. * This failure can be checked by interchaning right and left suction valves of swing motor and watching how condition changes.
40-500
35
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-24 Upper structure overruns remarkably when it stops swinging
SEN06139-00
H-24 Upper structure overruns remarkably when it stops swinging Failure Related information
(1) Upper structure overruns excessively when stop swinging in both right and left directions. q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
2 Defective swing motor
Failure Related information
40-500 36
If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may internal defect. Check it. a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment Leakage from swing Swing lock switch control lever motor Swing to hydraulic ON Below 10 l/min relief
(2) Upper structure overruns excessively when stop swinging in only one direction. q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
Criteria and troubleshooting procedure
a Be ready with engine stopped, then troubleshoot with engine high idle. Swing lock Left work equipment Swing relief pressure Improper adjustment or Malswitch control lever 1 function of swing motor 28.9 to 3 2.9 MPa Swing to hydraulic ON (safety valve) relief {295 to 335 kg/cm2}
Criteria and troubleshooting procedure
1
Malfunction of swing PPC valve
a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Left swing Right swing {29 to 35 kg/cm2}
2
Clogged swing PPC slow return valve
Swing PPC slow return valve may malfunction. Check it. * This failure can be checked by interchaning right and left swing PPC slow return valve and watching how condition changes.
3
Malfunction of swing control Spool of swing control valve may malfunction. Check the spool. valve (spool)
Malfunction of swing motor 4 (suction valve)
Suction valve of swing motor may malfunction. Check the valve. * This failure can be checked by interchaning right and left suction valves of swing motor and watching how condition changes.
Malfunction of swing motor 5 (check valve)
Check valve of swing motor may malfunction. Check the valve. * This failure can be checked by interchaning right and left suction valves of swing motor and watching how condition changes.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-25 Shock is large when upper structure stops swinging
SEN06139-00
H-25 Shock is large when upper structure stops swinging Failure
q
Shock is larger when upper structure stops swinging
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Criteria and troubleshooting procedure
1
Malfunction of swing PPC valve
a Be ready with engine stopped, then troubleshoot with engine high idle. Left work equipment control PPC valve output pressure lever 0 MPa Neutral {0 kg/cm2} 2.84 to 3.43 MPa Left swing Right swing {29 to 35 kg/cm2}
2
Clogged swing PPC slow return valve
Swing PPC slow return valve may malfunction. Check it. * This failure can be checked by interchaning right and left swing PPC slow return valve and watching how condition changes.
3
Malfunction of swing motor (shockless valve)
Shockless valve of swing motor may malfunction. Check it.
Probable causes and criteria
PC200, 200LC, 220, 220LC-8M0
40-500
37
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-26 Large sound is made when upper structure stops swinging
SEN06139-00
H-26 Large sound is made when upper structure stops swinging Failure
q
Large sound is made when upper structure stops swinging
Related information
q
Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
40-500 38
Criteria and troubleshooting procedure
Malfunction of back pressure 1 Backpressurevalve may have malfunction. Check it. valve Malfunction of swing motor 2 Safety valve of swing motor may malfunction. Check the valve. (safety valve) Malfunction of swing motor 3 (suction valve)
Suction valve of swing motor may malfunction. Check the valve. * This failure can be checked by interchaning right and left suction valves of swing motor and watching how condition changes.
4 Defective swing machinery
Swing machinery may have internal defect. Check it. * It may be checked by abnormal sound, abnormal heating,metal chips in drain oil, etc.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-27 Hydraulic drift of swing is large
SEN06139-00
H-27 Hydraulic drift of swing is large Failure
(1) Swing drift on a slope is large (when swing holding brake is being applied) q
Related information q
When swing lock switch is turned to ON position or when swing brake cancel switch is set to normal position, swing holding brake is applied and swinging motion of upper structure is stopped with disc brake. Perform all troubleshooting with working mode in power mode (P). Cause
Probable causes and criteria
2 Failure Related information
Malfunction of swing motor (swing holding brake)
Swing brake may malfunction. Check it.
(2) Swing drift on a slope is large (when swing brake is being released). q q
When swing holding brake release switch is in release position, swing holding brake is released andupper structure is secured by only hydraulic pressure. Perform all troubleshooting with working mode in power mode (P). Cause
Malfunction or defective seal of swing control valve (spool) Defective seal of swing con2 trol valve (pressure compensation valve) Defective seal of swing 3 motor (safety valve) 1
Probable causes and criteria
Criteria and troubleshooting procedure
a Be ready with engine stopped, then troubleshoot with engine high idle. Output pressure of swing holding Left work equipment control brake lever Malfunction of swing holding solenoid valve 1 brake solenoid valve 0 MPa Neutral {0 kg/cm2} Approx. 2.9 MPa Left swing Right swing {Approx. 30 kg/cm2}
Criteria and troubleshooting procedure Swingcontrolvalve spool may have malfunction or defective seal. Check it. Sealofpressure compensation valve of swing control valve may be defective. Check it. Sealing for safety valve of swing motor may be defective .Check the valve.
4
Defective seal of swing motor (suction valve)
Sealing of the suction valve of the swing motor may be defective. Check it.
5
Defective sealing of swing motor (check valve)
Sealing for check valve of swing motor may be defective . Check it.
6
Defective seaing for swing motor (shockless valve)
Sealing for shockless valve of swing motor may be defective. Check it.
PC200, 200LC, 220, 220LC-8M0
40-500
39
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-28 Attachment circuit cannot be changed
SEN06139-00
H-28 Attachment circuit cannot be changed For machines with provision for attachment Failure
q
Attachment circuit is not changed
q
When attachment installation specification is employed, service circuit is changed as follows according to selected working mode. 1) ATT mode: Service circuit is changed to double acting circuit and safety valve is set to low pressure. 2) B mode: Service circuit is changed to single acting circuit and safety valve is set to high pressure. Safety valve set pressure on only B port side is changed; that on A port side is kept low.
Related information q
Cause
Probable causes and criteria
40-500 40
1
MalfunctionofATT return selector solenoid valve
Criteria and troubleshooting procedure a Be ready with engine stopped, then troubleshoot with engine high idle. ATT return selector solenoid Working mode valve output pressure ATT mode B mode
0 MPa {0 kg/cm2} Approx. 2.9 MPa {Approx. 30 kg/cm2}
2
Malfunction of ATT return selector valve
3
Malfunction of service valve Safety valve (port B side) of service valve may malfunction. Check (safety valve) it.
ATT return selector valve may have malfunction. Check it.
PC200, 200LC, 220, 220LC-8M0
500 Troubleshooting of hydraulic and mechanical system (H-mode) H-29 Oil flow in attachment circuit cannot be controlled
SEN06139-00
H-29 Oil flow in attachment circuit cannot be controlled For machines with provision for attachment Failure Related information
q
Oil flow in attachment circuit cannot be changed
q
When attachment installation specification is employed, oil flow in service circuit changes according to selected user mode. How to adjust flow rate in ATT mode is different from that in B mode. For details, see Operation and Maintenance Manual.
q
Cause Probable causes and criteria
Malfunction of attachment 1 flow rate adjustment EPC valve Malfunction of service PPC 2 valve
PC200, 200LC, 220, 220LC-8M0
Criteria and troubleshooting procedure Attachment flow rate adjustment EPC valve may malfunction. Check it. Service PPC valve may have malfunction. Check it.
40-500
41
SEN06139-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06139-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-500
42
SEN06140-00 SEN05991-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
40 Troubleshooting 600 Troubleshooting of engine (S-mode) Method of using troubleshooting chart........................................................................................................
2
S-1 Startability is poor .................................................................................................................................
6
S-2 Engine does not start ...........................................................................................................................
7
S-3 Engine does not pick up smoothly........................................................................................................ 10 S-4 Engine stops during operation.............................................................................................................. 11 S-5 Engine runs rough or is unstable.......................................................................................................... 12 S-6 Engine lacks power .............................................................................................................................. 13 S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 14 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 15 S-9 Oil becomes contaminated early .......................................................................................................... 16 S-10 Fuel consumption is excessive........................................................................................................... 17 S-11 Oil is in coolant (or coolant spurts or coolant level goes down).......................................................... 18 S-12 Oil pressure drops .............................................................................................................................. 19 S-13 Oil level rises (coolant or fuel in oil).................................................................................................... 20 S-14 Coolant temperature rises too high (overheating) .............................................................................. 21 S-15 Unusual noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ......................................................................................................................... 23
PC200, 200LC, 220, 220LC-8M0
40-600
1
SEN06140-00
600 Troubleshooting of engine (S-mode) Method of using troubleshooting chart
Method of using troubleshooting chart The troubleshooting chart consists of the "Questions", "Check items", "Causes", and "Troubleshooting" blocks. The Questions and Check items are used to narrow down high probability causes by simple inspection or from symptoms without using troubleshooting tools. Next, use troubleshooting tools or perform direct inspection to check the selected Causes in the order of probability to determine the real cause according to the troubleshooting procedure. Questions: Questions placed in the sections A and B in the table on the right are those to be answered by the customer or operator. Questions in section A are for basic information about the failure. Depth and accuracy of their answers to the questions in section B may depend on their concerns on the machine condition. Check items: Check items placed in the section C in the table on the right are to be simply checked by the technician to select highly probable causes. Causes: Various causes are listed is this block. The technician will be able to narrows down the probable causes by taking the actions listed in the blocks A, B, and C. Troubleshooting: This section includes various items of troubleshooting that are performed in order to verify the results of the diagnosis made by asking the questions and inspecting the machine. The troubleshooting is performed in order from the most probable one by applying troubleshooting tools or direct inspection.
40-600 2
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) Method of using troubleshooting chart
SEN06140-00
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to their closer relationship with the causes. E: Reference information for estimation of the cause Q: Information and inspection result that indicate the cause of the failure w: A cause particularly probable among those marked with Q above. a Count the priority level of each marking as w > Q when determining the cause. Don't count E when determining the cause. The item with this marking may be counted, however, if no difference is present than this and the cause cannot be determined.
PC200, 200LC, 220, 220LC-8M0
40-600
3
SEN06140-00
600 Troubleshooting of engine (S-mode) Method of using troubleshooting chart
Exhaust gas is black (Incomplete combustion) Let us assume that a trouble of “Exhaust gas is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust gas gradually became black], [Power was lost gradually], and [Dust indicator indicates a red zone].
40-600 4
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) Method of using troubleshooting chart
SEN06140-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 – Step 3 shown below.
PC200, 200LC, 220, 220LC-8M0
40-600
5
600 Troubleshooting of engine (S-mode) S-1 Startability is poor
SEN06140-00
S-1 Startability is poor Cause
Troubleshooting
Check items
Questions
q
Check recent repair history. Machine operaOperated for long period tion hours Starting perforBecame worse gradually Engine starts easily when warm. mance Fuel other than specified one is used Filters are not replaced as indicated in the Operation and Maintenance Manual. Engine oil must be added more frequently. When engine is preheated or when temperature is low, preheating monitor does not indicate proper functioning of preheating system. During operation, charge level monitor indicates abnormal charge. Dust indicator indicates a red zone Air breather hole in fuel tank cap is clogged. Fuel leaks from fuel piping. If priming pump is operated, no resistance is felt or it is heavy. Starting motor cranks engine slowly. When engine is Even if air bleeding plug in fuel filter head is removed, fuel cranked with does not flow out. If spill hose from injector is disconnected, little fuel spills. starting motor, When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Engine does not pick up smoothly and combustion is irregular. Engine hunts. Blowby gas is excessive Check air cleaner. When compression pressure is measured, it is found to be low. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Even if starting switch is turned to HEAT, intake air heater mount does not become warm. Is voltage 20 – 30 V between alternator terminal B and terminal E Yes when engine is running at low idle speed? None Specific gravity of electrolyte and voltage of battery are low. Remedy
E
E
Q w w
Q
E
w
Q Q Q w Q Q
w
w
w w w w
w
w
w Q w Q
w
w w w Q Q w q
q q
w
Q w Q
q
q q q q q
q
q
Clean Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace Replace
Defective electrical system Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the engine is cranked properly, the engine may not start until the crankshaft rotates two turns under the most disadvantageous condition. This phenomenon does not mean a problem, however. q
Clogged air cleaner element Defective contact of valve with valve seat Worn piston ring or cylinder Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Stuck or seized supply pnmp pluger Defective injector Defective intake air heater system Defective alternator (regulator section) Defective alternator (generator section) Defective or deteriorated battery
General causes why startability is poor
*1: Failure codes [CA559] and [CA2249] 40-600 6
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-2 Engine does not start
SEN06140-00
S-2 Engine does not start Cause
a) Engine does not crank
q
Troubleshooting
Check items
Questions
q
Internal parts of engine seized. oSee "S-4 Engine stops during operations" Defective electrical system Defect in hydraulic pump
Check recent repair history. Machine operation Operated for long period EE hours Condition of horn Horn does not sound. Q Q w when starting switch Horn volume is low. w is turned ON Battery electrolyte level is low. w Battery cable terminal is loose w When starting switch is turned ON, no operating sound is heard from battery relay. Q w When starting switch is turned to START, starter pinion does not plunge. Q Q w w When starting switch Rotation speed is low. w w is turned to START, Unusual noise is heard around ring gear. starter pinion Pinion returns halfway. w plunges, but: Unusual noise is heard around relay and engine does not rotate. Q QQ Q Check flywheel ring gear. q Specific gravity of electrolyte and voltage of battery are low. q Voltage (20 – 30 V) between battery relay terminal B and terminal E is not found. Turn starting switch to When terminal B and terminal C of starting switch are connected, engine cranks. OFF position and When terminal B at safety relay outlet and terminal C are conconnect cable, and perform troubleshoot- nected, engine cranks. Even if terminal B at safety relay outlet and terminal C are coning with starting nected, engine will not crank. switch at ON. When terminal at safety switch and terminal B at starting motor are connected, engine cranks. Remedy
PC200, 200LC, 220, 220LC-8M0
Replace Replace Repair Replace Replace Replace Replace – Perform E-mode troubleshooting – Perform H-mode troubleshooting
q
Broken flywheel ring gear Defective or deteriorated battery Defective connection of battery cable terminal Defective battery relay Defective starting switch Defective safety relay Defective starting motor (motor section) Defective starting circuit wiring Defective hydraulic pump
General causes why engine does not crank
q
q
q
q q
40-600
7
600 Troubleshooting of engine (S-mode) S-2 Engine does not start
SEN06140-00
Cause Use of improper fuel Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Seized or prematurely worn feed pump Broken supply pump shaft Stuck or seized supply pump plunger Defective IMV for supply pump Malfunction of overflow valve (Does not close) Defective common rail pressure limiter Defective fuel injector
b) Engine cranks but no exhaust smoke comes out General causes why engine cranks but no exhaust smoke comes out
q
Troubleshooting
Check items
Questions
q
Fuel is not being supplied. Supply of fuel is extremely small. Improper selection of fuel (particularly in winter)
Check recent repair history. Machine operaOperated for long period EE tion hours Exhaust smoke suddenly stopped coming out (at restarting after short time w Q stoppage). Fuel other than specified one is used w Filters are not replaced as indicated in the Operation and Maintenance w Manual. Fuel tank is found to be empty. w Air breather hole in fuel tank cap is clogged. w Rust and water are found when fuel tank is drained. QE There is no fuel in the removal fuel filter. w w Fuel is leaking from fuel piping. w When priming pump is operated, no resistance is felt or it is heavy. w Q Even if air bleeding plug in fuel filter head is removed, fuel When engine is Q Q w Q does not flow out. cranked with Even if spill hose from injector is disconnected, little fuel Q w starting motor, spills. When air is bled from fuel system, air comes out. Check fuel filter. Check feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Perform troubleshooting for the error "IMV/IMA short or open circuit" according to failure code (*2). Check pressure relief valve. Fuel flows out when pressure limiter return piping is disconnected. Remedy
q
q
w w E
EE
w w
Q
q q q q q
q
Replace Add Clean Repair Replace Replace Replace Replace Replace Replace Replace Replace
q
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA271] and [CA272]
40-600 8
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-2 Engine does not start
SEN06140-00
Cause
General causes why exhaust smoke comes out but engine does not start
q q
Troubleshooting
Check items
Questions
q
Lack of cranking force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel
Check recent repair history. Machine operation Operated for long period E E E hours Suddenly become unstartable. w w Q Fuel other than specified one is used Q Q Filters are not replaced as indicated in the Operation and Maintenance Manw w ual. Oil must be added more frequently w When engine is preheated or when temperature is low, preheating monitor w does not indicate proper function of preheating system. Dust indicator indicates a red zone w Air breather hole of fuel tank cap is clogged. Q Rust and water are found when fuel tank is drained. w There is no fuel in the removal fuel filter. w Fuel is leaking from fuel piping. w When priming pump is operated, no resistance is felt or it is heavy. wQ Starting motor cranks engine slowly. w When engine is running, unusual noise is heard around cylinder head. w Even if air bleeding plug in fuel filter head is removed, fuel When engine is Q w does not flow out. cranked with startEven if spill hose from injector is disconnected, little fuel w ing motor, spills. When exhaust manifold is touched immediately after starting engine, temperaw ture of some cylinders is low. Check air cleaner. Check valve system. When compression pressure is measured, it is found to be low. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Specific gravity of electrolyte and voltage of battery are low. Coolant temperature gauge indication is not correct. Even if starting switch is turned to HEAT, intake air heater mount does not become warm. Remedy
q
q
q
q
q q q
q q
Clean Replace Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace
q
Clogged air cleaner element Worn valve system (valve, rocker lever, etc.) Worn piston ring or cylinder Use of improper fuel Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel system Clogging of fuel filter Stuck or seized supply pump plunger Clogged injection nozzle, or defective spray Defective or deteriorated battery Defective coolant temperature sensor or wiring harness Defective intake air heater system
c) Exhaust smoke comes out but engine will not start (fuel is injected)
*1: Failure codes [CA559] and [CA2249] PC200, 200LC, 220, 220LC-8M0
40-600
9
SEN06140-00
600 Troubleshooting of engine (S-mode) S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly Cause
q q q
Troubleshooting
Check items
Questions
q
Insufficient intake of air Insufficient supply of fuel Improper of fuel injection Improper selection of fuel Controller is controlling in derate mode (limiting injection rate (power) because of an error in electrical system)
Check recent repair history. Machine operaOperated for long period tion hours Engine pickup suddenly became worse. Fuel other than specified one is used Filters are not replaced as indicated in the Operation and Maintenance Manual. Engine oil must be added more frequently. Dust indicator indicates a red zone Air breather hole in fuel tank cap is clogged. Rust and water are found when fuel tank is drained. Fuel is leaking from fuel piping. When priming pump is operated, no resistance is felt or it is heavy. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Color of exhaust Blue under light load. smoke Black. While engine is running, unusual noise is heard around cylinder head. While engine is running, interference sound is heard around turbocharger. High idle speed is normal, but speed suddenly drops when load is applied. Engine hunts. Blowby gas is excessive. Check air cleaner. When compression pressure is measured, it is found to be low. Check valve clearance. When turbocharger is rotated by hand, it is found to be heavy. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). When a certain cylinder is cut out, engine speed does not change. Remedy
EE
E w
w
E QQ
w
w
w
Q www w
w w wQ Qw
wQ
w
w
w
w w
q
q
q
w Q Q
w Q
Q
q q
q
q q q
Clean Repair Adjust Replace Replace Clean Repair Replace Replace Replace
q
Clogged air cleaner element Defective contact of valve with valve seat Improper valve clearance Seizure or interference at turbocharger Worn piston ring or cylinder Clogged air breather hole in fuel tank cap Leaking or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Stuck or seized supply pump plunger Clogged injection nozzle, or defective spray
General causes why engine will not pick up smoothly
*1: Failure codes [CA559] and [CA2249]
40-600 10
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-4 Engine stops during operation
SEN06140-00
S-4 Engine stops during operation
Check recent repair history. Machine operation Operated for long period. hours Unusual noise was heard and engine wwww stopped suddenly. Condition when Engine overheated and stopped. wQ engine stopped Engine stopped slowly. Engine hunted and stopped. Fuel other than specified one is used Filters are not replaced as indicated in the Operation and Maintenance Manual. Fuel level monitor indicates low level. Fuel tank is found to be empty. Air breather hole in fuel tank cap is clogged. Fuel is leaking from fuel piping. When priming pump is operated, no resistance is felt or it is Rust and water are found when fuel tank is drained. Metal particles are found in oil drained from oil pan. ww It does not rotate at all. ww It rotates only in opposite direction. w When engine is Crankshaft moves by amount of gear w rotated by hand: backlash. Supply pump shaft does not turn. Engine operates, but stops when load is applied from machine.
Remedy
q
q
q
q
Defective engine controller power supply wiring Defective starting switch wiring
QwQw w w wQ
w w
w
Q Q Q w
Q
Q QQ QQ w
QQ QQ
Q
w wQQ ww QQ w w
q
q
w
q qq q
q
q
Repair Repair
Check valve system. Check piston and connecting rod. Check crankshaft bearing. Check gear train. Check fuel filter. Check feed pump gauze filter. Check the feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Engine operates if auxiliary equipment (pump, air compressor, etc.) is removed. Check engine controller power supply wiring. Check starting switch wiring.
EE
Perform H-mode troubleshooting
Troubleshooting
Check items
Questions
q
Internal parts of engine seized Insufficient supply of fuel Engine overheating Defect in hydraulic pump
–
q
Damage of valve system (valve, rocker lever, etc.) Broken or seized piston connecting rod Broken or seized crankshaft bearing Broken or seized gear train Insufficient fuel in tank Clogged air breather hole in fuel tank cap Clogged or leaking fuel piping Clogging of fuel filter Clogging of feed pnmp gauze filter Broken or seized feed pump Broken supply pump shaft Stuck or seized supply pnmp pluger Broken auxiliary equipment (pump or air compressor, etc.)
q
Replace Replace Replace Replace Add Clean Repair Replace Clean Replace Replace Replace Replace
q
Defective hydraulic pump
Cause
General causes why engine stops during operation
*1: Failure codes [CA559] and [CA2249] PC200, 200LC, 220, 220LC-8M0
40-600
11
SEN06140-00
600 Troubleshooting of engine (S-mode) S-5 Engine runs rough or is unstable
S-5 Engine runs rough or is unstable Cause
Troubleshooting Check items
Questions
q
Air in fuel system Defective engine speed sensor (error at degree that does not generate failure code)
Check recent repair history. Machine operation Operated for long period hours Occurs at a certain speed range. Occurs at low idle. Hunting: Occurs even when speed is raised. Occurs on slope. Filters are not replaced as indicated in the Operation and Maintenance Manual. Fuel tank is found to be empty. Air breather hole in fuel tank cap is clogged. Rust and water are found when fuel tank is drained. Fuel is leaking from fuel piping.
E
w w
Q Q Q Q Q Q Q Q Q Q w w w
Q
When priming pump is operated, no resistance is felt or it is heavy.
w Q
When air is bled from fuel system, air comes out. Check fuel filter. When a certain cylinder is cut out, engine speed does not change. Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1).
q
q
q
q
Perform troubleshooting for "Eng Backup Speed Sensor Error" according to failure code (*2).
q
Remedy
Add Clean Replace Replace Replace Replace Replace
q
Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Clogged injector or defective spray (dirt in injector) Defective Ne speed sensor, or wiring harness Defective Ne speed sensor, or wiring harness
General causes why engine runs rough or is unstable
*1: Failure code [CA689] *2: Failure code [CA778]
40-600 12
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-6 Engine lacks power
SEN06140-00
S-6 Engine lacks power General causes why engine lacks power
Check recent repair history. Machine operation Operated for long period hours suddenly Power was lost gradually
Q
Q w
w
Oil must be added more frequently.
w w
Dust indicator indicates a red zone
Q
Q
Q
Q
Q Q QQ Q w w
black
blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. While engine is running, interference sound is heard around turbocharger.
w
w
Clogged fuel spill piping
Defective boost pressure sensor or wiring harness
Defective installation of boost pressure sensor (air leak)
Defective injector drive (signal or solenoid)
Q Q Q
Q Q
w
w w w
w
w
While engine is running, unusual noise is heard around cylinder head. High idle speed is too high. High idle speed is normal, but speed suddenly drops when load is applied.
w w
Engine does not pick up smoothly and combustion is irregular. Engine hunts.
w
Blowby gas is excessive
w
Q Q wQ Q QQ w QQQ Q Q
q
q q q q
Check air intake piping. When boost pressure is measured, it is found to be low. When compression pressure is measured, it is found to be low.
q
Check valve clearance.
q
q q
Check fuel piping. Check fuel filter.
q
Check spill port check valve. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). When a certain cylinder is cut out, engine speed does not change.
q q q q
Check boost air pressure sensor mount. Perform troubleshooting for "Charge pressure sensor error" according to failure code (*2). Replace
Replace
Replace
Replace
Repair
Clean
Replace
Adjust
Repair
Replace
Repair
q Clean
Remedy
q Replace
Check air cleaner.
Replace
Check items
Color of exhaust smoke
Clogged injector nozzle, or defective spray (dirt in injector)
E
Fuel is leaking from fuel piping.
w
Stuck or seized supply pnmp pluger
E
Air breather hole in fuel tank cap is clogged. Power becomes insufficient after short stop of operation.
Clogging of fuel filter
E
Fuel other than specified one is used Filters are not replaced as indicated in the Operation and Maintenance Manual.
Troubleshooting
Clogged or leaking fuel piping
Clogged air breather hole in fuel tank cap
Worn piston ring or cylinder
Improper valve clearance
Defective contact of valve with valve seat
Seizure or interference at turbocharger
E
Repair
Questions
Clogged air cleaner element
q
Causes
Insufficient intake of air Insufficient supply of fuel Improper fuel injection Improper selection of fuel Engine overheating oSee “S-14 Coolant temperature becomes too high (overheating)“. Controller is controlling in derate mode. (limiting injection rate (power) because of an error in electrical system)
Air leakage from air intake piping and aftercooler
q q q q q
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA122] and [CA123]
PC200, 200LC, 220, 220LC-8M0
40-600
13
SEN06140-00
600 Troubleshooting of engine (S-mode) S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
q q q
Troubleshooting
Check items
Questions
q
Insufficient intake of air Improper fuel injection Improper selection of fuel Engine overheating oSee “S-14 Coolant temperature becomes too high (overheating)“. Controller is controlling in derate mode. (limiting injection rate (power) because of an error in electrical system)
Check recent repair history. Machine operaOperated for long period tion hours Color of exhaust Suddenly became black. Gradually became black. smoke Is blue under light load. Fuel other than specified one is used Engine oil must be added more frequently. Suddenly Power was lost Gradually Dust indicator indicates a red zone Muffler is crushed. Air leaks at tubing between turbocharger and cylinder head, and loose clamp. Engine is operated in low-temperature mode at normal temperature. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. While engine is running, interference sound is heard around turbocharger. While engine is running, unusual noise is heard around cylinder head. Torque converter stall speed or pump relief speed is high (Fuel is injected excessively). Exhaust noise is unusual. Engine does not pick up smoothly and combustion is irregular. Blowby gas is excessive When spill hose from injector is disconnected, fuel spills excessibly.
E w
Q w
E
E
w
w
w Q
Q
Q
Q
w Q
QQQ Q QQ QQ
w w QQQ Qw w
w Q
Q Q
w QQQ
Check air cleaner. q When turbocharger is rotated by hand, it is fount to be heavy. q When compression pressure is measured, it is found to be low. q Check valve clearance. q If muffler is removed, exhaust sound improves. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). When a certain cylinder is cut out, engine speed does not change. Perform troubleshooting for "Coolant sensor error" according to failure code (*2). Check the condition by using monitoring function of the machine monitor. Remedy
w
E
w
Q Qw w
q q q
q q q qq
Clean Replace Repair Adjust Repair Replace Replace Replace Replace Replace Replace Replace Replace
q
Clogged air cleaner element Seizure or interference at turbocharger Defective contact of valve with valve seat Improper valve clearance Air leak at tubing between turbocharger and cylinder head Crushed or clogged muffler Worn piston ring or cylinder Stuck or seized supply pnmp pluger Cloggedor seized injector Prematurely worn injector Improper fuel injection timing Improper fuel injection pressure Defective coolant temperature sensor or wiring harness
Cause
General causes why exhaust smoke is black
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145] 40-600 14
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-8 Oil consumption is excessive (or exhaust smoke is blue)
SEN06140-00
S-8 Oil consumption is excessive (or exhaust smoke is blue)
Check recent repair history. Machine operation Operated for long period hours Oil consumption suddenly increased. Engine oil must be added more frequently. Oil becomes contaminated quickly. Outside of engine is dirty with oil. Loose hose clamps are found in air intake system. Inside of air outlet pipe at turbo compressor side is dirty with oil. Inside of turbo exhaust outlet pipe is dirty with oil. Oil in coolant Oil level in damper chamber is increasing. Exhaust smoke is blue under light load. Excessive Amount of blowby gas None When intake manifold is removed, dust is found inside. When intake manifold is removed, inside is abnormally dirty. Excessive play of turbocharger shaft Check breather or breather hose. When compression pressure is measured, it is found to be low. Check rear oil seal. Pressure tightness test result of oil cooler shows oil leakage. External leakage of oil from engine Remedy
PC200, 200LC, 220, 220LC-8M0
Dust sucked in at air intake system Worn/damaged valve (stem, guide, seal) Worn seal at turbine end Turbocharger Worn seal at blower end Clogged breather or breather hose Broken piston ring Worn piston ring or cylinder Worn or damaged rear oil seal Broken oil cooler Oil leakage from oil cooler Oil leakage from oil filter Oil leakage from oil piping Oil leakage from oil drain plug Oil leakage from oil pan, cylinder head, etc.
Cause
EEE
E w
Q Q
w Q Q w w Q w
Q q
q
w w w w w
w
Q
q q
w
q
w w w w
q q
w
q
w
q q
q q q q
Repair Repair Replace Replace Clean Replace Replace Replace Replace Replace Repair Repair Repair Repair
Troubleshooting
Check items
Questions
General causes why oil consumption is excessive q Excessive oil carry-over q Long-time operation of engine at low idle or high idle (Do not idle the engine for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system
40-600
15
SEN06140-00
600 Troubleshooting of engine (S-mode) S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early Cause
q q
Troubleshooting
Check items
Questions
q
Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Use of improper fuel Use of improper oil Operation under excessive load
Check recent repair history. Machine operation hours Operated for long period Fuel other than specified one is used Oil must be added more frequently. Metal particles are found in the removed oil filter. Inside of exhaust pipe is dirty with oil. Engine oil temperature rises quickly. Blue under light load Color of exhaust smoke Black Excessive Amount of blowby gas None
EEE Q w Q Q w
Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low. Check breather or breather hose. Check oil cooler. Check oil filter. Spring of oil filter safety valve is stuck or broken. Check turbocharger lubrication oil drain tube.
q
w w
w Q Q w
Q
w
w
Remedy
40-600 16
Q
q q
q
q
q
q
See S-7
q
q
Replace Replace Replace Clean Clean Replace Replace Clean –
q
Defective sealing at turbocharger turbine end Worn valve or valve guide Worn piston ring or cylinder Clogged breather or breather hose Clogged oil cooler Clogged oil filter Defective oil filter safety valve Clogged turbocharger lubrication oil drain tube Exhaust smoke is bad
General causes why oil becomes contaminated early
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-10 Fuel consumption is excessive
SEN06140-00
S-10 Fuel consumption is excessive Cause
q
Troubleshooting
Check items
Questions
q
Leakage of fuel Improper fuel injection (fuel pressure or injection timing) Excessive injection of fuel
Check recent repair history. Machine operaOperated for long period tion hours is more than that on other machines of same model. Fuel consumpGradually increased. tion: Suddenly increased. External leakage of fuel from engine Combustion is irregular. Engine oil level rises and oil smells of diesel fuel. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Low idle speed is high. Pump relief speed is high. Color of exhaust Black smoke White Remove head cover and check for fuel leak. Check oil seal of feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). When a certain cylinder is cut out, engine speed does not change. Too much fuel is returned from injector. Perform troubleshooting for "Coolant sensor error" according to failure code (*2). Check the condition by using monitoring function of machine monitor. Remedy
EE Q
QQ w w
E Q
Q
QQQ
w
w
w
Q q
QQ
Q Q
QQ
q q q q
q q
q
Repair Repair Replace Replace Repair Replace Replace Replace Replace
q
Fuel leakage at cylinder head Fuel leakage from fuel filter, piping, etc. Defective feed pump oil seal Defective supply pump plunger Improper common rail pressure Defective atomization by injector Defective operation of injector Improper injection timing Defective coolant temperature sensor or wiring harness
General causes why fuel consumption is excessive
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145]
PC200, 200LC, 220, 220LC-8M0
40-600
17
SEN06140-00
600 Troubleshooting of engine (S-mode) S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) Cause
Troubleshooting
Check items
Questions
q
Internal leakage in lubrication system Internal leakage in cooling system
Check recent repair history. Machine operation Operated for long period hours suddenly Oil level rose: gradually Hard water is being used as coolant. Oil level has risen and oil is milky.
Q
Unusual air bubbles are found in radiator, or coolant spurts.
w
Pressure tightness test result of cylinder head shows oil leakage.
q
EE Q Q Q Q Q Q w
q q
Check cylinder block.
q
Pressure tightness test result of oil cooler shows oil leakage. Remedy
40-600 18
Q
Replace Replace Replace Replace
q
Broken cylinder head or cylinder head gasket Internal cracks in cylinder block Holes caused by pitting Broken oil cooler core or O-ring
General causes why oil is present in coolant
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-12 Oil pressure drops
SEN06140-00
S-12 Oil pressure drops
Check recent repair history. Machine operaOperated for long period tion hours Oil pressure monitor indicates low oil pressure. Oil other than specified one is used Filters are not replaced as indicated in the Operation and Maintenance Manual. Indicates pressure drop at low idle. Oil pressure Indicates pressure drop at low and high idle. monitor: Indicates pressure drop on slope. (if installed) Sometimes indicates pressure drop. Oil pressure monitor indicates low oil pressure. Oil level in oil pan is low. External lubrication piping is leaking or crushed. Oil is milky or smells of diesel fuel. Metal particles are found in oil drained from oil pan.
Worn main hearing Lack of oil in oil pan Coolant or fuel in oil Clogged strainer in oil pan Clogged or broken pipe in oil pan Defective oil pump Defective regulator valve Clogged oil filter Leaking, crushed, clogged oil piping Defective coolant temperature sensor or wiring harness
Cause
E
w
Q w
wwwQ w
w w w
Metal particles are found in oil filter. Inspect oil pan strainer and pipe. Oil pump rotation is heavy or there is play in oil pump. Valve and spring of regulator valve are fatigued or damaged. Check oil filter. If oil level sensor is replaced, oil level monitor indicates correct oil level.
q
Remedy
Q w w
w Q See S-13
w
E Qw Q w
Q
Metal particles are found in the removed oil filter.
PC200, 200LC, 220, 220LC-8M0
E
qq
q
q
q
q
Replace Add – Clean Clean Replace Adjust Adjust Repair Replace
Troubleshooting Check items
Questions
General causes why oil pressure drops q Leakage, clogging, or wear on lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating
40-600
19
SEN06140-00
600 Troubleshooting of engine (S-mode) S-13 Oil level rises (coolant or fuel in oil)
S-13 Oil level rises (coolant or fuel in oil) Causes Broken cylinder head or cylinder head gasket Broken injector O-ring Internal cracks in cylinder block Holes caused by pitting Worn or damaged rear oil seal Broken oil cooler core or O-ring Defects in supply pump Defective seal of auxiliaries (water pump or air compressor)
General causes why oil level rises Coolant in oil (milky) Fuel in oil (oil smell of diluted diesel fuel) a If oil is in coolant, perform troubleshooting for “S-11 Oil is in coolant”. q
Check recent repair history. Machine operaOperated for long period tion hours Fuel must be added more frequently. Coolant must be added more frequently. Oil in coolant Oil smells of diesel fuel Oil is milky. While engine is running, drops of water come from muffler. If radiator cap is removed and engine is run at low idle, an unusual number of bubbles appears, or coolant spurts. Exhaust smoke is white.
E
EE
w Q Q QQQQ w Q Q Q w
w w
w
Q Q w
Oil level in damper chamber decreases.
q
When compression pressure is measured, it is found to be low. Remove injector and check O-ring. Check cylinder block. Check rear oil seal. Pressure tightness test result of oil cooler shows oil leakage. Remove and check supply pump. Check seal of auxiliaries. Remedy
40-600 20
E
q
qq
q
q
q
q
Replace Replace Replace Replace Replace Replace Replace Replace
Troubleshooting
Check items
Questions
q
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-14 Coolant temperature rises too high (overheating)
SEN06140-00
S-14 Coolant temperature rises too high (overheating) Causes
Broken cylinder head or cylinder head gasket Holes caused by pitting Clogged or broken oil cooler Lack of coolant Malffunction of water pump Malfunction of thermostat Clogged or crushed radiater fins Clogged radiator core Defective radiator cap (pressure valve) Slipping fan belt or worn fan pulley Defective coolant temperature gauge Rise in hydraulic oil temperature
Check recent repair history. Machine operaOperated for long period EE EE tion hours Suddenly occurred. Q w Overheating Tends to occur always. Q w w Q w Coolant temper- Indiacates quick temperature rise. ature gauge: Does not go down from red range. Radiator coolant level monitor indicates drop of coolant level. w Engine oil level has risen and oil is milky. w Q Fan belt tension is low. When fan pulley is turned, it has play. w Milky oil is floating on coolant. w Unusual air bubbles are found in radiator or coolant spurts. w When light bulb is held behind radiator core, no light passes through. w Radiator shroud and inside of underguard are clogged with dirt or mud. w Coolant is leaking because of cracks in hose or loose clamps. w Coolant flows out from radiator overflow hose. w Fan belt whines under sudden acceleration. Hydraulic oil temperature gauge enters red range faster than engine coolant temperature gauge.
w
w w w
Perform H-mode troubleshooting.
q
Check cylinder.
q
Check oil cooler. Troubleshooting
w
q
When compression pressure is measured, it is found to be low.
Temperature difference between upper and lower tanks of radiator is large. When operation of thermostat is tested, it does not open at specified opening temperature. Temperature difference between upper and lower tanks of radiator is slight.
q q q q
Check radiator core. When operation of radiator cap is tested, its opening pressure is low.
q q
Check fan belt and pulley.
q
When coolant temperature is measured, it is found to be normal. Remedy
PC200, 200LC, 220, 220LC-8M0
Q Q
Replace Replace Replace Add Replace Replace Repair Repair Replace Repair Replace –
Check items
Questions
General causes why coolant temperature rises too high q Lack of cooling air (deformation or damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system
40-600
21
600 Troubleshooting of engine (S-mode) S-15 Unusual noise is made
SEN06140-00
S-15 Unusual noise is made General causes why unusual noise is heard
w
Dirt caught in injector
Clogged or seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Dislocated or seized bushing
Excessively worn piston ring or cylinder
Improper valve clearance
Defective inside of muffler (partition board out of position)
Damage of valve system (valve or rocker lever)
Improper gear train backlash
Q
w w w
w
w
Q Q
w
w wQ
q
qq q Replace
qq
Replace
q
Repair
q
Adjust
q
Replace
Replace
Replace
q
w
w QQ
Q
Replace
Q
w
Replace
Q
Replace
Qw
q
Remedy
Q
QQ
When turbocharger is rotated by hand, it is found to be heavy. Check valve system. If muffler is removed, unusual noise disappears. Check valve clearance. When compression pressure measured, it is found to be low. Check gear train. Check fan and fan belt. Even if a cylinder is cut out, engine speed does not change. Unusual noise is heard only when engine is cranked. Check the condition by using monitoring function of machine monitor.
40-600 22
Seizure or interference at turbocharger
Air leak at tubing between turbocharge and cylinder head
E
Replace
Questions Check items Troubleshooting
Check recent repair history. Machine operaOperated for long period tion hours Gradually occurred. Abnormal noise Sudden occurred. Fuel other than specified one is used Engine oil must be added more frequently. Metal particles are found in the removed oil filter. Air leaks at tubing between turbocharger and cylinder head. While engine is running, interference sound is heard from turbocharger. While engine is running, unusual noise is heard around cylinder head. While engine is running, beat noise is heard around muffler. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Color of exhaust Blue under light load smoke: Black Engine does not pick up smoothly and combustion is irregular. Unusual noise is loud when engine is accelerated Blowby gas is excessive
q Replace
Abnormality due to defective parts Abnormal combustion Air sucked in from air intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about three seconds. This does not indicate abnormality, however. q q q
Improper fuel injection timing (defect in low coolant temperature sensor or boost temperature sensor)
Cause
PC200, 200LC, 220, 220LC-8M0
600 Troubleshooting of engine (S-mode) S-16 Vibration is excessive
SEN06140-00
S-16 Vibration is excessive Cause Stuck valve system (valve, rocker arm, etc.) Worn main bearing and connecting rod bearing Improper gear train backlash Worn camshaft bushing Improper injection timing (Problem with coolant or boost temperature sensor) Loose engine mount bolts or broken cushions Misalignment of engine and hydraulic pump Broken parts in damper chamber
General causes why vibration is excessive Defective parts (premature wear or breakage) Misalignment between engine snd hydraulic pump q Abnormal combustion a If unusual noise is made and vibration is excessive, perform troubleshooting also for “S-15 Unusual noise is made”. q
Check recent repair history. Machine operaOperated for long period tion hours Suddenly increased. Vibration Gradually increased. Oil other than specified one is used Metal particles are found in the removed oil filter. Metal particles are found in oil drained from oil pan. Oil pressure is low at low idle. Vibration occurs at mid-range speed. Vibration follows engine speed.
Q
E
E
Q Q w w Q
Q Q w w Q
Q
w
Check valve system. Check main bearing and connecting rod bearing. Check gear train. Check camshaft bushing. Check the condition by using monitoring function of machine monitor. Check engine mounting bolts and cushions. When radial runout and facial runout are checked, misalignment is found. Check inside of damper chamber.
q
Remedy
Q
Q Q Q Q Q
Q
Exhaust smoke is black.
PC200, 200LC, 220, 220LC-8M0
E
Q q
q
q
q
q
q
q
Replace Replace Replace Replace Replace Replace Adjust Replace
Troubleshooting
Check items
Questions
q
40-600
23
SEN06140-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06140-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
40-600
24
SEN06142-00
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
100 General information on disassembly and assembly How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tools list .............................................................................................................................................. 7 Sketches of special tools .............................................................................................................................. 12
PC200, 200LC, 220, 220LC-8M0
50-100
1
100 General information on disassembly and assembly How to read this manual
SEN06142-00
How to read this manual 1.
(Rev. 2009.1)1
Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Removal q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6:
Amount of oil or coolant to be drained
4:
Weight of part or component
Installation Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. q
k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
q
50-100
2
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly How to read this manual
2.
SEN06142-00
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k
a
: Precautions related to work safety : Guidance or precautions for the work
6:
Amount of oil or coolant drained
Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
q
PC200, 200LC, 220, 220LC-8M0
50-100
3
100 General information on disassembly and assembly Coating materials list
SEN06142-00
Coating materials list a a
1
(Rev. 2009.08)
The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu code
Part No.
Capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
790-129-9040
50 g
LT-3
790-129-9060 (Set of adhesive and hardener)
LT-4 Holtz MH 705 ThreeBond 1735
Main features and applications q
Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
q
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
Polyethylene container
q q
Features: Resistance to heat and chemicals. Use to fix and seal bolts and plugs.
Adhesive: 1 kg Hardener: 500 g
Can
q
Use to bond and seal metal, glass and plastics.
790-129-9040
250 g
Polyethylene container
q
Use to seal plugs for blank holes
790-129-9120
75 g
Tube
q
Heat-resistant seal used to repair engines.
q
50 g
Polyethylene container
2g
Polyethylene container
Instantaneous adhesive. Curing time: From 5 sec. to 3 min. Use mainly to bond metals, rubbers, plastics, and woods. Instantaneous adhesive. Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Use for fitted portions subjected to high temperature. Use to seal various threaded portions, pipe joints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Use to seal flange surfaces and threaded portions. Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant. Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint.
790-129-9140
q q q
Aron-alpha 201
790-129-9130
q q
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
1 kg
Polyethylene container
q q q
LG-5
790-129-9080
q q
Liquid gasket
LG-6
790-129-9160
200 g
Tube
q q q
LG-7
790-129-9170
1 kg
Tube
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
LG-9 ThreeBond 1206D
50-100
4
q q q q
790-129-9310
200 g
Tube q
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Coating materials list
Seizure Molybdenum disulfide prevention compound lubricant
Liquid gasket
Category
Komatsu code LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 LM-P
Capacity
Container
790-129-9320
200 g
Tube
Main features and applications q q q
200 g
Tube
q
790-129-9090
100 g
Tube
q
Liquid gasket used to repair engine.
q
Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.
09940-00040
200 g
Tube q q
—
09995-00250
190 g
Can q
q
LC-G NEVERSEEZ
—
—
Can
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
Molybdenum disulfide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White G2-T, G0-T (*) *: For cold district
SYG2-400T-A SYG0-400T-A (*) SYG2-16CNT SYG0-16CNT (*)
Biogrease G2-B G2-BT (*) *: For use at high temperature and under high load
SYG2-400B SYG2-400BT (*) SYGA-16CNB SYGA-16CNBT (*)
G2-S ThreeBond 1855
Use as lubricant/sealant when installing the radiator hoses to the water tubes. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc.
790-129-9330
q
G2-LI G0-LI (*) *: For cold district
Grease
Part No.
SEN06142-00
—
400 g × 10 400 g × 20 16 kg
400 g 16 kg
400 g 16 kg
200 g
q
q
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
q
Use for parts under heavy load. Caution: q Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. q Use this grease for work equipment pins only when installing them, but do not use it afterward.
q
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type container Can
Bellows-type container Can
Bellows-type container Can
q
q
Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.
q
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Use for oil seals of the transmission, etc.
Tube q
PC200, 200LC, 220, 220LC-8M0
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc. Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
50-100
5
100 General information on disassembly and assembly Coating materials list
SEN06142-00
Category
Komatsu code
Part No.
Capacity
Container
Main features and applications
SUNSTAR PAINT PRIMER 580 SUPER 417-926-3910 SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT 22M-54-27230 PRIMER 435-95
Caulking material
Adhesive
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
SUNSTAR SASH 22M-54-27250 PRIMER GP-402 SUNSTAR PENGUINE SEAL580 417-926-3910 SUPER "S" or "W" Sika Japan, Sikaflex 20Y-54-39850 256HV SUNSTAR PENGUINE 22M-54-27210 SUPER 560 SUNSTAR PENGUINE 417-926-3920 SEAL No. 2505 SEKISUI SILICONE 20Y-54-55130 SEALANT GE TOSHIBA SILICONES 22M-54-27220 TOSSEAL 381
50-100
6
2 kg
Can q
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
150 ml
Can
20 ml
Glass container
For adhered window glass
G2-U-S 427-12-11871 ENS grease
Feature: Urea (organic system) grease with heat resistance and long life, can be packed into the confined space and left intact until next overhaul. Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease. q Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture) q
Use as primer for glass. (Effective period: four months after date of manufacture)
q
Use as primer for painted cab sheet metal surface. (Effective period: four months after date of manufacture) Use as primer for black ceramic-coated glass surface and for hard polycarbonatecoated surface. (Effective period: four months after date of manufacture) Use as primer for sash (anodized aluminum surface). (Effective period: four months after date of manufacture) Use "S" in high-temperature season and "W" in low-temperature season as adhesive for glass. (Effective period: four months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture) Use as adhesive for glass. (Effective period: six months after date of manufacture)
q
q
q
320 ml
Polyethylene container
310 ml
Polyethylene container
320 ml
Ecocart (Special container)
320 ml
Polyethylene container
333 ml
Polyethylene container
333 ml
Cartridge
q
For adhered window glass
Primer
Grease
q
q
q
Use to seal glass-to-glass joints. (Effective period: four months after date of manufacture)
q
Use to seal front window. (Effective period: six months after date of manufacture)
q
Use to seal glass-to-glass joint. Translucent white seal. (Effective period: 12 months after date of manufacture)
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Special tools list
SEN06142-00
Special tools list a a
a
* *** ****
Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e. tools to be made locally). Necessity: t ............ Special tools that cannot be substituted and should always be used q ............ Special tools that will be useful if available and are substitutable with tools available on the market New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively. R ............ Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank ..... Tools already available for other models. They can be used without any modification. Tools marked with Q in the sketch column are presented in the sketches of the special tools (See “Sketches of special tools”). Work item
Symbol
Part number
Part name
Necessity Q'ty N/R Sketch
a
1
Work content
Engine front oil seal
1 795-799-6400
Seal puller
t 1 N
Installation of engine front oil seal
Engine rear oil seal
2 795-799-6500
Seal puller
t 1 N
Installation of engine rear oil seal
3 795-799-6700
Primer
t 1 N
Removal of fuel injector
4 795-799-1131
Gear
t 1
Positioning with 3RD and 4TH cylinder top
5 795-799-8150
Remover
q 1 N
Removal of inlet connector
6 790-331-1120
Wrench (Angle)
q 1
Angle tightening of bolt
7 795-790-4510
Gauge
q 1 N
Judgment of cylinder head bolt length
Cylinder head assembly, fuel injector assembly
Cylinder head assembly
A
Hydraulic pump assembly, Engine and hydraulic pump assembly, Control valve assembly, Center swivel joint assembly
Lifting tool
10 796-460-1210
Oil stopper
q 1 Stopping oil
Fuel supply pump assembly
Swing motor and swing machinery assembly
9 795-790-9300
q 1 N Q Removal and installation of engine and hydraulic pump q 1 N assembly
8 796T-401-1110 Plate
Engine and hydraulic pump assembly
11 796-770-1320
Adapter
q 1
12 795-799-6130
Support
t 1
1 796T-426-1410 Push tool
t 1
2 796-426-1120
t 1
F
J 1
t 1
Grip
t 1
01010-81240
Bolt
t 1
796-427-1400
Wrench assembly
t 1 N
796-427-1410
• Wrench
1 N
796-427-1140
• Pin
3
01314-20612
• Screw
3
3 790-101-5421
Final drive assembly
Push tool
796T-426-1130 Plate
PC200, 200LC, 220, 220LC-8M0
Removal and installation of gear Q Press fit of main bearing Press fit of sub bearing Q Press fit of oil seal
Removal and installation of nut
50-100
7
Work item
Symbol
J
Track roller assembly Idler assembly
50-100
8
Work content
t 1 N Q
790-101-2510
Block
t 1
790-101-3310
Block
t 1
790-101-2610
Rod
t 2
790-101-2730
Adapter
t 2
01580-11613
Nut
t 2
790-101-2570
Plate
t 2
01643-31645
Washer
t 2
790-101-2102
Puller (294 kN {30 ton})
t 1
790-101-1102
Pump
t 1
3 796-427-1520
Installer
t 1 N
Installation of floating seal
4 796-427-1400
Wrench assembly
t 1
Removal and installation of ring nut
5 796-427-1520
Installer
t 1
Installation of floating seal
6
Carrier roller assembly
Part name
796T-427-1510 Push tool
2
Final drive assembly
Part number
Necessity Q'ty N/R Sketch
100 General information on disassembly and assembly Special tools list
SEN06142-00
796T-427-1510 Push tool
t 1
790-101-2510
Block
t 1
790-101-3310
Plate
t 1
790-101-2610
Leg
t 2
790-101-2730
Adapter
t 2
01580-11613
Nut
t 2
790-101-2570
Plate
t 2
01643-31645
Washer
t 2
790-101-2102
Puller (294 kN {30 ton})
t 1
790-101-1102
Pump
t 1
7 790-331-1110
Wrench
t 1
1 790-434-1660
Installer
t 1
L 2 796-670-1020
Installer
t 1
3 791-530-1510
Installer
t 1
Installation of bearing
Q
Installation of hub assembly
Angle tightening of bolt Installation of floating seal
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Special tools list
Symbol
Part number
Part name
Necessity Q'ty N/R Sketch
Work item
SEN06142-00
Compressor (A)
t 1
Compressor (B)
t 1
Spacer
t 1
Extension
t 1
790-101-1600
Cylinder (686 kN {70 ton})
t 1
790-101-1102
Pump
t 1
790-640-2180
Guide bolt
t 1
790-101-5201
Push tool kit (B)
q 1
790-101-5241
• Plate
1
790-101-5221
• Grip
1
01010-51225
• Bolt
2
790-201-1500
Push tool kit
790-201-1620
• Plate
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
791-630-3000
Remover and installer
t 1
790-101-1300
Cylinder (980 kN {100 ton})
t 1
790-101-1102
Pump
t 1
791-600-2001
Work content
or 791-685-8006 790-201-2780 1 791-635-3160
Recoil spring assembly
M
2
3
Track shoe assembly
R
Hydraulic pump assembly S
Center swivel joint assembly
Disassembly and assembly of recoil spring assembly
q 1
Separation and installation of track shoe assembly
1 796T-467-2410 Push tool
t 1 N Q Press fit of input shaft oil seal
2 796T-416-1010 Push tool
t 1 N Q
3 796T-416-1030 Push tool
t 1 N Q
4 796T-416-1020 Push tool
t 1 N Q Press fitting of pin q 1
790-101-2501
Push puller
790-101-2510
• Block
1
790-101-2520
• Screw
1
791-112-1180
• Nut
1
• Washer
1
790-101-2630
• Leg
2
790-101-2570
• Plate
4
790-101-2560
• Nut
2
790-101-2650
• Adapter
2
T 1 790-101-2540
PC200, 200LC, 220, 220LC-8M0
Press fitting of bushing
Disassembly and assembly of center swivel joint assembly
50-100
9
Work item
Symbol
Part number 796-946-1310
Part name Guide f21.8 mm
(For 723-46-40100) 796-946-1610
Guide f21.4 mm
(For 723-46-41100) 2
796-946-1810
Guide f21.2 mm
(For 723-46-43100 and 723-46-43400) 796-946-1910
Guide f21.0 mm
(For 723-46-46101 and 723-46-46300) 796-946-2210
Guide f20.6 mm
(For 723-46-45100 and 723-46-45700) 796-946-1320
Guide f21.8 mm
(For 723-46-40100) 796-946-1620
Guide f21.4 mm
(For 723-46-41100) 796-946-1820 3 Control valve assembly
T
Guide f21.2 mm
(For 723-46-43100 and 723-46-43400) 796-946-1920
Guide f21.0 mm
(For 723-46-46101 and 723-46-46300) 796-946-2220
Guide f20.6 mm
(For 723-46-45100) 796-946-1420
Guide f21.6 mm
(For 723-46-42700) 796-946-1330
Sleeve
(For 723-46-40100) 796-946-1630
Sleeve
(For 723-46-41100) 796-946-1830 4
Sleeve
(For 723-46-43100 and 723-46-43400) 796-946-1930
Sleeve
(For 723-46-46101 and 723-46-46300) 796-946-2230
Sleeve
(For 723-46-45100) 796-946-1430
Sleeve
(For 723-46-42700)
50-100
10
Necessity Q'ty N/R Sketch
100 General information on disassembly and assembly Special tools list
SEN06142-00
Work content
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Replacement of pressure compensation valve seal
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Special tools list
Symbol
1 2
Part number 790-502-1003
Cylinder repair stand
q 1
790-101-1102
Pump
q 1
790-102-4300
Wrench assembly
t 1
790-102-4310
Pin
t 2
Expander
q 1
796-720-1670
Rubber band (for boom and arm)
q 1
07281-01279
Clamp
q 1
796-720-1680
Rubber band (for bucket)
q 1
07281-01589
Clamp
q 1
790-201-1702
Push tool kit
t 1
790-201-1841
• Push tool (for boom and bucket)
1
790-201-1851
• Push tool (for arm)
1
790-101-5021
• Grip
1
01010-50816
• Bolt
2
790-201-1500
Push tool kit
790-201-1650
• Push tool (for boom and bucket)
1
790-201-1660
Plate (for arm)
1
790-101-5021
Grip
1
3 790-720-1000
4
Hydraulic cylinder assembly
U 5
6
Work equipment assembly
Operator cab glass (stuck glass)
Counterweight assembly
V
X
Z
Part name
Necessity Q'ty N/R Sketch
Work item
SEN06142-00
Disassembly and assembly of hydraulic cylinder assembly Removal and installation of piston assembly
Installation of piston ring
Press fit of bushing
q 1
01010-50816
Bolt
796-900-1200
Remover
796-900-1210
• Sleeve
1
792-900-1520
• Plate
1
799-900-1230
• Screw
1
796-900-1240
• Adapter
1
01643-33080
• Washer
1
01803-13034
• Nut
1
790-101-4000
Puller (490 kN {50 ton} long)
t 1
790-101-1102
Pump (294 kN {30 ton})
t 1
Press fit of dust seal
2 t 1
2 793-498-1210
Lifter (Suction cup)
t 2
3 20Y-54-13180
Stopper rubber
t 2
Commercially available
Impact wrench
q 1
Commercially available
Socket wrench q 1 (width across flats: 41 mm)
PC200, 200LC, 220, 220LC-8M0
Work content
Removal of foot pin
Installation of operator cab glass (stuck glass) Removal and installation of the counterweight mounting bolt
50-100
11
SEN06142-00
Sketches of special tools
100 General information on disassembly and assembly Sketches of special tools
1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A8 Plate
F1 Push tool
50-100
12
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Sketches of special tools
SEN06142-00
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F3 Plate
J2, J6 Push tool
PC200, 200LC, 220, 220LC-8M0
50-100
13
SEN06142-00
100 General information on disassembly and assembly Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. S1 Push tool
S2 Push tool
50-100
14
PC200, 200LC, 220, 220LC-8M0
100 General information on disassembly and assembly Sketches of special tools
SEN06142-00
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. S3 Push tool
S4 Push tool
PC200, 200LC, 220, 220LC-8M0
50-100
15
SEN06142-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06142-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-100
16
SEN06143-00
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
200 Engine and cooling system Removal and installation of fuel supply pump assembly ................................................................................ 2 Removal and installation of fuel injector assembly ......................................................................................... 6 Removal and installation of engine front oil seal........................................................................................... 13 Removal and installation of engine rear oil seal ........................................................................................... 18 Removal and installation of cylinder head assembly .................................................................................... 21 Removal and installation of radiator assembly ............................................................................................. 36 Removal and installation of hydraulic oil cooler assembly ............................................................................ 38 Removal and installation of aftercooler assembly......................................................................................... 40 Removal and installation of fuel cooler assembly ......................................................................................... 43 Removal and installation of engine and hydraulic pump assembly .............................................................. 44
PC200, 200LC, 220, 220LC-8M0
50-200
1
200 Engine and cooling system Removal and installation of fuel supply pump assembly
SEN06143-00
Removal and installation of fuel supply pump assembly
7.
Disconnect fuel return hose (4).
[*1]
8.
Remove fuel filter and bracket assembly (5).
9.
Disconnect connector CP3 (6).
1
A 12 795-799-6130
Part name Support
Q’ty
Part number
Necessity
Symbol
Special tools
t
1
Removal k
k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
1.
Turn the upper structure by 90°.
2.
Remove the cover under the fuel tank (B section).
3.
Close the fuel stop valve.
4.
Remove cover (1).
10. Disconnect fuel supply hose (7).
5.
Open the engine hood.
6.
Disconnect fuel filter hoses (2) and (3) from fuel supply pump (16). [*1] a Remove dirt on the connector in advance. (Because dirt sometimes makes lock (L) fit tight.) a Pull out the hose while pushing lock (L) from both sides. a When disconnecting the hose, fuel will flow out. Plug the fitting of the hose to prevent fuel from flowing out. (Place an oil container below.)
50-200
2
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of fuel supply pump assembly
11. Remove bellows (8).
[*2]
12. Disconnect high-pressure pipe (9).
[*2]
13. Disconnect 2 tube clamps (10).
[*2]
14. Disconnect fuel return tube (11).
[*3]
15. Remove bellows (15).
[*2]
16. Disconnect tube (9).
[*2]
SEN06143-00
17. Remove 3 nuts (A parts) and remove fuel injection pump assembly (16). [*4]
a
PC200, 200LC, 220, 220LC-8M0
Fuel injection pump assembly (16) comes off in one piece with the gear. No treatment (tooth extraction etc.) has been given to the gear teeth for aligning the 1st and 6th cylinder tops.
18. When disassembling the fuel pump drive gear from the fuel supply pump, follow the procedure described below. [*5] 1) Use a support A12 and a 1/2 inch spinner handle [1] to retain the gear, then loosen the nut (18). a Do not remove the nut (18) from the shaft.
50-200
3
SEN06143-00
2) 3) 4) 5)
Install a puller [2] between the flange and gear (19). Install a puller [3] onto the puller [2] and the shaft. Rotate the center bolt [4] until the gear is separated from the shaft. Remove the pullers [2], [3].
200 Engine and cooling system Removal and installation of fuel supply pump assembly
Installation q
a Figure: Refer to Removal. [*1] a The internal parts of the hose adapter may be damaged when the hose is removed. Accordingly, do not reuse the adapter but use new one when installing the hose again, as a rule. [*2] q How to install high-pressure pipe (9) 1. Tighten the sleeve nuts by hand. (both sides) 2. Tighten the sleeve nuts in the order of firstly the pump side, then the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3. Install 2 tube clamps (10). 3 Clamp mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4. Install bellows (8) and (15). a Set the slits of each bellows out and down. a The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. [*3]
6)
50-200
Remove the nut (18), lock washer (20), and gear (19) from the shaft (21).
4
Installation is done in the reverse order of removal.
3
Fuel return tube (11) mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
[*4] a If too much grease is applied to O-ring (17), it will ooze out. Accordingly, do not apply grease so much. (Apply grease to the O-ring groove area of part A.) a When installing new fuel supply pump mounting stud bolts (SB) to replace the existing ones, apply LOCTITE to them. 3 Fuel supply pump mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of fuel supply pump assembly
SEN06143-00
[*5] q
a 1.
How to install the gear (19) The shaft (21) and gear (19) mating face must be clean (without dirt or foreign material) and dry prior to assembly. Install the gear (19) onto the shaft (21).
2.
Install the lock washer (20) and nut (18) and finger tighten.
3.
Use the support A12 and 1/2 inch spinner handle [1] to hold the gear in place while tightening the nut (18). 3 Mounting nut of fuel supply pump gear: 105 ± 5 Nm {10.7 ± 0.51 kgm}
q
Air bleeding Bleed air from the fuel injection system. Refer to the "Testing and adjusting" chapter.
a
PC200, 200LC, 220, 220LC-8M0
50-200
5
200 Engine and cooling system Removal and installation of fuel injector assembly
SEN06143-00
a
Removal and installation of fuel injector assembly
1
When removing head cover (9), take care not to hit it against the peripheral parts.
Q’ty
Primer
t
1
Gear
t
1
Remover
q
1
Part number
3 795-799-6700 A 4 795-799-1131 5 795-799-8150
a
Necessity
Symbol
Special tools Part name
In the case of exchanging fuel injector assembly, exchange inlet connector, too. (See Installation item 1. 6)) 3.
Remove twelve wiring harness nuts (11) from six fuel injectors (10). [*2]
4.
Remove the three connectors of engine wiring harness (12). [*3] a Pull out each connector while pressing the lock stopper. At this time, hold the gasket with the hand to prevent it from moving.
5.
Lift up and remove gasket assembly (13). a When removing the gasket, take care that foreign material does not enter the engine. a When removing head cover (9), check gasket assembly (13) visually. If gasket assembly (13) is cracked, deteriorated, or worn, replace it with a new one.
Removal k
k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
1.
Remove clamp (7) of wiring harness (10) and two bands (7a).
2.
Remove five head cover mounting bolts (8) to remove head cover (9). [*1] a After loosening head cover mounting bolts (8), remove mud and foreign material sticking around the head cover by blowing air while holding the head cover with the hand in order to prevent entry of mud and foreign material.
50-200
6
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of fuel injector assembly
6.
Remove cap (14) of high-pressure pipe (15).
7.
Disconnect six high-pressure pipes (15) from the cylinder head. [*4] a Remove the cap on the common rail side, as well, and loosen the sleeve nut. a Do not remove fuel pressure sensor (10a) for any purpose other than replacement. [*5]
8.
Remove the mounting bolts to remove rocker arms (16). a Loosen locknut (17) and loosen adjustment screw (18) two to three turns so that an excessive force is not applied to the push rod when the rocker arm is installed.
SEN06143-00
9.
Remove crossheads (19). a Record the installed position and direction (shapes of holes (a) and (b)) of each crosshead. (When reassembling, install the crosshead in the recorded direction)
10. Remove retainer (20) and remove inlet connector (21). a Remove mud and dirt sticking around the inlet connector in advance so that they do not enter the hole of the inlet connector. a Tool A5 is provided to remove inlet connector (21).
PC200, 200LC, 220, 220LC-8M0
50-200
7
SEN06143-00
11. Remove mounting bolts (23) of fuel injector assembly (22).
200 Engine and cooling system Removal and installation of fuel injector assembly
Installation 1.
Fuel injector assembly When replacing a fuel injector assembly with a new one, be sure to replace the inlet connector with a new one as well. a Check that the fuel injector sleeve is free from flaws and dirt. 1) Fit O-ring (24) and gasket (25) to fuel injector (22). 2) Apply engine oil (EO15W-40) to the O-ring of fuel injector (22) and the mounting hole on the head. 3) Install holder (26), while setting its concave part (C) to convex part (A) of fuel injector (22).
12. By using tool A2, remove fuel injector assembly (22). a Do not pry up the injector top. a Take care that dirt and foreign material do not enter the fuel injector assembly mounting area.
4) 5)
Insert fuel injector (22) in the cylinder head, while directing its fuel inlet hole toward the air intake manifold. Tighten mounting bolts (23) of fuel injector (22) by 3 to 4 turns.
a
50-200
8
When replacing the fuel injector assembly with a new one, be sure to replace the inlet connector with a new one as well.
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of fuel injector assembly
6)
Check the inlet connector visually. If it has any of the following faults, replace it with a new one. 1] There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector. 2] There is foreign material in the edge filter at rear end (c) of the inlet connector. 3] The O-ring at upper part (d) of the inlet connector is cracked or deteriorated.
SEN06143-00
7) 8)
Apply engine oil (EO15W-40) to the mounting hole of inlet connector (21) on the head. Apply engine oil (EO15W-40) to O-ring (24) of inlet connector (21) and insert inlet connector (21) fully into the head while matching part (B) with the groove in the head.
9)
4]
There is a worn part or an uneven seat contact mark on sealing surface (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the sealing surface has fine streaks or cracks.
PC200, 200LC, 220, 220LC-8M0
Tighten inlet connector (21) lightly by using retaining nut (20). (Push into the hole of the injector) 3 Retaining nut: 15 ± 5 Nm {1.5 ± 0.5 kgm} 10) Tighten mounting bolts (23) of fuel injector (22) alternately. 3 Fuel injector mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 11) Tighten retaining nut (20). 3 Retaining nut: 50 ± 5 Nm {5.1 ± 0.5 kgm}
50-200
9
200 Engine and cooling system Removal and installation of fuel injector assembly
SEN06143-00
2.
Crosshead and rocker arm 1) Install the crosshead and rocker arm. a Since the hole shapes at parts "a" and "b" of each crosshead are different, install them to their respective intake and exhaust valves in the original directions. a Check that the spherical portion of adjustment screw (18) is fitted properly in the socket of the push rod, and then tighten the mounting bolt. 3 Rocker arm mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm} 2) Adjust the valve clearance. For details, see Testing and adjusting, "Adjusting valve clearance". 3 Lock nut (17): 20 to 28 Nm {2.04 to 2.86 kgm}
q
[*1]
3
3
Fuel injector wiring harness nut: 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm} a Check the wiring harness that does not interfere with the rocker arm.
[*3]
k
Install each high-pressure pipe and wiring harness at least 10 mm apart from each other.
[*4] q
k
a
q
q
10
Head cover mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*2]
k
50-200
Perform the subsequent installation in the reverse order to removal.
High-pressure pipe Do not bend the fuel high-pressure pipe to collect before installing. Be sure to use the Komatsu genuine highp r e s s u r e p i p e c l a m ps a n d o b s e r v e t h e specified tightening torque. Before installing the high-pressure pipe, check it for the following. If the high-pressure pipe has any defect, replace it with a new one since fuel may leak. Check that the taper seal part (part "a": area of 2 mm from end) of the joint portion is free of visible lengthwise slit "b" and dent "c". Check that part "d" (end of taper seal part: part at 2 mm from end) is free of stepped wear (fatigue) felt with a fingernail.
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of fuel injector assembly
1.
Install and fasten lightly high pressure-pipes (25) to (30) between common rail (24) and cylinder head. 3 Sleeve nut: 0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2.
Fasten high-pressure pipes (25) to (30) according to the following procedure. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 1) Cylinder head side of high-pressure pipes (25) and (30) 2) Common rail side of high-pressure pipes (30) and (25) 3) Cylinder head side of high-pressure pipes (26), (27), (28), and (29) in order 4) Common rail side of high-pressure pipes (26), (27), (28), and (29) in order
3.
Install the cap to each high-pressure pipe. a Install each cap with the slits out and down. a The cap is installed for fire prevention and is expected to prevent fuel from flying directly to highly heated portions of the engine if fuel leaks.
PC200, 200LC, 220, 220LC-8M0
SEN06143-00
[*5] q
Fuel pressure sensor and relief valve 1) Replace fuel pressure sensor (2), if necessary, according to the following procedure. a Do not remove fuel pressure sensor (2) from common rail (1) unless replacement of the sensor is necessary. a Once the fuel pressure sensor is removed from the common rail, be sure to replace it with a new one. 1] Before removing the fuel pressure sensor, clean around it to remove mud, etc. thoroughly. 2] Remove the fuel pressure sensor. 3] Check the fuel pressure sensor connector for crack, breakage, damage of the seal, foreign material on the pin, and corrosion, bend, and breakage of the pin. 4] Install a new fuel pressure sensor. 2 Threaded portion of fuel pressure sensor: Gear oil (#90) 3 Fuel pressure sensor: 70 ± 5 Nm {7.1 ± 0.5 kgm} 5] Connect the engine wiring harness. At this time, take care not to connect reversely. 6] Start the engine and check that there is no leakage. For the testing procedure, see Testing and adjusting, "Testing fuel system for leakage".
50-200
11
SEN06143-00
2)
50-200
200 Engine and cooling system Removal and installation of fuel injector assembly
Replace relief valve (3), if necessary, according to the following procedure. 1] Before removing the relief valve, remove dirt around the valve thoroughly. 2] Remove the relief valve. 3] If the leakage through the relief valve exceeds the specified value, do not reuse the relief valve. 4] Check that there is no damage on high-pressure sealing surfaces (A) on the relief valve and common rail. 5] Install the relief valve. 2 Threaded portion of relief valve: Gear oil (#90) 3 Relief valve: 100 ± 4 Nm {10.2 ± 0.4 kgm} Take care not to tighten excessively. Excessive tightening can cause leakage. 6] Start the engine and check that there is no leakage. For the testing procedure, see Testing and adjusting, "Checking fuel system for leakage".
12
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine front oil seal
SEN06143-00 a
Removal and installation of engine front oil seal
1
Hydraulic oil cooler hoses (5a) and (5b) have already been removed at 2. above
Q’ty
A
Necessity
Symbol
Special tools
1 795-799-6400
Seal puller
t
1
6 790-331-1120
Wrench (Angle)
q
1
Part number
Part name
Removal 1.
Remove the radiator assembly referring to the section of "Removal and installation of radiator assembly".
2.
Remove the hydraulic oil cooler assembly referring to the section of "Removal and installation of hydraulic oil cooler assembly".
3.
Remove the aftercooler assembly referring to the section of "Removal and installation of aftercooler assembly".
4.
Remove mounting bolts for air conditioner condenser (1) and put aside air conditioner condenser (1).
5.
Remove bracket (2).
6.
Remove cover (3).
7.
Remove nets (4) and (5).
PC200, 200LC, 220, 220LC-8M0
8.
Remove fan guards (6), (6a) and (7).
50-200
13
200 Engine and cooling system Removal and installation of engine front oil seal
SEN06143-00
9.
Remove fan (8).
[*1]
14. Remove 6 mounting bolts and remove vibration damper (13).
10. Loosen air conditioner compressor bracket adjustment bolts (9). a There is another bolt behind. 11. Move air conditioner compressor assembly (10). 12. Remove air conditioner compressor drive belt (11). [*2]
15. Remove dust seal (17).
13. Remove fan belt (12) as follows. [*3] q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (16), and rotate it to the opposite to the winding-up direction (R) to decrease the fan belt (12) tension, then remove. k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (16) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing the fan belt (12), return the tensioner assembly (16) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (12) during work.
50-200
14
16. Remove oil seal (14).
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine front oil seal
17. Remove engine front oil seal (14) according to the following procedure. 1) Install tool A1 to crankshaft. 2) Screw in tapping screw [1] of tool A1 to seal carrier part of engine front oil seal (14). 3) Rotate the handle clockwise to remove engine front oil seal (14).
a
Take care not to damage the crankshaft while removing the seal.
PC200, 200LC, 220, 220LC-8M0
SEN06143-00
Installation 1.
Install front oil seal (14) using tool A1. a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. a When installing the seal, do not apply oil, grease, etc. to the shaft and seal lip. Also, wipe off grease from the shaft completely.
a
From cover (C) of oil seal (14) q Extrusion (x): less than 0.38 mm q Facial runout (y): less than 0.25 mm
50-200
15
SEN06143-00
2.
Install dust seal (17). a Check the installed dimension (L). Installed dimension (L): 12 ± +0.1/0 mm
200 Engine and cooling system Removal and installation of engine front oil seal
a 5]
6]
3.
When angle tightening tool A6 is not used After above steps 1] to 3] are finished, put a paint mark across vibration damper (13) and mounting bolts. Retighten the bolts by 90 ± 5 degrees.
Vibration damper 1) Match dowel pin (a) to dowel pin hole, and install vibration damper (13). 2) Tighten mounting bolts (15) according to the following procedure. 1] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2] Loosen bolts by 180 degrees. 3] Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4] Using tool A6 and retighten the bolts by 90 ± 5 degrees.
50-200
16
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine front oil seal
q
SEN06143-00
Carry out the rest of installation in the reverse order to removal.
[*1]
3
Fan mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}
[*2] a Refer to the "Checking and adjusting air conditioner compressor belt tension" section in the Testing and adjusting chapter in this manual. [*3] a Install fan belt (12) as follows. q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (16), and rotate it to the opposite to the winding-up direction (R) to install the fan belt (12). k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (16) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After installing the fan belt (12), return the tensioner assembly (16) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (12) during work.
PC200, 200LC, 220, 220LC-8M0
50-200
17
200 Engine and cooling system Removal and installation of engine rear oil seal
SEN06143-00
Removal and installation of engine rear oil seal
6.
Lift off flywheel assembly (4) to remove it. [*2] 4
1
Flywheel assembly: 35 kg
2 795-799-6500
Part name Seal puller
Q’ty
A
Part number
Necessity
Symbol
Special tools
t
1
Removal 1.
Remove the hydraulic pump assembly referring to the section of "Removal and installation of hydraulic pump assembly".
2.
Remove mounting bolt (1) and set guide bolt [1].
3.
Remove damper assembly (2).
4.
Remove mounting bolt (3) and insert guide bolts [2]. [*1] a Width across flats: 18 mm
5.
Lift temporarily flywheel assembly (4) and pull out flywheel assembly (4). a Be careful not to let the guide bolts drop out.
50-200
18
7.
Remove oil seal (5) as follows. 1) Set tool A2 to crankshaft. 2) Install tapping screw [1] of the tool A2 to seal carrier of rear oil seal. a Remove rear oil seal (5) not to break the crankshaft.
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine rear oil seal
Installation 1.
Install the oil seal according to the following procedure. a Do not remove pilot [5] which is attached to oil seal (5) until oil seal (5) is inserted to the crankshaft. a Before installing the oil seal, degrease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leakage.
2.
Insert pilot [5] to crankshaft (6) and push oil seal (5) into flywheel housing (7).
3.
Push in oil seal (5) further and pull out pilot [5].
PC200, 200LC, 220, 220LC-8M0
SEN06143-00
4.
Install oil seal (5) on flywheel housing (7) to the proper depth by using tool A2. a Push in oil seal (5) taking care that there are no bend etc. on it. a Extrusion of oil seal (5) from flywheel housing (7) (X): less than 0.38 mm
50-200
19
200 Engine and cooling system Removal and installation of engine rear oil seal
SEN06143-00
q
Carry out the rest of installation in the reverse order to removal.
[*1] a Tighten the 8 flywheel mounting bolts in the order of (1) through (8) as shown in the figure below. 3 Flywheel assembly mounting bolt: 137 ± 7 Nm {13.97 ± 0.71 kgm}
a
q
Measurement of facial runout a Facial runout: less than 0.20 mm 1) As in the case of measurement of facial runout, bring the dial gauge probe into contact with end surface (b) near the outer perimeter of the flywheel at a right angle. a Conduct measurement pulling the crankshaft to either the front or rear side to prevent errors caused by shakiness. 2) Rotate the flywheel 360° and measure the difference of the maximum swing of the dial gauge indicator.
Tighten the bolts using plate [3] for preventing rotation of the flywheel assembly.
[*2] q
Measurement of radial runout a Radial runout: less than 0.13 mm 1) Set dial gauge [4] to the stand, and set it to flywheel housing (7). 2) Bring the dial gauge probe into contact with faucet joint portion (a) or the outer perimeter surface of the flywheel at a right angle. 3) Rotate the flywheel 360° and measure the difference of the maximum swing of the dial gauge indicator. a Check that the dial gauge indicator is back in the original position after the flywheel is rotated 360°.
50-200
20
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of cylinder head assembly
Removal and installation of cylinder head assembly
SEN06143-00
4.
Disconnect fuel filter hoses (2) and (3) from fuel supply pump (FSP). [*1] a Remove dirt on the connector in advance. (Because dirt sometimes makes lock (L) fit tight.) a Pull out the hose while pushing lock (L) from both sides.
5.
Disconnect fuel return hoses (4) and (4a). [*1]
6.
Remove fuel filter and bracket assembly (5).
1
Q’ty
A
Necessity
Symbol
Special tools
3 795-799-6700
Primer
t
1
4 795-799-1131
Gear
t
1
5 795-799-8150
Remover
q
1
6 790-331-1120
Wrench (Angle)
q
1
7 795-790-4510
Gauge
q
1
Part number
Part name
Removal k
k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
1.
Remove cover (1).
2.
Drain the engine coolant. 6
3.
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
Remove the following referring to the section of "Removal and installation of engine and hydraulic pump assembly", steps 5 to 20 in "Removal". q Engine hood q Top cover on control valve q Cover between hydraulic pump and engine q Frame between control valve and engine q Cover between control valve and engine a The frame between the control valve and the engine should be kept installed as a foothold.
PC200, 200LC, 220, 220LC-8M0
50-200
21
SEN06143-00
7.
Remove cover (6).
8.
Remove clamp (7).
9.
Remove the mounting bolt and lift off muffler assembly (8) to remove it. [*2] 4
200 Engine and cooling system Removal and installation of cylinder head assembly
Muffler assembly: 19 kg
14. Disconnect ambient pressure sensor (14) and boost pressure sensor connector (15).
10. Remove hose (10). [*3] a MIKALOR clamp a Mark the hose edge and tube to show the original hose installation positions. (See figure below.) a If disconnecting air intake connector (C), replace the gasket. 11. Disconnect radiator hoses (11). [*4] 12. Disconnect heater hose (12).
a
13. Remove fan guard (13). a
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22
When disconnecting ambient pressure sensor connector (14), move the lock to right (R) and pull out the connector while pressing stopper (T). Move wiring harness to the left.
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200 Engine and cooling system Removal and installation of cylinder head assembly
15. Disconnect coolant temperature sensor connector (17).
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22. Remove clamp (25a) from the cylinder block and disconnect high-pressure pipe (25b). [*11] a FSP: Fuel supply pump a Remove the bellows from the sleeve nut portions.
16. Disconnect fuel pressure sensor connector (18). 17. Remove fuel return hose (19) from common rail (20) and cylinder head rear surface. [*5] 18. Remove the two clamps of high-pressure pipe (21) between the common rail and fuel supply pump. [*6]
23. Remove protection cover (26). 24. Loosen air tube clamp (27).
[*12]
25. Loosen hose clamp (28).
[*13]
19. Remove cap (22) and remove high-pressure pipe (21). [*7] 20. Remove caps (23) and remove six high-pressure pipes (24). [*8] 21. Remove common rail (20). [*9] a Do not remove fuel pressure sensor and relief valve (25) for any purpose other than replacement. [*10]
PC200, 200LC, 220, 220LC-8M0
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23
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26. Disconnect lubrication inlet tube (29) and lubrication outlet tube (30). [*14] a When loosening the lubrication inlet hose mounting nut, fix the connector with a spanner to prevent it from being dragged.
200 Engine and cooling system Removal and installation of cylinder head assembly
30. Remove fan (32). a Keep the fan dropped down.
[*17]
27. Remove all the mounting bolts for exhaust manifold (31) except a few pieces. [*15]
31. Loosen air conditioner compressor bracket mounting bolts (33) and (34). 32. Remove air conditioner compressor drive belt (35). [*18] 28. Lift temporarily exhaust manifold and turbocharger assembly (80), and remove the remaining mounting bolts. [*16] 29. Lift off exhaust manifold and turbocharger assembly (80) to remove it. 4
50-200
Exhaust manifold and turbocharger assembly: 25 kg
24
33. Disconnect connector AC02 (36). 34. Remove air conditioner compressor assembly (37). a Remove air conditioner compressor assembly in one piece with the bracket and put them on the counterweight.
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of cylinder head assembly
35. Remove fan belt (38) from alternator (39) as follows. [*19] q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (38a), and rotate it to the opposite to the winding-up direction (R) to decrease the fan belt (38) tension, then remove. k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly (38a) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing the fan belt (38), return the tensioner assembly (38a) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (38) during work.
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39. Remove five head cover mounting bolts (45) to remove head cover (46) together with blowby duct (47). a After loosening head cover mounting bolts (45), remove mud and foreign material sticking around the head cover by blowing air while holding the head cover with the hand in order to prevent entry of mud and foreign material. a When removing head cover (46), take care not to hit it against the peripheral parts. 40. Remove blowby duct (47) from head cover (46). Remove fuel return tube (46a). 41. Remove fuel return tube (46a).
36. Disconnect connectors AB (40) and E12 (41). 37. Remove alternator (39).
42. Remove twelve wiring harness nuts (49) from six fuel injectors (48). 43. Remove the three connectors of engine wiring harness (50). [*20] a Pull out each connector while pressing the lock stopper. At this time, hold the gasket with the hand to prevent it from moving.
38. Remove clamp (43) and two bands (44) of wiring harness (42).
PC200, 200LC, 220, 220LC-8M0
44. Lift up and remove gasket assembly (51). a When removing the gasket, take care that foreign material does not enter the engine. a When removing head cover (46), check gasket assembly (51) visually. If gasket assembly (51) is cracked, deteriorated, or worn, replace it with a new one.
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25
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45. Remove the mounting bolts to remove rocker arms (52). a Loosen locknut (53) and loosen adjustment screw (54) two to three turns so that an excessive force is not applied to the push rod when the rocker arm is installed.
46. Remove crossheads (55). a Record the installed position and direction (shapes of holes (a) and (b)) of each crosshead. (When reassembling, install the crosshead in the recorded direction)
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26
200 Engine and cooling system Removal and installation of cylinder head assembly
47. Remove retaining nut (56) and remove inlet connector (57). a Remove mud and dirt sticking around the inlet connector in advance so that they do not enter the hole of the inlet connector. a Tool A5 is provided to remove inlet connector.
48. Remove mounting bolts (59) of fuel injector assembly (58).
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200 Engine and cooling system Removal and installation of cylinder head assembly
49. By using tool A3, remove fuel injector assembly (60). a Do not pry up the injector top. a Take care that dirt and foreign material do not enter the fuel injector assembly mounting area.
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Installation 1.
Cylinder head assembly 1) Measure stem length "a" of mounting bolt for every cylinder head and check that it is less than the using limit. q Using limit length of bolt: Below 132.1 mm a If a bolt is longer than the using limit, do not reuse it but replace it.
50. Remove push rod (61).
2)
3)
51. Remove mounting bolts (62), and then sling and remove cylinder head assembly (63). 3 Cylinder head assembly: 75 kg
Set cylinder head gasket (64) on the cylinder block. a Check that the cylinder head mounting face and inside of the cylinder are free of dirt and foreign material. a Check that the cylinder head gasket is matched with the holes on the cylinder head. Sling cylinder head assembly (63) and set it on the cylinder block, and then fingertighten mounting bolts (62) at least two to three turns.
52. Remove cylinder head gasket (64).
PC200, 200LC, 220, 220LC-8M0
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27
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4)
Tighten the cylinder head mounting bolts in the order from [1] to [26] according to the following procedure. 2 Apply engine oil (EO15W-40) to the threaded portion and seat surface of each cylinder head mounting bolt. 1] Tighten bolt to 90 ± 3 Nm {9.2 ± 0.3 kgm}. 2] Confirm that the bolt is tightened to the torque of 90 ± 3 Nm {9.2 ± 0.3 kgm}. 3] Using tool A6 and retighten the bolts by 90 ± 5 degrees.
a 4] 5]
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28
When angle tightening tool A6 is not used After above steps 1] to 2] are finished, put a paint mark across cylinder head and mounting bolts. Retighten the bolts by 90 ± 5 degrees.
200 Engine and cooling system Removal and installation of cylinder head assembly
2.
Install push rods (61).
3.
Fuel injector assembly a When replacing the fuel injector assembly with a new one, be sure to replace the inlet connector with a new one as well. a Check that the fuel injector sleeve is free of flaw and dirt. 1) Fit O-ring (58a) and gasket (58b) to fuel injector (58). 2) Apply engine oil (EO15W-40) to the O-ring of fuel injector (58) and the mounting hole on the head. 3) Install holder (58c), while setting its concave part (C) to convex part (A) of fuel injector (58).
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200 Engine and cooling system Removal and installation of cylinder head assembly
4) 5)
6)
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Insert fuel injector (58) in the cylinder head, while directing its fuel inlet hole toward the air intake manifold. Tighten mounting bolts (59) of fuel injector (58) by 3 to 4 turns.
Check the inlet connector visually. If it has any of the following faults, replace it with a new one. 1] There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector. 2] There is foreign material in the edge filter at rear end (c) of the inlet connector. 3] The O-ring at upper part (d) of the inlet connector is cracked or deteriorated.
PC200, 200LC, 220, 220LC-8M0
4]
7) 8)
There is a worn part or an uneven seat contact mark on sealing surface (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the sealing surface has fine streaks or cracks.
Apply engine oil (EO15W-40) to the mounting hole of inlet connector (57) on the cylinder head. Apply engine oil (EO15W-40) to O-ring (57a) of inlet connector (58) and insert inlet connector (57) fully into the head while matching part (B) with the groove in the head.
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29
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200 Engine and cooling system Removal and installation of cylinder head assembly
9)
Tighten inlet connector (57) lightly by using retaining nut (56). (Push into the hole of the injector) 3 Retaining nut: 15 ± 5 Nm {1.5 ± 0.5 kgm} 10) Tighten mounting bolts (57) of fuel injector (58) alternately. 3 Fuel injector mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 11) Tighten retaining nut (60). 3 Retaining nut: 50 ± 5 Nm {5.1 ± 0.5 kgm}
4.
Crosshead and rocker arm 1) Install the crosshead and rocker arm. a Since the hole shapes at parts "a" and "b" of each crosshead are different, install them to their respective intake and exhaust valves in the original directions. a Check that the spherical portion of adjustment screw (54) is fitted properly in the socket of the push rod and then tighten the mounting bolt. 3 Rocker arm mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm} 2) Adjust the valve clearance. For details, see Testing and adjusting, "Adjusting valve clearance". 3 Locknut (53): 20 to 28 Nm {2.04 to 2.86 kgm}
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30
5.
Install harnesses and nuts (49). a Check the wiring harness that does not interfere with the rocker arm. 3 Mounting nut (49): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
6.
Install gasket assembly (51).
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200 Engine and cooling system Removal and installation of cylinder head assembly
7.
Install head cover (46). 3 Mounting bolt (45): 24 ± 4 Nm {2.4 ± 0.4 kgm}
8.
Install blow-by duct (47). 3 Blow-by duct mounting bolt: 7 ± 2 Nm {0.71 ± 0.2 kgm}
9.
Install fuel drain hose (46a). 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
PC200, 200LC, 220, 220LC-8M0
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q
Carry out the following installation in the reverse order to removal.
[*1] a The internal parts of the hose adapter may be damaged when the hose is removed. Accordingly, do not reuse the adapter but use new one when installing the hose again, as a rule. [*2] Install muffler assembly (8) according to the following procedure. 1. Sling muffler assembly (8), and set it to the mounting position. 3 Whole circumference of (e) of exhaust pipe (8a): Heat-hardening sealant (FIREGUM manufactured by Holts or equivalent) 2. Install muffler assembly (8) and exhaust pipe (8a) loosely. 3. Install muffler assembly (8) and turbocharger assembly loosely, then check the installing position of them. 4. Install U-bolt (8c), and tighten nut (8d). 3 Nut (8d): 9.8 to 14.7 Nm (1.0 to 1.5 kgm) 5. Tighten turbocharger outlet port clamp (8e). 3 Turbocharger outlet port clamp (8e): 6.8 to 8.8 Nm {0.7 to 0.9 kgm} 6. Tighten seal clamp (8f). 3 Seal clamp (8f): 1st time: 39.2 to 49.9 Nm {4 to 5 kgm} 2nd time: 68.6 to 122.5 Nm {7.0 to 12.5 kgm} a Be sure to replace the seal clamp (8f) with the new one.
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31
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200 Engine and cooling system Removal and installation of cylinder head assembly
q
When using a new hose Tighten until dimension (BDG) is 7 – 10 mm.
[*3]
3
q
q
Air intake connector mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
MIKALOR clamp a Use a new clamp. 1) Align the hose to the original position (marking position). a Reference Depth of insertion: 60 mm (aftercooler side) 2) Set the bridge (BR) under the clamp bolt and lap it over band (BD) at least (b) reaches 5 mm. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Tighten to torque of at least 6 Nm {0.6 kgm}.
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32
[*4]
3
Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*5]
3
Fuel return hose joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*6]
k
When installing, keep the distance of more than 10 mm between the high-pressure pipe and the harness.
[*7], [*8], [*9], [*10], [*11] High-pressure pipes and common rail k Do not use high-pressure pipes with bending modification. k Be sure to use a genuine high-pressure pipe fixing clamp and observe strictly the tightening torque. a A high-pressure pipe which has depressions such as visible vertical slit scar (b), patchy scars (c) etc. on the taper seal section of its connector ((a) part: within 2 mm from the tip), or a highpressure pipe whose (d) part (end of the taper seal section: 2 mm from the tip) catches on a finger nail due to fatigue, may cause fuel leakage. In these cases, replace the high-pressure pipe.
q
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200 Engine and cooling system Removal and installation of cylinder head assembly
1)
2)
3) 4)
5)
6)
7)
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Assemble common rail (20) and highpressure pipes (71) – (76) temporarily. 3 Sleeve nut and mounting bolt: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten high-pressure pipes (71) – (76) according to the following procedure. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 1] Head side of high-pressure pipes (71) and (76) 2] Common rail side of high-pressure pipes (76) and (71) 3] Head side of high-pressure pipes (72), (73), (74) and (75) 4] Common rail side of high-pressure pipes (72), (73), (74) and (75) Tighten the sleeve nut of high-pressure pipe (25b) temporarily. Tighten high-pressure pipe (25b) in the order of firstly pump (FSP) side, then common rail (20) side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} Tighten clamp (25a) of high-pressure pipe (25b). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Tighten common rail (20) with 4 bolts. a Coat the 2 bolt threads on the inner side of the engine with sealant (LG-7). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} Install bellows (22) and (23) to each highpressure pipe. (14 pieces) a Set the slits of each bellows out and down. a The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. a FSP: Fuel supply pump
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200 Engine and cooling system Removal and installation of cylinder head assembly
Reference
2.
q
1.
Handling of fuel pressure sensor (PS) and relief valve (RV) Fuel pressure sensor (PS). a Check the fuel pressure sensor connector for crack, breakage, damage of the seal, foreign matter on the pin and corrosion, bend and breakage of the pin. a Do not remove fuel pressure sensor (PS) from common rail (CR) for a purpose other than replacement. a Once the fuel pressure sensor (PS) is removed from the common rail (CR), be sure to replace it. q Fuel pressure sensor (PS), if necessary, according to the following procedure. 1) 2) 3)
Before removing the fuel pressure sensor, remove mud etc. from around it thoroughly and clean it. Remove the fuel pressure sensor (PS). Install a new fuel pressure sensor. 2 Threaded part of fuel pressure sensor: Gear oil (#90) 3 Fuel pressure sensor: 70 ± 5 Nm {7.1 ± 0.5 kgm}
Relief valve (RV) a If the leakage from the relief valve (RV) exceeds the specified value, do not reuse it. q Replace relief valve (RV), if necessary, according to the following procedure. 1) Before removing the fuel pressure sensor, remove mud etc. from around it thoroughly and clean it. 2) Remove relief valve (RV). 3) Check that high-pressure seal surfaces (A) of the relief valve (RV) and rail (CR) are free from damage. 4) Install a new relief valve (RV). 2 Threaded section: Gear oil (#90) 3 Relief valve: 100 ± 4 Nm {10.2 ± 0.4 kgm} a Excessive tightening can cause leakage. Take care not to tighten too strongly.
5)
4) 5)
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34
Connect the engine wiring harness. At this time, take care not to connect the wiring harness in reverse. Start the engine and check that fuel does not leak. a For the testing procedure, see Testing and adjusting, "Measuring fuel return rate and leakage".
Start the engine and check that fuel does not leak. a For the testing procedure, see Testing and adjusting, "Measuring fuel return rate and leakage".
[*12]
3
Air tube clamp: 10.0 – 11.0 Nm {1.02 – 1.12 kgm}
[*13] MIKALOR clamp a Reference Length of insertion: 40 mm (turbocharger side) a Refer to [*4].
q
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200 Engine and cooling system Removal and installation of cylinder head assembly
SEN06143-00
[*14]
3
Lubrication inlet hose tightening sleeve nut: 35 ± 5 Nm {3.5 ± 0.5 kgm} a When tightening the hose mounting nut, secure the connector with a spanner since the connector tightening torque is small. 3 Connector on turbocharger side (if loosened): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} 3 Lubrication outlet hose mounting bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm}
k
k
(38a) is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) After installing the fan belt (38), return the tensioner assembly (38a) slowly with care. Be careful not to get your fingers caught between the pulley and fan belt (38) during work.
[*15], [*16] a Tighten the bolts in the order shown below. 3 Exhaust manifold mounting bolt: First time: in the order of [1] – [12] Tighten to a torque of 24 ± 4 Nm {2.4 ± 0.4 kgm}. Second time: in the order of [1] – [12] Tighten to a torque of 53 ± 6 Nm {5.4 ± 0.6 kgm}. Third time: in the order of [1] – [4] Tighten to a torque of 53 ± 6 Nm {5.4 ± 0.6 kgm}. [*20] k Install each high-pressure pipe and wiring harness at least 10 mm apart from each other. q
Refilling engine coolant Refill coolant through the coolant filler port up to the specified level. Start the engine and circulate the coolant, and then check the coolant level. 5
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
[*17]
3
Fan mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}
[*18] a Refer to the "Checking and adjusting of air conditioner compressor belt tension" section in the Testing and adjusting chapter of this manual. [*19] a Install fan belt (38) as follows. q Insert a wrench to the portion (A) (width across flats T 12.7 mm) of the tensioner assembly (38a), and rotate it to the opposite to the winding-up direction (R), then install fan belt (38). k Make sure that the wrench is secured at the portion (A) before rotating it. (The spring of the tensioner assembly
PC200, 200LC, 220, 220LC-8M0
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35
200 Engine and cooling system Removal and installation of radiator assembly
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Removal and installation of radiator assembly
1
7.
Remove cover (5).
8.
Disconnect radiator hoses (6) and (6a). [*1] a Mark the hose edge and tube to show the original hose installation positions. (See figure below.)
9.
Disconnect radiator hose (7). [*2] a Mark the hose edge and tube to show the original hose installation positions. (Refer to the above figure.)
Removal k
k k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery. If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant temperature drops before starting the work.
1.
Turn the upper structure by 90°.
2.
Remove cover (1).
3.
Drain the engine coolant. 6
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
4.
Open up the engine hood.
5.
Disconnect reservoir tank hose (2).
6.
Remove cover (3).
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36
10. Move cover (8). a In order to avoid the contact with the flange.
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200 Engine and cooling system Removal and installation of radiator assembly
11. Remove the mounting bolts (10) and lift out radiator assembly (9). [*3] 4
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Installation q
Radiator assembly: 15 kg
Installation is done in the reverse order of removal.
[*1], [*2] a Align the hose to the original position (marking position). a Align the clamp to the original position. a Reference Inserted air hose length q 45 mm (Radiator side) q 40 mm (Engine side) 3 Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*3] a Confirm that the heat insulating seal material (sponge) of the radiator peripheral part is not damaged. If the heat insulating seal material (sponge) is damaged, replace it to the new one. Confirm from the under cover side that convexity (A) of the radiator is correctly set to concavity (B).
q
Refilling engine coolant Refill coolant through the coolant filler port up to the specified level. Start the engine and circulate the coolant, and then check the coolant level. 5
PC200, 200LC, 220, 220LC-8M0
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
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37
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Removal and installation of hydraulic oil cooler assembly
200 Engine and cooling system Removal and installation of hydraulic oil cooler assembly
1
6.
Open the left side cover.
7.
Disconnect control valve drain hose (4). a Stop oil flow.
8.
Disconnect reservoir tank hose (5).
9.
Remove cover (6).
Removal k
k
Lower the work equipment to the ground completely, after the engine is stopped, loosen the hydraulic tank cap gradually to reduce the pressure inside, and set the lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery.
1.
Turn the upper structure by 90°.
2.
Remove cover (1).
3.
Open up the engine hood.
4.
Remove hydraulic oil cooler drain plug (2) to drain the hydraulic oil. a Loosen upper side (return) hose (7) of the hydraulic tank and induce air into the tank. 6
5.
Hydraulic oil cooler: 7 l
Move cover (3).
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38
10. Disconnect hydraulic tank return hose (7). a Stop oil flow. 11. Remove hydraulic oil cooler mounting bolt (8).
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200 Engine and cooling system Removal and installation of hydraulic oil cooler assembly
12. Move cover (9).
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Installation q
Installation is done in the reverse order of removal.
[*1] a Confirm that the heat insulating seal material (sponge) of the radiator peripheral part is not damaged. If the heat insulating seal material (sponge) is damaged, replace it to the new one. Confirm from the under cover side that convexity (A) of the radiator is correctly set to concavity (B). 13. Lift out hydraulic oil cooler assembly (10) by using eyebolt (M10) [1]. [*1] 4
Hydraulic oil cooler assembly: 25 kg
q
PC200, 200LC, 220, 220LC-8M0
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
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39
200 Engine and cooling system Removal and installation of aftercooler assembly
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Removal and installation of aftercooler assembly
6.
Remove hose (4). [*1] a MIKALOR clamp a Mark the hose edge and tube to show the original hose installation positions. (See figure below.) a Inserted air hose length: 80 mm
7.
Remove cover (5).
1
Removal k
k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
1.
Turn the upper structure by 90°.
2.
Remove cover (1).
3.
Open up the engine hood.
4.
Disconnect reservoir tank hose (2).
5.
Remove cover (3).
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40
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of aftercooler assembly
8.
Disconnect tube (6) from the lower side.
[*2]
9.
Move cover (7). a In order to avoid the contact with the flange.
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Installation q
Installation is done in the reverse order of removal.
[*1] 1. Install hose and tube assembly (4). a Use a new MIKALOR clamp. 1) Align the hose to the original position (marking position). a Inserted air hose length q Aftercooler side: 60 mm q Engine side: 80 mm
10. Remove the mounting bolt and lift out aftercooler assembly (8). [*3] 4
Aftercooler assembly: 15 kg
2)
Set the bridge (BR) under the clamp bolt and lap it over band (BD) at least (b) reaches 5 mm. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B)
PC200, 200LC, 220, 220LC-8M0
q
When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Tighten to torque of at least 6 Nm {0.6 kgm}.
q
When using a new hose Tighten until dimension (BDG) is 7 – 10 mm.
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41
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200 Engine and cooling system Removal and installation of aftercooler assembly
[*2] a Replace the O-ring to the new one. [*3] a Confirm that the heat insulating seal material (sponge) of the radiator peripheral part is not damaged. If the heat insulating seal material (sponge) is damaged, replace it to the new one. Confirm from the under cover side that convexity (A) of the radiator is correctly set to concavity (B).
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42
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200 Engine and cooling system Removal and installation of fuel cooler assembly
Removal and installation of fuel cooler assembly
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Installation 1
q
Installation is done in the reverse order of removal.
Removal k
a 1.
2.
Disconnect the cable from the negative (–) terminal of the battery. If the fuel is too much, drain the fuel in order to stop the fuel flow from the fuel tank return hose. Disconnect fuel hoses (1) and (2) with the precaution described below. a Be sure to disconnect the hoses in avoiding the input force to the cooler body by fixing elbow (L) with wrench (1). a Be sure to use wrench [1], otherwise the force is loaded to the cooler body and the weld portion (M) may be separated. Remove fuel cooler assembly (3).
PC200, 200LC, 220, 220LC-8M0
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43
200 Engine and cooling system Removal and installation of engine and hydraulic pump as-
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Removal and installation of engine and hydraulic pump assembly
3.
Remove cover (1).
4.
Drain the engine coolant.
A
Part number
Part name
Necessity Q’ty
Symbol
Special tools
8 796T-401-1110
Plate
q 1
9 795-790-9300
Lifting tool
q 1
10 796-460-1210
Oil stopper
q 1
11 796-770-1320
Adaptor
q 1 6
Removal k
k k
a
After lowering the work equipment to the g ro u n d c om p l e t e l y a n d s t o p p i n g t he engine, release the internal pressure of the hydraulic tank by gradually loosening the cap of the hydraulic tank. Disconnect the cable from the negative (–) terminal of the battery. If you drain the coolant when it is still hot, you may be scalded. Wait until the coolant temperature drops before starting the work. Attach an identification tag to each piping to avoid a mistake in the position of installation later.
1.
Turn the upper structure by 90°.
2.
Remove hydraulic tank strainer and stop oil flow-out using tool A10, A11. a If tool A10, A11 are not used, remove the drain plug and drain oil from the hydraulic tank and piping. 6
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5. 6. 7.
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
Temporarily sling engine hood (2). a When slinging the engine hood, take care not to damage the rubber seal. Remove pins (3) and (4), then remove 2 gas springs (5). Lift off engine hood (2) to remove it. 4
Engine hood: 50 kg
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0)
44
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200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly
8.
Disconnect pre-cleaner (6), pre-cleaner base pipe (7). (If equipped)
9.
Remove covers (8) and (9).
a
SEN06143-00
The hatched area is made of rubber (lower side).
10. Disconnect hose (10a). 11. Remove cover (10). 12. Remove frame (11). 13. Remove cover (12). 14. Remove frame (13). 15. Remove covers (14) and (15). a Cover (15) cannot be removed unless removing cover (9).
16. Remove mounting bolt (16). 17. Remove mounting bolt (17). 18. Remove covers (18) and (19). 19. Remove frame (20). 20. Remove cover (21). 21. Remove frame (22) between the control valve and the engine. a Cover (24) can be removed after removing frame (22). 22. Remove mounting bolt (23) and remove cover (24) upwards. a As cover (24) is just stuck, there is no need to remove the lower bolt.
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SEN06143-00 a
200 Engine and cooling system Removal and installation of engine and hydraulic pump as-
Install frame (22). (For scaffold)
23. Remove fuel filter and bracket assembly (25). a Put it on the engine.
27. Remove fan guard (29).
28. Disconnect air cleaner tube (30).
[*4]
29. Remove aftercooler hose and tube assembly (31). a MIKALOR clamp [*5] a Mark the hose edge and tube to show the original hose installation positions. (See figure below.)
24. Remove hose (26). a MIKALOR clamp [*2] a Mark the hose edge and tube to show the original hose installation positions. (See figure below.) a If disconnecting air intake connector (C), replace the gasket. 25. Disconnect radiator hose (27). [*3] a Mark the hose edge and tube to show the original hose installation positions. 26. Disconnect heater hose (28).
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46
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200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly
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30. Disconnect fuel filter hose (32) from fuel supply pump (FSP). [*6] a The fuel filter hose can be disconnected by pushing locks (L) at both sides. 31. Disconnect fuel supply hose (33). 32. Disconnect fuel return hose (34). a Disconnect the clamp.
33. Remove fan (35).
[*7]
34. Loosen air conditioner compressor bracket adjusting bolt (36). a There is another bolt behind.
40. Disconnect connectors CE02 (41) and (42) from the engine controller. a The connector is locked with the inside hex head bolt L6 (4 mm). a Connector (42) is attached at the engine side, however it needs to be removed not to be obstructive in removing the engine mounting bolts. 41. Disconnect connector (43) from the engine controller by pushing the lock. 42. Disconnect connector E06 (44).
35. Shift air conditioner compressor assembly (37). [*8] 36. Remove fan belt (38).
37. Disconnect connector AC02 (39). 38. Remove air conditioner compressor assembly (37). a Remove air conditioner compressor assembly in one piece with the bracket and put them on the counterweight. 39. Disconnect electrical intake air heater connector E01 (40).
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200 Engine and cooling system Removal and installation of engine and hydraulic pump as-
43. Disconnect engine controller ground T12 (45). 44. Disconnect bracket (46) and remove spacer (47). 45. Disconnect clamp (48).
52. Disconnect 6 hoses. q (56): Rear load pressure input port hose (Color band: No color) q (57), (58): EPC basic pressure port hose (Color band: No color) q (59): Pump pressure input port hose (Color band: blue) q (60): Front load pressure input port hose (Color band: red) q (61): Drain port hose 53. Disconnect bracket (62). 54. Turn elbow (63) downward. a Not to be obstructive in removing the engine.
46. Disconnect terminal (49) from the starter (ST). 47. Disconnect connector E10 (50). a Connector at the starting motor side: T13 48. Disconnect connectors E08 (51) and P44 (52). 49. Disconnect clamp (53).
55. Disconnect 4 hoses and 1 tube. q (64): Branch hose q (65): Rear pump discharge port hose q (66): Front pump discharge port hose q (67): Pump suction port tube 56. Return bracket (62) to the original position. (Install it to the pump.)
50. Disconnect clamp (54). 51. Remove filter and bracket assembly (55). a Put it on hose bracket (HB).
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200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly
57. Disconnect pump wiring connectors at 4 points. q (68): V12 PC-EPC R solenoid valve (Color band: yellow) q (69): P22 hydraulic oil temperature sensor (Color band: no color) q (70): V19 LS-EPC solenoid valve (Color band: red) q (71): V11 PC-EPC F solenoid valve (Color band: white) a It is behind bracket (72).
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60. Disconnect hydraulic tank hoses (74) and (75). a Not to be obstructive in removing the engine.
58. Disconnect bracket (72).
61. Remove fan belt (76) from the alternator with wrench [1].
59. Disconnect clamp (73).
62. Disconnect connectors AB (77) and E12 (78). 63. Remove alternator (79). 64. Disconnect heater hose (80). 65. Remove 3 bolts and disconnect radiator hose and flange assembly (81). [*9]
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200 Engine and cooling system Removal and installation of engine and hydraulic pump as-
66. Disconnect engine ground (82). 67. Remove 4 engine mounting bolts (83). [*10] a The nut is not welded except at the engine ground point. Due to that reason firstly fix nut locking tool (plate) A8 with bolt (B) to restrict nut (N) from turning, then remove engine mounting bolt (83).
68. Lift out engine and hydraulic pump assembly (84). a Lift it at the 3 points, i.e. 2 points at the engine and 1 point at the hydraulic pump. Recommended lifting tool A9 (Refer to the special tool list) is proposed from Cummins. a Before removing the assembly, make sure that all the necessary wiring and piping are disconnected. 4
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50
Engine and hydraulic pump assembly: 800 kg
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly
Installation q
Installation is done in the reverse order of removal.
[*1]
3
Air cleaner band: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
[*2], [*5] a Use a new MIKALOR clamp. 1) Align the hose to the original position (marking position). a Reference Inserted air hose length q Aftercooler side: 60 mm q Engine side: 80 mm q Turbocharger side: 65 mm 2) Set the bridge (BR) under the clamp bolt and lap it over band (BD) at least (b) reaches 5 mm. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) q
q
When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Tighten to torque of at least 6 Nm {0.6 kgm}. When using a new hose Tighten until dimension (BDG) is 7 – 10 mm.
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[*3] a Align the hose to the original position (marking position). a Align the clamp to the original position. a Reference Inserted air hose length: 49 mm 3 Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*4]
3
Tube clamp: 10.0 – 11.0 Nm {1.02 – 1.12 kgm}
[*5] Refer to [*2]. [*6] a The internal parts of the hose adapter may be damaged when the hose is removed. Accordingly, do not reuse the adapter but use new one when installing the hose again, as a rule. [*7]
3
Fan mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}
[*8] a Refer to the "Checking and adjusting air compressor belt tension" section in the Testing and adjusting chapter in this manual. [*9]
3
Flange mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} a Reference Inserted radiator hose length: 40 mm 3 Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*10] a The bolt length of the engine front side is shorter than that of rear side. a The engine mounting rubber size of the engine front side is smaller than that of rear side.
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200 Engine and cooling system Removal and installation of engine and hydraulic pump as-
3
a
Engine mounting bolt (4 points): 245 – 308.9 Nm {25 – 31.5 kgm} The nut is not welded except at the engine ground point. Due to that reason firstly fix nut locking tool (plate) A8 with bolt (B) to restrict nut (N) from turning, then remove engine mounting bolt (82).
q
Refilling engine coolant Refill coolant through the coolant filler port up to the specified level. Start the engine and circulate the coolant, and then check the coolant level. 5
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. 5
3
a
Reference Engine mounting bracket (4 points) bolts (B): 122.5 – 147 Nm {12.5 – 15 kgm}
3
a
q
Coolant: 20.3 l (PC200/200LC-8M0) 19.9 l (PC220/220LC-8M0)
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0) Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
Reference Overview of the depth of the insertion of the air hoses and radiator hoses.
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52
PC200, 200LC, 220, 220LC-8M0
200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly
PC200, 200LC, 220, 220LC-8M0
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PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06143-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
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SEN06144-00
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
300 Power train Removal and installation of final drive assembly ............................................................................................ 2 Disassembly and assembly of final drive assembly........................................................................................ 4 Removal and installation of swing motor and swing machinery assembly ................................................... 22 Disassembly and assembly of swing motor and swing machinery assembly ............................................... 24 Removal and installation of swing circle assembly ....................................................................................... 34
PC200, 200LC, 220, 220LC-8M0
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1
300 Power train Removal and installation of final drive assembly
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Removal and installation of final drive assembly
1
4. 5.
Removal 1.
Remove the sprocket, referring to the section “Removal and installation of sprocket”. k
k
2.
Remove 18 mounting bolts (7) and sling final drive assembly (6) to remove it. [*1] a Be careful so that the nipple sealing surface on the hose mounting block may not be damaged. 4
Completely lower the work equipment to the ground and stop the engine. Then loosen the oil filler cap for the hydraulic tank to release the pressure inside the tank. Disconnect the cable from the negative (–) terminal of the battery.
Final drive assembly: 300 kg
Remove cover (1).
6. 7.
3.
a PC200-8M0, PC200LC-8M0 Temporarily sling the final drive assembly (6).
Disconnect the travel speed selector hose (2), the motor hoses (3) and (4), and the drain hose (5).
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2
a PC220-8M0, PC220LC-8M0 Temporarily sling the final drive assembly (8). Remove 18 mounting bolts and sling final drive assembly (8) to remove it. [*2] a Be careful so that the nipple sealing surface on the hose mounting block may not be damaged. 4
Final drive assembly: 350 kg
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300 Power train Removal and installation of final drive assembly
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Installation q
Installation is done in the reverse order of removal.
[*1]
3
Mounting bolts: 245 – 309 Nm {25 – 31.5 kgm}
[*2]
3
Mounting bolts: 265 – 309 Nm {27 – 31.5 kgm} (Average torque: 275 Nm or more {28 kgm or more})
q
Refilling with oil Fill the power train oil (TO30) via the oil filler port to the specified level. Start the engine to circulate the oil through the pipings and recheck the oil level.
q
Air bleeding Refer to the “Bleeding air from each part” in the Testing and adjusting chapter of this manual.
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3
300 Power train Disassembly and assembly of final drive assembly
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Disassembly and assembly of final drive assembly
796-427-1400
Wrench assembly
796-427-1410
• Wrench
1
796-427-1140
• Pin
3
01314-20612
• Screw
3 t 1
790-101-2510
Block
t 1
790-101-3310
Block
t 1
790-101-2610
Rod
t 2
790-101-2730
Adapter
t 2
01580-11613
Nut
t 2
790-101-2570
Plate
t 2
01643-31645
Washer
t 2
790-101-2102
Puller (30 t)
t 1
790-101-1102
Pump
t 1
3 796-427-1520
Installer
t 1
7 790-331-1110
Wrench
t 1
2
No.1 planetary carrier assembly 1) Remove No.1 planetary carrier assembly (3).
t 1
796T-427-1510 Push tool
J
4.
Necessity Q’ty
Symbol 1
Part name
Washer Remove washer (2).
1
a PC200-8M0, PC200LC-8M0 Special tools Part number
3.
2)
Disassemble No.1 planetary carrier assembly in the following procedure. 1] Drive pin (4) into shaft (5) to remove shaft (5) from No.1 planetary carrier (6). a Remove pin (4) from shaft (5) after shaft (5) is removed. 2] Remove thrust washer (7), No.1 planetary gear (8), needle bearing (9) and thrust washer (10).
Disassembly 1.
Oil drain Remove drain plug to drain the oil from final drive case. 6
2.
Final drive case: 3.8 l
Cover Remove 18 mounting bolts and sling cover (1) using eyebolts [1] to remove it. 4
a
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Cover: 20 kg When ring gear (12) is lifted together, separate the ring gear by lightly tapping it with a plastic hammer.
4
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300 Power train Disassembly and assembly of final drive assembly
5.
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No.1 sun gear shaft Remove No.1 sun gear shaft (11).
2) 6.
Ring gear Remove ring gear (12). 4
Ring gear: 40 kg
7.
Thrust washer Remove thrust washer (13).
8.
No.2 sun gear Remove No.2 sun gear (14).
9.
Thrust washer Remove thrust washer (15).
Disassemble No.2 planetary carrier assembly in the following procedure. 1] Drive pin (17) into shaft (18) to remove shaft (18) from No.2 planetary carrier (19). a Remove pin (17) from shaft (18) after shaft (18) is removed. 2] Remove thrust washer (20), No.2 planetary gear (21), needle bearing (22) and thrust washer (23).
11. Ring nut 1) Remove lock (24). 2) Use the tool J1 to remove ring nut (25).
10. No.2 planetary carrier assembly 1) Remove No.2 planetary carrier assembly (16).
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12. Hub assembly 1) Using eyebolts [2], sling hub assembly (26) and remove from travel motor. 4
Hub assembly: 80 kg
2)
Remove bearing (27).
3)
Remove bearing outer races (29) and (30) from hub (28).
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6
300 Power train Disassembly and assembly of final drive assembly
13. Remove floating seals (32) and (33) from travel motor (31). a The floating seals (32) and (33) may be both on the hub assembly (26) and the travel motor (31).
14. Use the puller [3] and push tool [4] to remove bearing (34). a Bearing may come off without using the puller.
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300 Power train Disassembly and assembly of final drive assembly
Assembly a
Clean the parts completely and inspect them for any foreign material or damage. Apply power train oil (TO30) on the sliding surfaces before assembly.
1.
Hub assembly 1) Use push tool to press fit bearing outer races (29) and (30) into hub (28).
2)
2.
Use the tool J3 to install floating seal (32). a Install floating seal with the O-ring and O-ring contact surface degreased and dried completely. a After installing the floating seal, check that the angle of the floating seal is within 1 mm. a After floating seal installation, apply a thin coat of power train oil (TO30) on the sliding surfaces.
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3.
Use the tool J3 to install floating seal (33) to travel motor (31). a Install floating seal with the O-ring and Oring contact surface degreased and dried completely. a After installing the floating seal, check that the angle of the floating seal is within 1 mm. a After floating seal installation, apply a thin coat of power train oil (TO30) on the sliding surfaces.
4.
Using eyebolts [2], set hub assembly (26) to travel motor.
5.
Install bearing (27) by tapping it lightly with the push tool.
Install bearing (34) to travel motor (31). a Warm the inner race of the bearing (34) to 50 – 70°C with heater. a Cool the bearing (34) down. Tap the bearing (34) with a drift and listen to the sound to check that it is fully seated.
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7
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6.
Ring nut 1) Install ring nut as follows. 1] Rotate the hub 2-3 times. 2] Use the tool J2 and the push tool [5] to press the inner race of the bearing (27). a Pressing force: 29.4 – 38.2 kN {3.0 – 3.9 ton} 3] Rotate the hub to the both directions at least 5 times in total with the bearing inner race pressed. 4] Release the pressing force. 5] Press the bearing again. a Pressing force: 17.7 – 21.6 kN {1.8 – 2.2 ton} 6] Rotate the hub 2 – 3 times.
7] a
300 Power train Disassembly and assembly of final drive assembly
2)
Measure the tangential force of the hub against the motor case in the rotation direction using the push scale [6]. a Tangential force: 490 N or less {50 kg or less} a The tangential force denotes the maximum force at start of the rotation.
3)
Install lock plate (24). a Install the lock plate so that the splines (A) of the lock plate and the motor are in full contact. 2 Mounting bolt thread: Adhesive (LT-2) a Do no apply the adhesive (LT-2) to the tapped portion of the nut.
Measure the size (a) under the condition described in 6] above. After measuring the size (a), remove the tool J2.
8]
(b) is the thickness of the ring nut (25) itself. 9] Calculate the value of (c) by subtract (b) from (a). 10] Using tool J1, tighten ring nut (25) until dimension (d) becomes value below. Dimension (d): c (+0.06/-0.04) mm
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8
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of final drive assembly
7.
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a
No.2 planetary carrier assembly 1) Assemble No.2 planetary carrier assembly as follows. a Replace thrust washers (20) and (23) as well as pin (17) with new ones. a There are traces of expansion on the end surface of No.2 planetary carrier side hole (e) which were originally caused when the pin was inserted. Make such the end surfaces are smooth enough before reassembly. 1] Assemble needle bearing (22) to No.2 planetary gear (21), fit top and bottom thrust washers (20) and (23) and then set the gear assembly on No.2 planetary carrier (19). 2] Align the pin holes on the shaft (18) and the carrier, and install the shaft (18) by tapping it lightly with a plastic hammer. a Install the shaft, rotating the No.2 planetary gear (21). Take care so the thrust washer is not damaged.
2)
3]
Insert pin (17). a When inserting the pin, take care so that any of the three pawls on the circumference (Portion (f)) may not touch the thin-walled portion on the No.2 planetary carrier (Portion (g)).Take note, however, that the thin-walled portion is likely to be on the opposite side of the carrier, depending on ac tual indi vid ual i tems . Pay attention so that a pin pawl will not come to the slender side of the No.2 planetary carrier any way. And when traces of the groove are present, assembly must be done avoiding such locations. a After assembling the No.2 planetary carrier assembly, check that No.2 planetary gear (21) rotates smoothly.
PC200, 200LC, 220, 220LC-8M0
8.
After the pin is inserted, stake the pin (B) on the carrier.
Install No.2 planetary carrier assembly (16). a Align the 4 gear shaft ends of the No.2 planetary carrier assembly (16) with the 4 dimples on the motor case end surface to install.
Thrust washer Install thrust washer (15).
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9.
No.2 sun gear Install No.2 sun gear (14).
10. No.1 sun gear shaft Install No.1 sun gear shaft (11). 11. Thrust washer Install thrust washer (13).
300 Power train Disassembly and assembly of final drive assembly
13. No.1 planetary carrier assembly 1) Assemble No.1 planetary carrier assembly as follows. a Replace thrust washers (7) and (10) and pin (4) with new ones. (Refer to Pin (4): 3].) a There are remains of caulking when the pin is inserted at the end face of hole (h) at the side of the No.1 planetary carrier. Remove the caulked metal from the inside diameter of the hole before starting to assemble. 1] Assemble bearings (8) and (9), fit top and bottom thrust washers (7) and (10) and then set the No.1 planetary gear assembly on carrier (6).
12. Ring gear 1) Install O-ring to the hub. 2) Install ring gear (12) to hub. 4
a a
Ring gear: 40 kg Degrease the mating surfaces of the ring gear and the hub, and do not apply liquid gasket on the mating surfaces. Align the holes in the ring gear and the hub.
2]
3]
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10
Align the pin holes on the shaft (5) and the No.1 planetary carrier, and install the shaft (5) by tapping it lightly with a plastic hammer. a Install the shaft, rotating the planetary No.1 planetary gear. Take care so the thrust washer is not damaged. Insert pin (4). a When inserting the pin, take care so that any of the three pawls on the circumference (Portion (f)) may not touch the thin-walled portion on the No.1 planetary carrier (Portion (g)).Take note, however, that the thin-walled portion is likely to be on the opposite side of the carrier, depending on actu al i ndiv idua l i tems. Pay attention so that a pin pawl will not come to the slender side of the carrier any way. And when traces of the groove are present, assembly must be done avoiding such locations.
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of final drive assembly
a
a
2)
After assembling the No.1 planetary carrier assembly, check that No.1 planetary gear (8) rotates smoothly. After the pin is inserted, stake the pins (C) on the carrier at 2 locations.
SEN06144-00
14. Washer Install washer (2). a After installing washer (2), measure distance (i) from the top of No.1 planetary gear (8) to the top of ring gear (12) and check the assembly condition. a If dimension (i) is not within 0.54 ± 0.56 mm range, they are not assembled correctly. In this case, check again.
Install No.2 planetary carrier assembly (3).
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300 Power train Disassembly and assembly of final drive assembly
15. Cover 1) Using eyebolts [1], install cover (1) 4
2
Cover: 20 kg Contacting face of cover and ring gear: Liquid gasket (LG-6)
2)
Using tool J7, tighten the 18 mounting bolts. 3 Mounting bolts: First time: 98 Nm {10 kgm} Sencond time: 80 – 90° (rotating angle)
16. Oil refill Tighten drain plug and fill power train oil (TO30) from the oil filler port. 5
a
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Final drive case: Approx. 3.8 l
Do a final check of the oil level at the determined position after installing the final drive assembly to the chassis.
12
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300 Power train Disassembly and assembly of final drive assembly
Part number
4 796-427-1400 5 796-427-1520 796T-427-1510 790-101-2510 790-101-3310 790-101-2610 J 790-101-2730 6 01580-11613 790-101-2570 01643-31645 790-101-2102 790-101-1102 7 790-331-1110
Part name Wrench assembly Installer Push tool Block Plate Leg Adapter Nut Plate Washer Puller (294 kN {30 ton}) Pump Wrench
Necessity Q’ty
Symbol
a PC220-8M0, PC220LC-8M0 Special tools
t t t t t t t t t t t t t
1 1 1 1 1 2 2 2 2 2 1 1 1
Disassembly 1.
Oil draining Remove the drain plug to drain the oil from the final drive case. 6
2.
Final drive case: 5.4 l
Remove 20 mounting bolts. Using eyebolts [1], sling and remove cover (1). 4
a
Cover: 25 kg If ring gear (12) is slung together with the cover, gently tap the ring gear off the cover by using a plastic hammer.
PC200, 200LC, 220, 220LC-8M0
SEN06144-00
3.
Washer Remove washer (2).
4.
No. 1 planetary carrier assembly 1) Remove No. 1 planetary carrier assembly (3).
2)
Disassemble No. 1 planetary carrier assembly according to the following procedure. 1] Drive pin (4) into shaft (5) to remove shaft (5) from No. 1 planetary carrier (6). a After removing shaft (5), remove pin (4) from shaft (5). 2] Remove thrust washer (7), No. 1 planetary gear (8), needle bearing (9), and thrust washer (10).
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5.
No. 1 sun gear shaft Remove No. 1 sun gear shaft (11).
300 Power train Disassembly and assembly of final drive assembly
9.
Thrust washer Remove thrust washer (15).
10. No. 2 planetary carrier assembly 1) Remove No. 2 planetary carrier assembly (16).
6.
Ring gear Remove ring gear (12). 4
Ring gear: 45 kg
7.
Thrust washer Remove thrust washer (13).
8.
No. 2 sun gear Remove No. 2 sun gear (14).
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14
2)
Disassemble the No. 2 planetary carrier assembly according to the following procedure. 1] Drive pin (17) into shaft (18) to remove shaft (18) from No. 2 planetary carrier (19). a After removing shaft (18), remove pin (17) from shaft (18). 2] Remove thrust washer (20), No. 2 planetary gear (21), needle bearing (22), and thrust washer (23).
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300 Power train Disassembly and assembly of final drive assembly
11. Ring nut 1) Remove lock plate (24). 2) By using tool J4, remove ring nut (25).
12. Hub assembly 1) Using eyebolts [2], sling and remove hub assembly (26) from the travel motor. 4 Hub assembly: 80 kg
2)
Remove bearing (27).
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3)
Remove bearing outer races (29) and (30) from hub (28).
13. Remove floating seals (32) and (33) from travel motor (31). a Floating seals (32) are attached to hub assembly (26) and travel motor.
14. Use the puller [3] and push tool [4] to remove bearing (34). a Bearing may come off without using the puller.
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Assembly a
Clean the parts completely and inspect them for any foreign material or damage. Apply power train oil (TO30) to the sliding surfaces before assembly.
1.
Hub assembly 1) Use push tool to press fit bearing outer races (29) and (30) into hub (28).
2)
50-300
Using tool J5, install floating seal (32). a Install the floating seal after degreasing and drying the O-rings and O-ring contacting surfaces completely. a After installing the floating seal, check the inclination of the seal. It must be 1 mm or less. a After floating seal installation, apply a thin coat of power train oil on the sliding surfaces. 2 Sliding surface: Power train oil (TO30)
16
300 Power train Disassembly and assembly of final drive assembly
2.
Install bearing (34) to travel motor (31). a Warm the inner race of the bearing (34) to 50 to 70°C with heater. a Cool bearing (34) down. Tap the bearing (34) with a wood bar and listen to the sound to check that it is fully seated.
3.
Using tool J5, install floating seal (33) to travel motor (31). a Install the floating seal after degreasing and drying the O-rings and O-ring contacting surfaces completely. a After installing the floating seal, check the inclination of the seal. It must be 1 mm or less. a After floating seal installation, apply a thin coat of power train oil on the sliding surfaces. 2 Sliding surface: Power train oil (TO30)
4.
Using eyebolts [2], place hub assembly (26) on the travel motor. 4
Hub assembly: 80 kg
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of final drive assembly
5.
Install bearing (27) by tapping it lightly with the push tool.
6.
Ring nut 1) Install the ring nut according to the following procedure. 1] Rotate the hub two to three times. 2] Use tool J6 and push tool [5] to press the inner race of bearing (27). a Pressing force: 29.4 to 38.2 kN {3.0 to 3.9 ton} 3] Rotate the hub to the both directions at least five times in total with the bearing inner race pressed. 4] Release the pressing force. 5] Press the bearing again. a Pressing force: 17.7 to 21.6 kN {1.8 to 2.2 ton} 6] Rotate the hub two to three times.
SEN06144-00
7]
8]
Measure the thickness of ring nut (25) and name it (b) dimension. 9] Subtract (b) from (a), and name it (c). 10] By using tool J4, tighten ring nut (25) until dimension (d) is as shown. Dimension (d): c (+0.06/-0.04) mm
2)
PC200, 200LC, 220, 220LC-8M0
Measure dimension (a) under the condition described in 6]. a After measuring dimension (a), remove tool J6.
Measure the tangential force of the hub against the motor case in the rotation direction using the push scale [6]. a Tangential force: Max. 490 N {50 kg} a The tangential force denotes the maximum force at start of the rotation.
50-300
17
SEN06144-00
3)
300 Power train Disassembly and assembly of final drive assembly
Install lock plate (24). a Install the lock plate so that the splines (A) of the motor and the lock plate are in full contact. 2 Mounting bolt threads: Adhesive (LT-2) a Do not apply the adhesive (LT-2) to the thread portion of the nut.
3]
7.
No. 2 planetary carrier assembly 1) Assemble No. 2 planetary carrier according to the following procedure. a Replace thrust washers (20) and (23) as well as pin (17) with new ones. a There is trace of punching on the end face of carrier side hole (e) which was caused when the pin was inserted and locked. Before pin installation, remove the protrusion in the pin hole as a result of punching. 1] Install needle bearing (22) to No. 2 planetary gear (21). Fit upper and lower thrust washers (20) and (23) and set the gear assembly to No. 2 planetary carrier (19). 2] Align the pin holes on shaft (18) and the carrier, and install shaft (18) by tapping it lightly with a plastic hammer. a Install the shaft, while rotating No. 2 planetary gear (21) with care not to damage the thrust washer.
50-300
18
Insert pin (17). a When inserting the pin, take care that the three claws (parts (f)) on the periphery of the pin will not be placed on the thin-wall parts of No. 2 planetary carrier (parts (g)). The thin-wall part may be on the opposite side depending on carriers. Check each carrier and avoid setting any claw of the pin to the thin-wall part. If there is a groove, avoid the groove. a After assembling the No. 2 planetary carrier, check that No. 2 p l a n e ta r y g e a r ( 2 1 ) r o ta t e s smoothly. a After the pin is inserted, punch the pin (B) on the carrier.
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of final drive assembly
SEN06144-00
9.
No. 2 sun gear Install No. 2 sun gear (14).
10. No. 1 sun gear shaft Install No. 1 sun gear shaft (11). 11. Thrust washer Install thrust washer (13).
2)
8.
Install No. 2 planetary carrier assembly (16). a Align the four gear shaft ends of No. 2 planetary carrier assembly (16) with the four dimples on the motor case end face to install.
Thrust washer Install thrust washer (15).
PC200, 200LC, 220, 220LC-8M0
12. Ring gear 1) Install the O-ring to the hub. 2) Install ring gear (12) on the hub. 4 Ring gear: 45 kg a Degrease the mating faces of the ring gear and hub. Do not apply liquid gasket on the mating faces. a Align the bolt holes of the ring gear with those of the hub.
50-300
19
SEN06144-00
300 Power train Disassembly and assembly of final drive assembly
13. No. 1 planetary carrier assembly 1) Assemble the No. 1 planetary carrier according to the following procedure. a Replace thrust washers (7) and (10) as well as pin (4) with new ones. (See Pin (4): 3].) a There is a punching mark made when the pin was inserted on the end face of carrier side hole (h) and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. 1] Assemble needle bearing (9) in No. 1 planetary gear (8), fit top and bottom thrust washers (7) and (10), and then set the gear assembly on No. 1 planetary carrier (6).
2)
2]
3]
50-300
20
Install No. 1 planetary carrier assembly (3).
Align the pin holes in shaft (5) and the No. 1 planetary carrier, and install the shaft (5) by tapping it lightly with a plastic hammer. a Install the shaft, while rotating No. 1 planetary gear (8) with care not to damage the thrust washer. Insert pin (4). a When inserting the pin, take care that the three claws (parts (f)) on the periphery of the pin will not be placed on the thin-wall parts of No. 1 planetary carrier (parts (g)). The thin-wall part may be on the opposite side depending on carriers. Check each carrier and avoid setting any claw of the pin to the thin-wall part. If there is a groove, avoid the groove. a After assembling the carrier, check that No. 1 planetary gear (8) rotates smoothly. a After the pin is inserted, punch the pins (C) on the carrier at 2 locations.
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of final drive assembly
14. Washer Install washer (2). a After installing washer (2), measure dimension (i) from the upper end face of No. 1 planetary gear (8) to that of ring gear (12) to check for the correct assembly condition. a If dimension (i) does not fall within 2.11 ± 0.97 mm, the assembly is built incorrectly. Recheck.
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15. Cover 1) Using eyebolts [1], install cover (1). 4
Cover: 25 kg Mating faces of cover and ring gear: Liquid gasket (LG-6) Do not apply liquid gasket (LG-6) to tap.
2
a
2)
Using tool J7, install the 20 mounting bolts. 3 Mounting bolt 1st time: 98 Nm {10 kgm} 2nd time: 80 to 90 deg. (rotating angle)
16. Refilling of oil Tighten drain plug and supply power train oil (TO30) from the oil filler port. 5
a
PC200, 200LC, 220, 220LC-8M0
Final drive case: 5.4 l
Do a final check of the oil level at the determined position after installing the final drive assembly to the chassis.
50-300
21
SEN06144-00
300 Power train Removal and installation of swing motor and swing machin-
Removal and installation of swing motor and swing machinery 1 assembly Removal k
k
Lower the work equipment to the ground completely, after the engine is stopped, loosen the hydraulic tank cap gradually to reduce the pressure inside, and set the lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery.
a
Attach an identification tag to each piping to avoid a mistake in the position of installation later.
1.
Remove cover (1).
2.
5.
Disconnect 5 pcs. of swing motor hose (7) – (11). q (7): Between the swing motor – the control valve (port MA) q (8): Between the swing motor – the control valve (port MB) q (9): Suction hose (port S) q (10), (11): Drain hose (port T)
6.
Remove nipple (12) (port T).
7.
Disconnect clamp (13).
8.
Disconnect hose (14).
9.
Remove mounting bolts (15) and disconnect drain hose (16).
Open engine hood (2) and remove cover (3).
3.
Disconnect hoses (4) and (5). (If equipped)
4.
Disconnect the bracket hose assembly (6). (If equipped)
50-300
22
PC200, 200LC, 220, 220LC-8M0
300 Power train Removal and installation of swing motor and swing machin-
SEN06144-00
10. Pull drain hose (16) out. 11. Disconnect pilot hose to cancel swing brake (17) (B port).
Installation 12. Remove 12 pcs. of mounting bolt (18).
[*1]
q
Installation is done in the reverse order of removal.
[*1]
3
13. Lift and remove the swing motor and swing machinery assembly (19). a Being careful not to damage hose (H), etc. with bar [1], lift the swing motor and swing m a c h i n e r y as s e m b l y g r a d ua l l y a n d remove them. a Being very careful for the drain hose, lift them. a Lift them with full attention until surpass the hose of the center swivel joint. 4
Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
q
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, “Bleeding air from each part”.
Swing motor and swing machinery assembly: 250 kg
PC200, 200LC, 220, 220LC-8M0
50-300
23
300 Power train Disassembly and assembly of swing motor and swing ma-
SEN06144-00
Disassembly and assembly of swing motor and swing machinery assembly
Disassembly 1.
Set the swing motor and the swing machinery assembly into block [1].
2.
Oil drain Loosen drain plug (39) and drain the oil inside the swing machinery case.
1
1 796T-426-1410)
Push tool
t 1
2 796-426-1120
Push tool
t 1
F
Plate
t 1
Grip
t 1
Bolt
t 1
796T-426-1130 3 790-101-5421 01010-81240
q
a a
5
Q’ty
Part name
Symbol
Part number
Necessity
Special tools
6
3.
Remove drain hose (1).
4.
Remove 6 pcs. of the mounting bolt and remove the swing motor assembly (2). 4
Sectional view A number shows the number in the text. Though the drawing is for PC200, 200LC8M0, PC220, 220LC-8M0 also operates in a similar way basically. The different parts are indicated in the text.
50-300
24
Swing machinery case: PC200, 200LC-8M0: 7.1 l PC220, 220LC-8M0: 8.2 l
Swing motor assembly: 70 kg
5.
Remove No.1 sun gear (3).
6.
No.1 carrier assembly 1) Remove No.1 carrier assembly (4).
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of swing motor and swing ma-
2)
Disassemble No.1 carrier assembly by the following order. 1] Remove snap ring (5), thrust washer (6), gear (7), bearing (8), thrust washer (9) in order. 2] Remove plate (10). 3] Reverse carrier (34) and remove snap ring (35). a PC200-8M0, PC200LC-8M0
SEN06144-00
7.
Remove No.2 sun gear (12).
8.
Remove the mounting bolt and remove ring gear (13).
9.
Remove holder mounting bolt (14).
10. No.2 carrier assembly 1) Remove No.2 carrier assembly (15). a
3)
PC220-8M0, PC220LC-8M0
Using push tool [2], remove shaft (11) from carrier (34). q Input pin press (reference): 11.2 – 25.8 kN {1,140 – 2,630 kg}
PC200, 200LC, 220, 220LC-8M0
50-300
25
SEN06144-00
2)
300 Power train Disassembly and assembly of swing motor and swing ma-
Disassemble No.2 carrier assembly as follows. 1] Push pin (16) and shaft (17) from carrier (18). a After removing the shaft, remove pin (16). 2] Remove thrust washer (19), gear (20), and bearing (21). 3] Remove plate (22). a PC200-8M0, PC200LC-8M0
11. Shaft and case assembly 1) Reverse shaft and case assembly (23). 2) Remove cover mounting bolt (24).
3) 4)
a
50-300
26
Reverse shaft and case assembly (23) again and set to the press. Using push tool [3], remove shaft assembly (25) from shaft and case assembly (23).
PC220-8M0, PC220LC-8M0
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of swing motor and swing ma-
12. Shaft assembly 1) Using push tools [4], [5], remove shaft (26). 2) Remove bearing (27) and oil seal (29) from cover (28).
SEN06144-00
14. Remove bearing (31) from case (30). a Apply a suitable tool on the circumference of the outer race (thick line: (Q) section), strike the tool on the circumference with the hammer lightly, equally, by turns, and remove the bearing gradually. a If the outer race is made incline, bearing becomes hard, so remove it horizontally.
a PC220-8M0, PC220LC-8M0 only 13. Remove spacer (41) and O-ring (42) from shaft (26).
PC200, 200LC, 220, 220LC-8M0
50-300
27
SEN06144-00
300 Power train Disassembly and assembly of swing motor and swing ma-
Assembly a
Wash each part finely and check if there are not a garbage, a crack, etc., and apply power train oil to the sliding portion and assemble them.
a
The bearing and the oil seal, which were removed, are not re-used. New ones should be used.
1.
Oil seal Using tool F3, install oil seal (29) into cover (28). a Be careful for the direction of the oil seal (up and down). 2 Outside perimeter of oil seal: Gasket sealant (LG-6) a When press-fitting, take care so that gasket sealant (LG-6) will not stick to the lip surface of the oil seal.
a a
50-300
2.
Using push tool [9], press fit bearing (27) into case (30). a Use the new bearing.
3.
Install cover assembly (33) into case assembly (32). 2 Cover mounting face: Gasket sealant (LG-6) a Be careful not to adhere gasket sealant (LG-6) to drain port section (DP). a Align the drain process section of cover into the drain port section (DP).
If tool F3 is not used, use the push tool which can push outside perimeter section (A) of oil seal (29). Be careful not to incline oil seal (29).
28
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of swing motor and swing ma-
4.
SEN06144-00
Shaft and case assembly a 1) and 2): PC220-8M0, PC220LC-8M0 only 1) Install O-ring (42) to spacer (41). 2) Using push tool [16], press-fit spacer (41) to shaft (26). a Be careful not to bite O-ring (42) to the spacer.
3)
4)
5) 6)
Set case assembly (32) into shaft (26). 2 Oil seal lip section: Grease (G2-LI) a Put case assembly not to interfere the oil seal. Using tool F1, push tool [10], and hammer [11], strike inner race section of bearing (27) not to fall down the shaft. a Let lifting tool [12] be slacked.
5.
Bearing Using tool F2 and push tool [15], press fit bearing (31). a When press-fitting the bearing, press both inner and outer races of the bearing at the same time. Avoid pressing the inner race only. q Input pin press (reference): 9.4 – 35.5 kN {960 – 3,620 kg} a After the bearing is press-fitted, check that the case will turn freely.
Set into the press. Using tool F1, push tools [13], [14], press fit inner race section of bearing (27). a Put in push tool [14] for the cases that the case assembly is inclined a lot. a If case assembly (32) is inclined, strike the flange section lightly and correct it. a Just before oil seal (29) goes into shaft (B) part, case assembly (32) is leveled so that case assembly (32) may be located at the center of shaft (26), and be careful not to damage the oil seal lip part.
PC200, 200LC, 220, 220LC-8M0
50-300
29
SEN06144-00
6.
300 Power train Disassembly and assembly of swing motor and swing ma-
No.2 carrier assembly 1) Assemble No.2 carrier assembly as follows. a Since there is a mark to be caulked in the side hole (h) of carrier (18) at the time of pin insertion, remove protrusion for hole inner diameter beforehand. (Refer to 5]) 1] Incorporate plate (22) into carrier (18). 2] Incorporate bearing (21) and 2 pcs. of upper and lower thrust washer (19) into gear (20). 3] Set gear assembly into carrier (18). a PC200-8M0, PC200LC-8M0
a
4]
5]
PC220-8M0, PC220LC-8M0
2)
3)
50-300
30
Strike lightly with plastic hammer, etc., align pin hole location of shaft (17) and carrier and install shaft (17). a Install the shaft, rotating the planetary gear. Take care so the thrust washer is not damaged. Insert pin (16), a As inserting the pin, install not to interfere claw section ((a) section) which is in 3 places on circumference into carrier thin part ((b) section). However, actual thing may have the thin section on the other side. So make sure to confirm the actual thing and assemble not to interfere claw section of the pin into the thin part. a After inserting the pin, caulk 2 parts of the carrier (c) around the pin hole.
Install No.2 carrier assembly (15) with bolt (14). 2 Mounting bolt threaded section: Adhesive compound (LT-2) 3 Mounting bolts: 157 – 196 Nm {16 – 20 kgm} Install O-ring (36) into case (30).
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of swing motor and swing ma-
7.
No.2 sun gear Install No.2 sun gear (12).
8.
Ring gear Using eyebolt (M10 x 1.5), install ring gear (13).
SEN06144-00 a
PC220-8M0, PC220LC-8M0
a
Degrease mating face of ring gear (13) and case (30). a Do not adhere gasket sealant in mating face of the ring gear and the case. a Align the counter mark on the ring gear (Portion (c)) and the convex portion on the case flange (Portion (d)) in the position illustrated in the following figure, and then install it. 3 Mounting bolts: 157 – 196 Nm {16 – 20 kgm} 9.
Install O-ring (37).
a
10. No.1 carrier assembly 1) Assemble No.1 carrier assembly as follows. 1] Press fit shaft (11) into carrier (34) in the arrow direction (1st) until the slot on the snap ring can be seen. 2] After installing snap ring (35), push back (to the 2nd direction) from the opposite side until the snap ring adheres to the carrier (P) surface. Be careful not to push too much. q Input pin press (reference): 11.2 – 25.8 kN {1,140 – 2,630 kg}
PC200-8M0, PC200LC-8M0
3] 4]
PC200, 200LC, 220, 220LC-8M0
Install plate (10) into carrier (34). Install thrust washer (9), bearing (8), gear (7), thrust washer (6), snap ring (5) in order.
50-300
31
SEN06144-00
300 Power train Disassembly and assembly of swing motor and swing ma-
a
PC200-8M0, PC200LC-8M0
a
PC200-8M0, PC200LC-8M0
a
PC220-8M0, PC220LC-8M0
a a
PC220-8M0, PC220LC-8M0 P: Press-fit plate
2)
Install No.1 carrier assembly (4).
11. No.1 sun gear assembly Install No.1 sun gear (3). a When installing the No.1 sun gear, be careful not to install it upside down. a Install the No.1 sun gear with the tooth portion (Portion (e)) facing down.
12. Swing motor assembly Put swing motor assembly (2) on ring gear (13). 4
a a
Swing motor assembly: 70 kg
Degrease mating face of swing motor assembly (2) and ring gear (13). Do not adhere gasket sealant in mating face of swing motor assembly (2) and ring gear (13).
a
After aligning the position of swing motor assembly (2) and ring gear (13) as follows and install them. 3 Mounting bolts: 59 – 74 Nm {6.0 – 7.5 kgm} a PC200-8M0, PC200LC-8M0 q Align the relation between the positions of the filler ((f) section) and convex portion of the case ((d) section) as mentioned in the drawing and install them.((c), (d): Abovementioned)
50-300
32
PC200, 200LC, 220, 220LC-8M0
300 Power train Disassembly and assembly of swing motor and swing ma-
SEN06144-00
14. Install the drain hose. a As installing the hose, be careful that the drain plug to be downward. 3 Drain hose: 128 – 186 Nm {13.0 – 19.0 kgm} 15. Oil refill Fill the power train oil (TO30) from oil filler port up to the standard level by tightening the drain plug. 3 Drain plug: 19.6 – 24.5 Nm {2.0 – 2.5 kgm} 5
a q
PC220-8M0, PC220LC-8M0 Align the relation between the positions of the motor port ((g) section) and convex portion of the case ((d) section) as mentioned in the drawing and install them.((c), (d): Above-mentioned)
a
Swing machinery case PC200, 200LC-8M0: 7.1 l PC220, 220LC-8M0: 8.2 l
Check oil level by using oil level gauge.
13. Confirm mounting angle of elbow for drain (38): 15° and the tightening torque. 3 Elbow mounting nut: 128 – 186 Nm {13.0 – 19.0 kgm}
PC200, 200LC, 220, 220LC-8M0
50-300
33
300 Power train Removal and installation of swing circle assembly
SEN06144-00
Removal and installation of swing circle assembly 1
Installation
Removal
[*1] a Let the soft zone position S mark of an inner race: (a) and the soft zone position S mark of an outer race: (b) to be right side of the body as mentioned below and install it to the track frame. 2 Amount of filled grease: Grease (G2-LI) : 14.6 l (PC200, 200LC-8M0) 15.8 l (PC220, 220LC-8M0) 2 Swing circle mounting bolt threaded portion: Adhesive compound (LT-2) q In case of torque tightening: 3 Swing circle mounting bolt: 588 – 677 Nm {60 – 69 kgm} (PC200/200LC-8M0) 716 – 814 Nm {73 – 83 kgm} (PC220/220LC-8M0 q In case of angle tightening: a For PC200-8M0 3 Swing circle mounting bolt: 1) Initial torque: 191.3 ± 19.6 Nm {19.5 ± 2 kgm} 2) After that, rotate the bolt 48 ± 5°.
1.
Disassemble the revolving frame assembly referring to the section “Removal and installation of revolving frame assembly”.
2.
Sling swing circle assembly (1) at three points and remove the mounting bolt to remove the assembly. [*1] 4
50-300
Swing circle assembly: 270 kg
34
q
Installation is done in the reverse order of removal.
PC200, 200LC, 220, 220LC-8M0
300 Power train Removal and installation of swing circle assembly
PC200, 200LC, 220, 220LC-8M0
SEN06144-00
50-300
35
SEN06144-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06144-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-300
36
SEN06145-00
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
400 Undercarriage and frame Disassembly and assembly of carrier roller assembly .................................................................................... 2 Disassembly and assembly of track roller assembly ...................................................................................... 5 Removal and installation of idler and idler cushion assembly......................................................................... 7 Disassembly and assembly of idler................................................................................................................. 8 Disassembly and assembly of idler cushion ..................................................................................................11 Removal and installation of sprocket ............................................................................................................ 13 Separation and connection of track shoe assembly ..................................................................................... 14 Removal and installation of revolving frame assembly ................................................................................. 18 Removal and installation of counterweight assembly ................................................................................... 20
PC200, 200LC, 220, 220LC-8M0
50-400
1
400 Undercarriage and frame Disassembly and assembly of carrier roller assembly
SEN06145-00
Disassembly and assembly of carrier roller assembly
1
L 1 790-434-1660 q
a
Part name Installer
t 1
Q’ty
Part number
Necessity
Symbol
Special tools
Sectional view A number shows the number in the text. 3.
Remove ring (5) from roller (4).
4.
Remove floating seal (6) from ring (5). a Take care not to damage the sealing surface.
5.
Remove floating seal (7) from roller (4). a Take care not to damage the sealing surface.
Disassembly 1.
Remove plug (9) and drain the oil from carrier roller (1). 6
2.
Carrier roller: 75 – 85 ml
Using push tool [1], push the end surface of a shaft and remove followings from carrier roller (1): q Roller (4), ring (5) assembly, shaft (2) and cover (3). q Press fitting force (reference): 59 kN {6,000 kg} min. a The press fitted shaft (2) and ring (5), and also roller (4) and cover (3) will be both disassembled. a Cover (3) is placed under shaft (2).
50-400
2
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Disassembly and assembly of carrier roller assembly
6.
SEN06145-00
Using push tools [2] and [3], remove bushing (8) from roller (4).
Assembly 1.
Using push tools [3] and [4], press fit bushing (8) to roller (4). a Press it from the side of cover (3).
2.
Floating seal 1) Using tool L1, install floating seal (7) to roller (4). 2) Using tool L1, install floating seal (6) to ring (5). a When installing the floating seal, completely wash, degrease and dry both O-ring and the surfaces where the O-ring and the floating seal will contact each other (hatched area in the sketch). And take care that there is no dust sticking on the contact surface of floating seal. a When fitting the floating seal, use tool L1 and be sure that the O-ring is pushed during the insertion. a After inserting the floating seal, verify that the inclination of the seal is less than 1 mm per its diameter and that the protrusion height of the seal shown as (a) in the illustration falls within the range of 7 – 11 mm.
PC200, 200LC, 220, 220LC-8M0
50-400
3
SEN06145-00
3.
400 Undercarriage and frame Disassembly and assembly of carrier roller assembly
Install roller (4) and ring (5) to shaft (2). a On the sliding surfaces of floating seals, apply some oil and take care not to have any dirt stuck on them.
6.
Fill carrier roller assembly (1) with oil and tighten plug (9). 5
4.
To make the height gap between roller (4) and ring (5) 1.8 ± 0.2 mm, put washer [7] between push tool [6] and roller (4), then press fit ring (5) to shaft (2). a The thickness of washer [7] is 1.8 ± 0.2 mm. a Use push tool [5] to support shaft (2) on it.
5.
Using push tool [8], press fit cover (3) to roller (4). a Degrease, wash and dry the surfaces where roller (4) and cover (3) fit tight. q Press fitting force (reference): 59 kN {6,000 kg} min.
50-400
4
3
Carrier roller: 75 – 85 cc (EO30-DH) Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Disassembly and assembly of track roller assembly
Disassembly and assembly of track roller assembly
Assembly 1
L 2 796-670-1020
Part name
Necessity Q’ty
Symbol
Special tools Part number
SEN06145-00
Installer
t 1
1.
Using push tool [1], press fit bushings (9) and (10) to roller (4).
2.
Fit an O-ring and install collar (8) to shaft (5), and insert pin (7).
3.
Using tool L2, install floating seal (6a) to collar (8). a When installing the floating seal, completely wash, degrease and dry both Oring and the surfaces of floating seal where they contact each other (shown hatched area in the illustration). And take care that there is no dust sticking on the contact surfaces of floating seal. a After inserting the floating seal, verify that the inclination of the seal is less than 1 mm per its diameter and that the protrusion height shown as (a) in the illustration falls within the range of 7 – 11 mm.
Disassembly 1.
Remove pin (1) and then collar (2).
2.
Remove floating seal (3) from collar (2) and roller (4).
3.
Pull out roller (4) from shaft (5) and collar (8) assembly. a Since 195 cc of oil is filled in, drain it at this timing, or underlay some cloth to prevent any careless smearing.
4.
Pull out other side floating seal (6) from roller (4), shaft (5) and collar (8) assembly.
5.
Remove pin (7) and then collar (8) from shaft (5).
6.
Remove bushings (9) and (10) from roller (4).
PC200, 200LC, 220, 220LC-8M0
50-400
5
SEN06145-00
400 Undercarriage and frame Disassembly and assembly of track roller assembly
4.
7.
Using tool L2, install floating seal (3a) to collar (2). a As to notes for installation of floating seal (3a), refer to a marked comments in the step 3. a On the sliding surfaces of the floating seals, apply some oil and take care not to have any dust stuck on them.
8.
Fit an O-ring and install collar (2) to the shaft with pin (1).
9.
Add oil and tighten the plug.
Using tool L2, install floating seals (6b) and (3b) to roller (4). a As to notes for installation of floating seals (6b) and (3b), refer to a marked comments in the step 3.
5
3
5.
Install shaft (5) to roller (4).
6.
Put roller (4) and shaft (5) assembly upside down.
50-400
6
Amount of oil: 190 – 200 cc (EO30-DH) Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Removal and installation of idler and idler cushion assem-
Removal and installation of idler and idler cushion assembly
4. 1
Removal 1.
Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly".
2.
By using bar [1], move idler and idler cushion assembly (1) forward to a position where it can be lifted.
SEN06145-00
Disconnect idler cushion assembly (4) from idler assembly (3). 4
Idler assembly: 105 kg
4
Idler cushion assembly: 130 kg
Installation q
3.
Lift idler and idler cushion assembly (1), pull it forward to remove it from track frame (2). 4
Perform installation in the reverse order to removal.
Idler and idler cushion assembly: 235 kg
PC200, 200LC, 220, 220LC-8M0
50-400
7
400 Undercarriage and frame Disassembly and assembly of idler
SEN06145-00
Disassembly and assembly of idler
4.
Remove floating seals (6) on the other side from idler (4) and the assembly of shaft (5) and support (7).
5.
Remove dowel pin (8), and then remove support (7) from shaft (5).
6.
Remove bushings (9) and (10) from idler (4).
1
Part number
L 3 791-530-1510
Part name Installer
Necessity Q’ty
Symbol
Special tools
t 1
Figure of structure
Disassembly 1.
Remove dowel pin (1) to remove support (2).
2.
Remove floating seals (3) from support (2) and idler (4).
3.
Remove idler (4) from the assembly of shaft (5) and support (7). a Since approximately 250 cc of oil is filled in, drain it at this timing, or underlay some cloth against any careless smearing.
50-400
8
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Disassembly and assembly of idler
SEN06145-00
Assembly 1.
Press fit bushings (9) and (10) to idler (4).
2.
Install shaft (5) with O-ring (12) to support (2), and insert dowel pin (1).
4.
3.
Install the assembly of shaft (5) and support (2) to idler (4).
By using tool L3, install floating seals (3) to idler (4) and the assembly of shaft (5) and support (2). a Completely clean, degrease, and dry the contact surfaces (hatched area shown in the figure) of the floating seal and the Oring. a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it. a After inserting the floating seals, check that the inclination is less than 1 mm and the protrusion (a) is within the range of 7 to 11 mm.
PC200, 200LC, 220, 220LC-8M0
50-400
9
400 Undercarriage and frame Disassembly and assembly of idler
SEN06145-00
5.
Turn it over, and supply oil between shaft (5) and idler (4). 5
6.
Amount of oil to be sealed (EO-30DH): 245 to 255 cc
By using tool L3, install floating seal (6) to idler (4) and support (7). a Completely clean, degrease, and dry the contact surfaces (hatched area shown in the figure) of the floating seal and the Oring. a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it. a After inserting the floating seals, check that the inclination is less than 1 mm and the protrusion (a) is within the range of 7 to 11 mm.
50-400
10
7.
Install shaft (5) with O-ring (11) to support (7), and insert dowel pin (8). a See figure of structure.
8.
Supply oil and tighten plug (13). 3 Plug (13): 157 to 255 Nm {16 to 26 kgm}
a
When mounting the idler assembly on the machine, make sure that plug (13) faces right side of the machine.
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Disassembly and assembly of idler cushion
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Disassembly and assembly of idler cushion
Disassembly 1
Part number
Part name Compressor (A)
t 1
Compressor (B)
t 1
Spacer
t 1
Extension
t 1
790-101-1600
Cylinder (686 kN {70 ton})
t 1
790-101-1102
Pump
t 1
790-640-2180
Guide bolt
t 1
790-101-5201
Push tool kit (B)
q 1
790-101-5241
• Plate
1
790-101-5221
• Grip
1
01010-51225
• Bolt
790-201-1500
Push tool kit
790-201-1620
• Plate
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
791-600-2001
Remove piston assembly (2) from idler cushion assembly (1).
2.
Disassembly of idler cushion assembly 1) Set idler cushion assembly (1) to tool M1. a Load at installed length of spring: PC200-8M0: 109.3 kN {11,150 kg} PC200LC-8M0, PC220-8M0, PC220LC-8M0: 126.5 kN {12,900 kg}
Necessity Q’ty
Symbol
Special tools
1.
or 791-685-8006 790-201-2780 1 791-635-3160
M
2
3
k
a
2
2)
q 1
Since the load at installed length of the spring is large and dangerous, set the spring securely to the tool. Figure of structure 3) 4) 3.
PC200, 200LC, 220, 220LC-8M0
Apply hydraulic pressure gradually to compress the spring and remove lock plate (3) and nut (4). a Compress the spring until the nut becomes loose. a Release the hydraulic pressure slowly to release the compression of the spring. a Free length of spring: PC200-8M0: 503 mm PC200LC-8M0, PC220-8M0, PC220LC-8M0: 561 mm Remove yoke (6) and cylinder (7) from spring (5). Remove snap ring (8), dust seal (9) and bushing (10), in turn from cylinder (7).
Further disassembly of piston assembly (2) 1) Remove lock plate (12) from piston (11), and then remove valve (13). 2) Remove snap ring (14), then remove Upacking (15) and ring (16).
50-400
11
400 Undercarriage and frame Disassembly and assembly of idler cushion
SEN06145-00
Assembly 1.
Assembly of piston (2) 1) Install ring (16) and U-packing (15) to piston (11), and secure them with snap ring (14). 2) Tighten valve (13) lightly, and secure it with lock plate (12).
2.
Assembly of idler cushion 1) Using tool M2, press fit bushing (10) into cylinder (7). 2) Using tool M3, install dust seal (9) to cylinder (7). 3) Secure them by using snap ring (8).
3. 4)
50-400
Install plate (7a), cylinder (7) and yoke (6) to spring (5). Install the assembly to tool M1. 2 Sliding surface of cylinder: Grease (G2-LI)
12
5)
Apply hydraulic pressure slowly to compress the spring, and then tighten nut (4) so that the installed length of the spring is dimension (a) and secure it with lock plate (3) a Installed length (a) of spring: PC200-8M0: 389 mm PC200LC-8M0, PC220-8M0, PC220LC-8M0: 433 mm
6)
Remove idler cushion assembly (1) from tool M1.
Install piston assembly (2) to idler cushion assembly (1). 2 Sliding surface of cylinder: Grease (G2-LI) 2 Wear ring: Grease (G2-LI) a Install the piston assembly with the valve installed position facing outward. a Pump 300 cc of grease (G2-LI) into the cylinder and bleed air. Check that grease comes out of the grease hole.
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Removal and installation of sprocket
Removal and installation of sprocket
SEN06145-00
Installation 1
Removal 1.
Installation is done in the reverse order of removal.
[*1]
Expand the track shoe assembly referring to "Expansion and installation of track shoe assembly".
2.
Swing work equipment 90°, push up chassis with work equipment and place block [1] between track frame and track shoe.
3.
Remove sprocket (2), hanging as follows. 1) Remove fixing bolt (1). [*1] a Before removing the final fixing bolt, place block [2] under sprocket (2). 2) Put sprocket (2) on block [2], make a clearance from final drive (FD), and lead sling [3] in between. 4
q
2 3
Thread of sprocket mounting bolts: Adhesive compound (LT-2) Sprocket mounting bolts: 441 – 490 Nm {45 – 50 kgm}
Sprocket: 40 kg
PC200, 200LC, 220, 220LC-8M0
50-400
13
400 Undercarriage and frame Separation and connection of track shoe assembly
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Separation and connection of track shoe assembly
1
791-630-3000 R
790-101-1300 790-101-1102
Part name Remover and installer Cylinder (980 kN {100 ton}) Pump
Q’ty
Part number
Necessity
Symbol
Special tools
t 1 t 1 t 1
Separation 1.
Turn the upper structure by 90°.
2.
Loosen lubricator (1) to decrease the track shoe tension. [*1] k Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than one turn. If the grease does not come out sufficiently, start the engine and move the machine backward and forward.
3.
4.
Remove track shoes (5) on the right and left sides of master pin (2) of track (3). [*2] a Loosen the four bolts by one to two turns respectively and check that they rotate lightly, and then pull them out. a If a bolt does not turn smoothly and it is unscrewed forcibly, the threads of itself and the link may be damaged.
5.
Using tool R, remove master pin (2). [*3] a Press out master pin (2) with guide pin [1].
Position master pin (2). 1) Lift tracks (3) by stretching the work equipment against ground. 2) Move master pin (2) to a position above the idler where it can be removed easily. 3) Relieve the extended work equipment, and lower the machine.
50-400
14
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Separation and connection of track shoe assembly
6.
Move guide pin [1] and place block [2] under track shoe (3) to support in front of the idler.
7.
Pull out guide pin [1] and remove block [2] so that track shoe (3) can be separated.
8.
Move the machine slowly in reverse to separate the track shoe (3). [*4]
PC200, 200LC, 220, 220LC-8M0
SEN06145-00
Installation 1.
While tensing wire [3] with a forklift truck, work equipment, etc., move the machine forward slowly to wind track shoe (3).
2.
By using bar [4], hammer [5], etc., wind track shoe (3) and match the pin holes of link (6). a Place block [2] etc. under track shoe (3) in front of the idler to support the track shoe.
50-400
15
SEN06145-00
3.
400 Undercarriage and frame Separation and connection of track shoe assembly
Drive guide pin [1] into link (6).
Perform connection in the reverse order to separation. [*1] a See Testing and adjusting, "Testing and adjusting track shoe tension".
[*3] a Apply grease to master pin (2). (in the area where bushing (4) and master pin (2) come contact: shown hatched) 2 Between bushing and master pin (hatched area): Grease NIGTIGHT LYK-2 from Nippon grease Co., Ltd.: part No. 44392708
[*2] Installation of track shoe (5) 1. Remove mud, dirt, and rust from the mating faces of shoe (5) and link and the seating faces of bolt (7) and nut. 2.
Install shoe (5). 3 Mounting bolts (7) (4 pieces): 1) Tighten to 490 ± 50 Nm {50 ± 5 kgm}. a Finger-tighten the four bolts until the mating faces of the link are fitted. a If the bolts are tightened forcibly before the link mating faces are fitted, the threads of bolts and link may be damaged. 2) Retighten by 120 ± 10°.
50-400
16
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Separation and connection of track shoe assembly
SEN06145-00
a
Apply grease to the contact surfaces (B) of the bushing end and dust seal. 2 Contact surface (B portion) between bushing and dust seal: Grease NIGTIGHT LYK-2 from Nippon grease Co., Ltd.: part No. 44392708 a Press fit master pin (2) to push guide pin [1] out. a Using tool R, press fit master pin (2), so that the protrusion amount (a) of the master pin is the dimension designated below. Protrusion of master pin a: 2.5 ± 1 mm
PC200, 200LC, 220, 220LC-8M0
50-400
17
400 Undercarriage and frame Removal and installation of revolving frame assembly
SEN06145-00
Removal and installation of revolving frame assembly
1
Removal k
Safely lower the work equipment to the ground by extending the arm and the bucket completely. Set the lock lever in the lock position,
1.
Disassemble the work equipment assembly, referring to the "Removal and installation of work equipment assembly" section in this manual.
2.
Disassemble the counterweight assembly, referring to the "Removal and installation of counterweight assembly" section in this manual.
3.
Disconnect 4 boom cylinder hoses (1). a Plug the hose to stop oil flow-out.
6.
4.
Sling boom cylinder assembly (2).
5.
Remove plate (3) and pin (4), and then lift boom cylinder assembly (2) to remove. a Remove the boom cylinder assembly on the opposite side in the same manner. 4
50-400
Remove fuel filter and bracket assembly (5). a Fix it temporarily on the engine. a When other parts can interfere with the lifting hook in removal of the revolving frame, such parts must be removed beforehand.
Boom cylinder assembly: 180 kg (PC200/200LC-8M0) 200 kg (PC220/220LC-8M0)
18
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Removal and installation of revolving frame assembly
7.
8.
9.
From center swivel joint assembly, disconnect 6 hoses (8) – (13). q (8): Center swivel joint (D port) – Swing motor (T port) q (9): Center swivel joint (E port) – solenoid valve q (10): Center swivel joint (B port) – L.H. travel control valve (A2 port) q (11): Center swivel joint (D port) – R.H. travel control valve (B5 port) q (12): Center swivel joint (A port) – L.H. travel control valve (B2 port) q (13): Center swivel joint (C port) – R.H. travel control valve (A5 port) Pull out pin (14) on the center swivel joint, and disconnect jam plate (15) from the center swivel joint.
SEN06145-00
Installation q
Installation is done in the reverse order of removal.
[*1]
2
Swivel circle mating surface: Gasket sealant (LG-1) 2 Thread of revolving frame mounting bolts: Adhesive compound (LT-2) q In case of torque tightening: 3 Mounting bolts: 716 – 814 Nm {73 – 83 kgm} q In case of angle tightening: 3 Mounting bolts: 1) Initial torque: 294.2 ± 29.4 Nm {30 ± 3 kgm} 2) Then tighten the bolts turning by 60 ± 6°.
q
Refilling with oil (Hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
q
Air bleeding Bleed air from the travel motor referencing the "Bleeding air from each part" section in the Testing and adjusting chapter of this manual.
Remove 32 mounting bolts, and remove revolving frame assembly (16) off slinging it up. [*1] a Using levers and blocks, hold the balance of revolving frame assembly front and rear, and left and right. k When removing the revolving frame assembly, take care so that it does not hit the center swivel joint assembly. 4
Revolving frame assembly: 5,100 kg (PC200/200LC-8M0) 5,500 kg (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
50-400
19
400 Undercarriage and frame Removal and installation of counterweight assembly
SEN06145-00
Removal and installation of counterweight assembly
1
Z
a
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Commercially Impact wrench q 1 available Commercially Socket wrench q 1 available (width across flats: 41 mm)
Use an impact wrench or a socket wrench corresponding to the tightening torque of the counterweight mounting bolt. 3 Counterweight mounting bolt: 1,180 – 1,470 Nm {120 – 150 kgm}
Removal k
k
Park the machine on a level ground, lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery.
1.
Mirror specification 1) Remove mirror (1). 2) Sling counterweight assembly (2) temporarily.
2.
Remove 4 pieces of mounting bolt (3). [*1] a Record the locations where the shims were used.
3.
Sling counterweight assembly (2) off. [*2] a Be careful not to bump it against the engine or radiator or cooler assembly. 4
50-400
Counterweight assembly: 3,750 kg (PC200/200LC-8M0) 5,050 kg (PC220/220LC-8M0)
20
PC200, 200LC, 220, 220LC-8M0
400 Undercarriage and frame Removal and installation of counterweight assembly
Installation q
a
a
q
Confirm the followings before installing the counterweight. Confirm that recirculation prevention sheets (4) to (9) are installed securely. PC200/200LC: (4) only PC220/220LC: (4) to (9) Install recirculation prevention sheets (4) to (9) securely. If they are peeled, heated air in the engine room may flow into cooling side, and it will cause engine over heat.
SEN06145-00 a
Rear view (Enlarged drawing for right hand side)
Installation is done in the reverse order of removal.
[*1]
2 3
Mounting bolt threaded section: Adhesive compound (LT-2) mounting bolts: 1,180 – 1,470 Nm {120 – 150 kgm}
[*2] a Installation and adjustment of counterweight 1) Using shims, adjust the differences in level or gaps between the counterweight and the exterior of machine body. 2) Fix the counterweight so that the clearances in the direction of front and rear are even and within the limit of 10 ± 5 mm for both from the doors and from the revolving frame. 3) The difference in level in left to right direction between the exterior of door (D) and counterweight (C) (a): 10 ± 4 mm The difference in level in left to right direction between revolving frame (R) and counterweight (C) (b): 5 mm or less The difference in level in up and down direction between exterior upper cover (UC) and counterweight (C) (c): 0 ± 5 mm are the respective limits for the mounting adjustment.
PC200, 200LC, 220, 220LC-8M0
50-400
21
SEN06145-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06145-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-400
22
SEN06146-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
500 Hydraulic system Removal and installation of center swivel joint assembly ............................................................................... 2 Disassembly and assembly of center swivel joint assembly ........................................................................... 4 Removal and installation of hydraulic tank assembly...................................................................................... 5 Removal and installation of control valve assembly ....................................................................................... 9 Disassembly and assembly of control valve ................................................................................................. 14 Removal and installation of hydraulic pump assembly ................................................................................. 19 Removal and installation of oil seal in hydraulic pump input shaft ................................................................ 23 Disassembly and assembly of work equipment PPC valve assembly .......................................................... 24 Disassembly and assembly of travel PPC valve........................................................................................... 26 Disassembly and assembly of work equipment cylinder............................................................................... 28
PC200, 200LC, 220, 220LC-8M0
50-500
1
SEN06146-00
Removal and installation of center 1 swivel joint assembly
500 Hydraulic system Removal and installation of center swivel joint assembly
4.
Removal k
k
a
1.
2.
Lower the work equipment to the ground completely, after the engine is stopped, loosen the hydraulic tank cap gradually to reduce the pressure inside, and set the lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Attach an identification tag to each piping to avoid a mistake in the position of installation later. Swing to right 45°. (For hydraulic tank oil drain) a For the way not to drain the hydraulic tank oil by using oil stopper, see "Removal and installation of hydraulic pump assembly". Drain hydraulic tank oil. 6
3.
Disconnect 8 hoses (7) through (14). (7): Center swivel joint (E port) – L.H travel motor (P port) q (8): Center swivel joint (E port) – R.H travel motor (P port) q (9): Center swivel joint (D port) – Swing motor (T port) q (10): Center swivel joint (E port) – Solenoid valve q (11): Center swivel joint (B port) – L.H. travel control valve (A2 port) q (12): Center swivel joint (D port) – R.H. travel control valve (B5 port) q (13): Center swivel joint (A port) – L.H. travel control valve (B2 port) q (14): Center swivel joint (C port) – R.H. travel control valve (A5 port) q
5.
Pull out pin (15) on the center swivel joint side, and remove the jam plate from center swivel joint. [*1]
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0)
Disconnect 6 center swivel joint horses (1) through (6) from the travel motor. q (1): Center swivel joint (T port) – L.H. travel motor (T port) q (2): Center swivel joint (T port) – R.H. travel motor (T port) q (3): Center swivel joint (B port) – L.H travel motor (PA port) q (4): Center swivel joint (D port) – R.H travel motor (PB port) q (5): Center swivel joint (A port) – L.H travel motor (PB port) q (6): Center swivel joint (C port) – R.H travel motor (PA port)
50-500
2
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of center swivel joint assembly
6.
Remove 4 pieces of mounting bolt (16).
SEN06146-00
Installation q
Installation is done in the reverse order of removal.
[*1] a Set the lock plate with red mark at upper side. [*2] Install the center swivel joint (CSJ) facing in the direction shown in the figure. (The figure shows the machine body as seen from above.) a S: Sprocket A – D: Port name
7.
Lift off center swivel joint assembly (17) to remove. [*1] 4
Center swivel joint assembly: 40 kg
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. 5
3
q
PC200, 200LC, 220, 220LC-8M0
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0) Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
50-500
3
500 Hydraulic system Disassembly and assembly of center swivel joint assembly
SEN06146-00
Disassembly and assembly of center swivel joint assembly
1
T1
Part name
2.
Remove cover (4).
3.
Remove snap ring (5) and ring (6).
4.
Using tool T1, pull out swivel shaft (8) from swivel rotor (7).
5.
Remove seal (9) and O-ring (10) from swivel rotor (7).
6.
Remove dust seal (11) from cover (12).
q 1
790-101-2501
Push puller
790-101-2510
• Block
1
790-101-2520
• Screw
1
791-112-1180
• Nut
1
790-101-2540
• Washer
1
790-101-2630
• Leg
2
790-101-2570
• Plate
4
790-101-2560
• Nut
2
790-101-2650
• Adapter
2
Disassembly
Remove elbows (1), (2) and tee (3).
Q’ty
Part number
Necessity
Symbol
Special tools
1.
Assembly
50-500
4
a
See figure at left.
1.
Install seal (9) and O-ring (10) to swivel rotor (7).
2.
Install dust seal (11) to cover (12).
3.
Install cover (12) to swivel shaft (8).
4.
Set swivel shaft (8) to block, then using push tool, tap swivel rotor (7) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G2-LI) a When installing rotor, be extremely careful not to damage the dust seal and O-ring.
5.
Install ring (6) and fix with snap ring (5).
6.
Fit O-ring and install cover (4). 3 Mounting bolts: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
7.
Install elbows (1), (2) and tee (3). 3 Elbow (1): 128 – 186 Nm {13 – 19 kgm} 3 Elbow (2), tee (3): 35 – 63 Nm {3.5 – 6.5 kgm}
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic tank assembly k
k
SEN06146-00
4.
Carry out item 5. – 19. of "Removal and installation of hydraulic pump assembly" and remove frame (2) between hydraulic tank and engine. For that purpose, remove below mainly. q Engine hood q Control valve upper cover q Cover between hydraulic pump and engine q Air cleaner upper cover
5.
Shift cover (3) forward. a Keep away from bolt (B).
6.
Remove covers (4) and (5).
1
Lower the work equipment to the ground completely, after the engine is stopped, loosen the hydraulic tank cap gradually to reduce the pressure inside, and set the lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery.
Removal a
Attach an identification tag to each piping to avoid a mistake in the position of installation later.
1.
Swing to right 45°. (For hydraulic tank oil drain)
2.
Remove cover (1).
3.
Drain hydraulic tank oil. 6
[*1]
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
50-500
5
SEN06146-00
7.
Disconnect drain hoses (6) through (8). q (6), (7): From control valve q (8): From oil cooler upper side
8.
Disconnect filter bracket (11).
9.
Remove frame (12).
500 Hydraulic system Removal and installation of hydraulic tank assembly
10. Disconnect drain hoses (13) through (18). q (13): Solenoid valve drain q (14): Main valve drain q (15): Pressure reducing valve drain q (16): PPC drain q (17): Swing motor drain q (18): Pump drain
11. Disconnect clamp (19). 12. Disconnect suction hose (20). [*2] a Mark the hose edge and tube to show the original hose installation positions. (See figure below.)
50-500
6
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of hydraulic tank assembly
13. Remove 6 mounting bolts (21).
[*3]
SEN06146-00
Installation q
Installation is done in the reverse order of removal.
[*1]
3
14. Lift off hydraulic tank assembly (22) to remove it. 4
Hydraulic tank assembly: 130 kg
PC200, 200LC, 220, 220LC-8M0
Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
[*2] a Use new MIKALOR clamps. 1) Apply adhesive evenly over the tube side. 2 Apply evenly over the tube side: Adhesive (THREEBOND No.4314) 2) Set the hose to the original position. a Reference Hose insertion length: 85 mm (L.H and R.H) 3) Set the bridge (BR) under the clamp bolt and lap it over band (BD) at least (b) reaches 5 mm. 4) Tightening of the clamp. a Do not use an impact wrench. 2 Clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) q
When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Clamp bolt (BC): Min. 6 Nm {0.6 kgm}
q
When using a new hose Tighten until dimension (BDG) is as follows. BDG: 7 – 10 mm
50-500
7
SEN06146-00
500 Hydraulic system Removal and installation of hydraulic tank assembly
[*3]
3
q
Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. 5
q
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0)
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
50-500
8
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of control valve assembly
Removal and installation of control valve assembly
SEN06146-00
4.
Disconnect connector (9) from clip. (From the top) V06 V05 V04 V03 V02 V01
5.
Disconnect clamp (10).
6.
Keep away solenoid assembly (11) from control valve bracket (B).
7.
See "Removal and installation of engine and hydraulic pump assembly" to remove below. q Engine hood q Control valve upper cover q Cover between hydraulic pump and engine q Frame between control valve and engine q Cover between control valve and engine
8.
Disconnect PLS1 port hose (12). a Hose band: No color
9.
Disconnect PLS2 port hose (13). a Hose band: red
1
Removal k
k k
a
1.
2.
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery. Release the remaining pressure in the hydraulic circuit. For details, see Testing and adjusting, "Releasing residual pressure from hydraulic circuit". Attach an identification tag to each piping to avoid a mistake in the position of installation later. Remove cover (1).
Drain hydraulic tank oil. a Make the swing angle almost 0° for below (3. – 6.) and to remove the control valve mounting bolt. 6
a
3.
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0) For the way not to drain the hydraulic tank oil by using oil stopper, see "Removal and installation of hydraulic pump assembly".
Disconnect drain hoses (2) through (8). (Band color) q (2): No color q (3): Red q (4): No color q (5): No color q (6): Red and yellow q (7): Brown q (8): No color
PC200, 200LC, 220, 220LC-8M0
50-500
9
SEN06146-00
10. Disconnect connectors V 23 (14) and V24 (15). a Band: (14) red, (15) white 11. Disconnect connectors (14) and (15) from clip. 12. Disconnect bracket (16).
500 Hydraulic system Removal and installation of control valve assembly
16. Disconnect hoses (20) through (23). a Hose band: No color q (20): relief valve q (21) – (23): If equipped 17. Disconnect L.H. PPC hose (24). From the top, Bucket DUMP (Hose band: black) L.H. travel reverse (Hose band: no color) Boom RAISE (Hose band: green) L.H. swing (Hose band: red) R.H. travel reverse (Hose band: blue) Arm OUT (Hose band: yellow) 18. Disconnect Ls separation hose (25). 19. Disconnect clamp (26).
13. Disconnect clamp (17). 14. Disconnect R.H. PPC hose (18). From the top, OPT (Hose band: yellow) Bucket CURL (Hose band: white) L.H. travel forward (Hose band: red) Boom LOWER (Hose band: brown) R.H. swing (Hose band: no color) R.H. travel forward (Hose band: green) Arm IN (Hose band: blue) 15. Disconnect hose (19). (Hose band: brown) q (19): PST port hose (solenoid)
50-500
10
20. Disconnect drain hose (27). a Disconnect the hose clamp.
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of control valve assembly
21. Disconnect connector P26 (28). (front pump pressure sensor) 22. Disconnect bracket (29), then bracket junction box (J).
23. Disconnect hoses (30) and (31). q (30): Between control valve and swing motor q (31): Between control valve and hydraulic tank
SEN06146-00
25. Disconnect hoses (32) through (36) from the rear side. q (32): PP1 port hose (rear pump) q (33): PPS2 port hose (front pump) Hose band: blue q (34): PR port hose (pump) Hose band: yellow q (35): PP2 port hose (front pump) q (36): Drain hose (hydraulic tank)
26. Disconnect connector P25 (37). (Rear pump pressure sensor) 27. Disconnect hoses (38) and (39). q (38): ATT port hose (filter) (If equipped) q (39): T port hose (under the oil cooler)
24. Disconnect back pressure compensation connector (31a). a Rear figure
PC200, 200LC, 220, 220LC-8M0
50-500
11
SEN06146-00
28. Remove boom tube mounting clamp (40).
500 Hydraulic system Removal and installation of control valve assembly
q
(46): From the top B-1 port hose (If equipped) B1 port hose (Bucket bottom side) B2 port hose (Swivel joint A port) B3 port tube (Boom head side) B4 port hose (Swing motor MB port) B5 port hose (Swivel joint D port) B6 port hose (Arm bottom side)
q
BP1 port hose (25) (above)
q
T1 port (drain) hose (27) (above)
29. Disconnect 4 boom hoses (41). 30. Disconnect horn (42) from bracket.
31. Remove boom tube mounting clamp (43).
32. Disconnect hose (44). 33. Disconnect 14 control valve hoses and 2 tubes. q (45): From the top A-1 port hose (If equipped) A1 port hose (Bucket head side) A2 port hose (Swivel joint B port) A3 port tube (Boom bottom side) A4 port hose (Swing motor MA port) A5 port hose (Swivel joint C port) A6 port hose (Arm head side)
50-500
12
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of control valve assembly
34. Remove mounting bolt, and lift off control valve assembly (47) to remove. 4
SEN06146-00
Installation q
Installation is done in the reverse order of removal.
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
Control valve assembly: 260 kg
5
3
q
PC200, 200LC, 220, 220LC-8M0
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0) Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
50-500
13
500 Hydraulic system Disassembly and assembly of control valve
SEN06146-00
Disassembly and assembly of control valve a
1
Procedures for replacing pressure compensation valve seal a
This section explains only the precautions for assembling the contol valve assembly. 1.
Part number 796-946-1310
Part name Guide f21.8 mm
(For 723-46-40100) 796-946-1610
Guide f21.4 mm
(For 723-46-41100) 2
796-946-1810
Guide f21.2 mm
(For 723-46-43100 and 723-46-43400) 796-946-1910
Guide f21.0 mm
(For 723-46-46101 and 723-46-46300) 796-946-2210
Guide f20.6 mm
(For 723-46-45100 and 723-46-45700) 796-946-1320
Guide f21.8 mm
(For 723-46-40100) 796-946-1620
Guide f21.4 mm
(For 723-46-41100) 796-946-1820 3 T
Guide f21.2 mm
(For 723-46-43100 and 723-46-43400) 796-946-1920
Guide f21.0 mm
(For 723-46-46101 and 723-46-46300) 796-946-2220
Guide f20.6 mm
(For 723-46-45100) 796-946-1420
Guide f21.6 mm
(For 723-46-42700) 796-946-1330
Sleeve
(For 723-46-40100) 796-946-1630
Sleeve
(For 723-46-41100) 796-946-1830 4
Sleeve
(For 723-46-43100 and 723-46-43400) 796-946-1930
Sleeve
(For 723-46-46101 and 723-46-46300) 796-946-2230
Sleeve
(For 723-46-45100) 796-946-1430
Sleeve
(For 723-46-42700)
50-500
14
Necessity Q’ty
Symbol
Special tools
2.
Since many types of pressure compensation valves are installed, put a mark on each and record the installed position when removing them. Remove piston (2), plug (3) and spring (4) from pressure compensation valve (1). Remove seals (5) and (6) from piston (2).
t 1 t 1 t 1 t 1 t 1
a
t 1
3. t 1 t 1 t 1
There are many types of pistons.
Place tool T2 on piston (2), put seal (5) on the tool, and then push the seal down slowly in such a way that it expands evenly to install it in position. a Put the seal on the tool and push it down to the flat part of the tool. Then you may install the tool to the piston to push in the seal further.
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of control valve
4.
Repeat the same process to install another seal (6). Place tool T3 on the same end of piston (2). Slowly push seal (6) down in such a way that it expands evenly to install it in position. a Put the seal on the tool and push it down to the flat part of the tool. Then you may install the tool to the piston to push in the seal further.
5.
Install settling tool T4 on piston (2) and keep it installed for approximately one minute so that seals (5) and (6) fit in. a Check that there is no extrusion or cut on the seal.
6.
Fit plug (3) and spring (4) to piston (2), then install pressure compensation valve (1).
PC200, 200LC, 220, 220LC-8M0
SEN06146-00 a
After the installation, push piston (2) by hand and check that the piston returns with the spring force alone.
50-500
15
500 Hydraulic system Disassembly and assembly of control valve
SEN06146-00
Assembly of control valve
a a a
q
a
a
Assemble filter (9) installed to the bottom ports (PLS1) and (PLS2) in the direction shown in the figure below. (Pay attention to the position of caulked portion (10).)
Apply engine oil to the sliding surfaces before assembling. When installing spool (7) to the valve chamber, set drilled hole (H1) to the direction shown in the following figure. Do the same with section L-L.
When installing spool (8) to the valve chamber, set drilled hole (H2) to the direction shown in the following figure. Do the same with H-H, K-K and M-M shown in the sectional view.
50-500
16
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of control valve
PC200, 200LC, 220, 220LC-8M0
SEN06146-00
50-500
17
500 Hydraulic system Disassembly and assembly of control valve
SEN06146-00
q
Upper and lower control valve covers 2 Mating face of upper and lower control valve cover blocks (11): Loctite 222 or equivalent a Tighten the mounting bolts of the control valve upper and bottom cover blocks in the following order. (A → D → C → B) 3 Mounting bolts for control valve upper and lower cover blocks: 156.9 – 176.5 Nm {16 – 18 kgm}
q
a
q
q
q
q
q
q
Merge-divider valve 2 Merge-divider valve mating face (12): Loctite 222 or Sealend 242 equivalent a Tighten the mounting bolts of mergedivider valve in the same order as that for the control valve cover block. 3 Merge-divider valve mounting bolt: 156.9 – 176.5 Nm {16 – 18 kgm} Variable back pressure valve a Tighten the mounting bolts of the variable back pressure valve in the same order as that for the control valve cover block. 3 Variable back pressure valve mounting bolt: 58.8 – 73.6 Nm {6 – 7.5 kgm} Boom drift prevention valve a Tighten the mounting bolts of the boom hydraulic drift prevention valve in the same order as that for the control valve cover block. 3 Mounting bolt of boom hydraulic drift prevention valve: 58.8 – 73.6 Nm {6 – 7.5 kgm} Arm quick return valve a Tighten the mounting bolts of the arm quick return valve in the same order as that for the control valve cover block. 3 Mounting bolt of arm quick return valve: 58.8 – 73.6 Nm {6 – 7.5 kgm}
50-500
18
Arm drift prevention valve a Tighten the mounting bolts of the arm hydraulic drift prevention valve in the same order as that for the control valve cover block. 3 Mounting bolt of arm hydraulic drift prevention valve: 58.8 – 73.6 Nm {6 – 7.5 kgm} After assembling, put stoppers to prevent cleaning solvent from entering through f12 holes (13). Pressure compensation valve a Install each pressure compensation valve paying attention to the matchmark that was put when removing it. 3 Pressure compensation valve: 372.7 – 411.9 Nm {38 – 42 kgm} Main relief valve assembly a After installing to the control valve, check and adjust them. For details, see Testing and adjusting, "Measuring and adjusting oil pressure in work equipment, swing, and travel circuits". 3 Main relief valve assembly: 49 – 58.8 Nm {5 – 6 kgm}
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of hydraulic pump assembly
Removal and installation of hydraulic pump assembly
SEN06146-00
3.
Remove cover (1).
4.
Temporarily sling engine hood (2). a When slinging the engine hood, take care not to damage the rubber seal.
5.
Remove pins (3) and (4), then remove 2 gas springs (5).
6.
Lift off engine hood (2) to remove it.
7.
Remove cover (7).
1
A
Part number
Part name
Necessity Q’ty
Symbol
Special tools
10 796-460-1210
Oil stopper
q 1
11 796-770-1320
Adapter
q 1
Removal k
k
a
Lower the work equipment to the ground completely, after the engine is stopped, loosen the hydraulic tank cap gradually to reduce the pressure inside, and set the lock lever in the lock position. Disconnect the cable from the negative (–) terminal of the battery. Attach an identification tag to each piping to avoid a mistake in the position of installation later.
1.
Swing to right 45°. (For hydraulic tank oil drain)
2.
Remove hydraulic tank strainer and stop oil flow-out using tools A10, A11. a If tools A10, A11 are not used, remove the drain plug and drain oil from the hydraulic tank and piping. 6
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
50-500
19
SEN06146-00
500 Hydraulic system Removal and installation of hydraulic pump assembly
8.
Disconnect hose (8a).
14. Disconnect clamp (14).
9.
Remove cover (8).
15. Remove filter and bracket assembly (15). a Put it on hose bracket (HB).
10. Remove frame (9). 11. Remove cover (10). 12. Remove frame (11). 13. Remove covers (12) and (13). a Cover (13) cannot be removed unless removing cover (7).
16. Disconnect 6 hoses. q (16): Rear load pressure input port hose (Color band: No color) q (17), (18): EPC basic pressure port hose (Color band: No color) q (19): Pump pressure input port hose (Color band: Blue) q (20): Front load pressure input port hose (Color band: Red) q (21): Drain port hose 17. Disconnect bracket (22).
50-500
20
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of hydraulic pump assembly
18. Disconnect 4 hoses and 1 tube. q (23): Branch hose q (24): Rear pump discharge port hose q (25): Front pump discharge port hose q (26): Pump suction port tube
SEN06146-00
22. Remove clip (32). 23. Remove clamp (33).
24. Remove muffler bracket (34). 19. Drain oil from the damper case. 6
Damper case: 0.65 l
20. Disconnect pump wiring connectors at 4 points. q (27): V12 PC-EPC R solenoid valve (Color band: yellow) q (28): P22 hydraulic oil temperature sensor (Color band: no color) q (29): V19 LS-EPC solenoid valve (Color band: red) q (30): V11 PC-EPC R solenoid valve (Color band: white) a Located behind muffler bracket (31). 21. Disconnect bracket (31).
PC200, 200LC, 220, 220LC-8M0
25. Lift off hydraulic pump assembly (35) to remove the mounting bolt. [*1] a Muffler drain tube (36) is double tightened.
50-500
21
SEN06146-00
26. Lift off hydraulic pump assembly (37) to remove it. [*1] 4
500 Hydraulic system Removal and installation of hydraulic pump assembly
Installation q
Hydraulic pump assembly: 220 kg
Installation is done in the reverse order of removal.
[*1]
2
Hydraulic pump involute spline: Antifriction agent (LM-G) 2 Mating face of the hydraulic pump case: Gasket sealant (LG-6) a Since flywheel housing is made of aluminum, be careful not to over torque. a Impact wrench is not applicable to use. q
Refilling with oil (damper case) Refill hydraulic oil through the oil filler port to the specified level. 5
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. 5
3
q
50-500
22
Damper case: EO30-DH, 0.65 l
Hydraulic tank: 237 l (PC200/200LC-8M0) 244 l (PC220/220LC-8M0) Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Removal and installation of oil seal in hydraulic pump input
SEN06146-00
Special tools
[*1]
Part number
S
796T-467-2410
Part name Push tool
Necessity Q’ty
Installation
Symbol
Removal and installation of oil seal in hydraulic pump input shaft1
t 1
q
Installation is done in the reverse order of removal.
2
Oil seal lip portion: Grease (G2-LI) Oil seal outer periphery: Grease (G2-LI) Coat the oil seal outer circumference thinly with grease. Press fit oil seal (3) with tool S, [1], [2].
2
a a
Removal 1.
Remove the hydraulic pump assembly referring to the section of "Removal and installation of hydraulic pump assembly".
2.
Remove snap ring (1) and then remove spacer (2).
3.
Pry off oil seal (3) with a screwdriver. [*1] a Take care in removing the oil seal so that the shaft may not be damaged.
PC200, 200LC, 220, 220LC-8M0
50-500
23
SEN06146-00
500 Hydraulic system Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of work equipment PPC valve assembly
a
Only precautions for assembling the work equipment PPC valve assembly are explained below.
Assembly a
Disassembly a
Spring (6) and spring (7) consist of each one of two types of springs with different installed loads in four places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing.
a
a
a
50-500
24
1
Before assembly, thoroughly clean the parts and check them for dirt, rust, or damage to prevent failure. Assemble the parts with utmost care. Install spring (5) with its small diameter side on the shim (4) side. q Diameter of spring (Inside diameter) Small diameter side: f4.9 mm Large diameter side: f5.55 mm When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports. q Installed height: 31.9 mm (Common to both springs) q Installed load: Spring (6) (P1, P2): 35.3 N {3.6 kg} Spring (7) (P3, P4): 21.6 N {2.2 kg} When installing piston (8), apply grease (G2LI) to its outside and the inside of the body (1) hole. 3 Bolt (11): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of work equipment PPC valve
a
When installing joint (12) to body (1), apply LOCTITE as shown below. 1) When installing the joint, apply 1 drop (approx. 0.02 g) of LOCTITE (No. 262) each to 2 places of the female screw (A) of the body. Before installing the joint, thoroughly degrease and dry its male screw and the female screw of the body with DRYSOL. 2) Drop LOCTITE to the following positions. 2 Female screw (A) of body: LOCTITE No. 262 3 Joint (12): 39 – 49 Nm {4 – 5 kgm}
a
Apply grease (G2-LI) to the sliding parts of joint (12) and contact surfaces of disc (13) and piston (8). 2 Quantity of grease (G2-LI) The sliding portions of the joint (J portion): Apply grease (G2-LI) 7 – 10 ml to entire circumference. The sliding portions of the joint (P portion): Apply gear oil 0.2 – 0.4 ml to the sliding portions (4 places) between the joint and pin. Contact surfaces of disc and piston: 0.3 – 0.8 cc/place When assembling disc (13), adjust it so that the end play of the lever will be 0.5 – 3 mm at 200 mm from the center of revolution. a See Testing and adjusting, "Adjusting play of work equipment and swing PPC valve". a Tighten nut (14) to the following tightening torque. 3 Nut (14): 69 – 88 Nm {7 – 9 kgm}
a
PC200, 200LC, 220, 220LC-8M0
SEN06146-00
50-500
25
SEN06146-00
500 Hydraulic system Disassembly and assembly of travel PPC valve
Disassembly and assembly of travel PPC valve
1
Figure of structure
Disassembly 1.
Remove screws (19) and remove damper assemblies (18).
2.
Remove mounting bolt (17) and remove case (16), shafts (15) and levers (13) as a unit.
3.
Remove mounting bolts (11) to remove plate (10). a Note the thickness and installed position of washer (12). a Remove pin (21) from valve body (1).
4.
Remove seals (9) and collars (8).
5.
Remove pistons (7), and then to remove retainers (6), springs (5) and (4), and shims (3). a Note the installed position, quantity and thickness of shims (3) and keep them.
6.
Remove valves (2) from valve body (1).
50-500
26
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of travel PPC valve
SEN06146-00
Assembly a a
Only precautions for assembly are described. Before assembly, thoroughly clean the parts and check them for dirt, rust, or damage to prevent failure. Assemble the parts with utmost care. a When installing piston (7), apply grease (G2LI) to its periphery and the inside of the valve body hole. a Install spring (4) with its small diameter end facing shim (3). q Diameter of spring (inside diameter) Small diameter end: f 4.9 mm Large diameter end: f 5.55 mm a Apply grease (G2-LI) to the rocking parts of shaft (15), contact surfaces on lever (13) and piston (7), and contact surfaces on damper (18) and pin. 2 Grease (G2-LI) Rocking parts of shaft (15): 4 to 8 cc/entire periphery Contact surfaces on lever (13) and piston (7): 0.3 to 0.8 cc/part Contact surfaces on damper (18) and pin: 0.3 to 0.8 cc/part a For washer (12), install the one 1.6 mm in thickness (t) first. If the difference in the lever angle between right and left when the lever is at full stroke position exceeds 0.7 degree, change the thickness of the washer to make the difference 0.7 degree or smaller. a If the thickness of the washer is reduced by 0.3 mm, the full stroke angle of the lever increases by 0.39 deg. q Settings of thickness (t) of washer (12): 1.0, 1.3, 1.6, 1.9, 2.2 mm a Tighten each part to the following torque. 3 Bolt (11): 27 to 34 Nm {2.8 to 3.5 kgm} 3 Bolt (17): 25 to 31 Nm {2.5 to 3.2 kgm} 3 Screw (19): 0.441 to 0.588 Nm {0.045 to 0.06 kgm}
PC200, 200LC, 220, 220LC-8M0
50-500
27
500 Hydraulic system Disassembly and assembly of work equipment cylinder
SEN06146-00
Disassembly and assembly of work equipment cylinder
Disassembly 1
1 2
Part number 790-502-1003
Cylinder repair stand
q 1
790-101-1102
Pump
q 1
790-102-4300
Wrench assembly
t 1
790-102-4310
Pin
t 2
Expander
q 1
796-720-1670
Rubber band (for boom and bucket))
q 1
07281-01279
Clamp
q 1
796-720-1680
Rubber band (for bucket)
q 1
07281-01589
Clamp
q 1
790-201-1702
Push tool kit
t 1
790-201-1841
• Push tool (for boom and bucket)
1
790-201-1851
• Push tool (for arm)
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
3 790-720-1000
4
U
5
6
Part name
Necessity Q’ty
Symbol
Special tools
Push tool kit
790-201-1650
• Plate (for boom and bucket)
1
790-201-1660
• Plate (for arm)
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
28
2.
Remove 12 mounting bolts and disconnect cylinder head assembly (1).
3.
Pull out piston rod assembly (2). a Place a container under the cylinder to collect oil from the cylinder.
Disassembly of piston rod 1. Set piston rod assembly (2) on tool U1.
t 1
790-201-1500
50-500
Disconnection of cylinder assembly and piston rod assembly 1. Remove the piping from the cylinder assembly.
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of work equipment cylinder
2.
Using a hexagonal wrench (6 mm), remove lock screw (3) at the end of piston assembly (4). a Above operation is common to the boom, arm and bucket cylinder. q Screw size: M12 x 1.75 mm (16 mm in length)
a
SEN06146-00
4.
Remove plunger (5) and collar (6). a Only for the arm and boom cylinders
5.
Remove cylinder head assembly (7).
6.
Remove cap (8) to remove 12 balls (9), and remove plunger (10). a Arm cylinder only
If screw (3) is caulked too firmly to be loosened, squeeze the screw further once and then apply tap (T) to the threaded portion to ease the caulking.
Disassembly of piston 1. Remove two rings (11). 3.
Using tool U2, remove piston assembly (4). a When not using tool U2, use the drilled holes (H) (f10 mm, two places) to loosen the piston assembly.
PC200, 200LC, 220, 220LC-8M0
2.
Remove two wear rings (12).
3.
Remove piston ring (13).
4.
Remove the O-ring and two backup rings (14).
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29
SEN06146-00
500 Hydraulic system Disassembly and assembly of work equipment cylinder
Disassembly of cylinder head 1. Remove the O-ring and backup ring (15).
Assembly
2.
Remove snap ring (16), then remove dust seal (17).
a
3.
Remove rod packing (18) and buffer ring (19).
a
4.
Remove snap ring (30).
5.
Remove bushing (20).
a
Be careful not to damage the packings, dust seals, O-rings, etc. Clean each part. After assembling the cylinder, cover the piping ports and pin holes to prevent entering of dirt. Before installing the backup ring, warm it in hot water of approximately 50 to 60°C. Do not attempt to force it into position.
Assembly of cylinder (only for arm cylinder) 1. Install valve (23) and spring (22). 2.
Install plug (21) with O-ring (24). a Clean, degrease, and dry the thread portion of the plug, and then apply liquid gasket to the entire periphery of the thread portion. 3 Plug (21): 83.4 – 102.9 Nm {8.5 – 10.5 kgm} 2 Plug (21): Liquid gasket (LG-5)
Disassembly of cylinder (arm cylinder only) 1. Remove plug (21). 2.
Remove spring (22) and valve (23).
50-500
30
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of work equipment cylinder
Assembly of cylinder head 1. Using tool U5, press fit bushing (20). 2.
Install snap ring (30).
3.
Install buffer ring (19) and rod packing (18).
4.
Install dust seal (17) using tool U6, and install snap ring (16).
5.
Install backup ring (15) and the O-ring.
PC200, 200LC, 220, 220LC-8M0
SEN06146-00
Assembly of piston 1. Set piston ring (13) on tool U3. Expand piston ring (13) by turning the handle 8 to 10 turns. 2.
Remove piston ring (13) from tool U3. Install the ring to the piston.
3.
Using tool U4, compress piston ring (13).
4.
Install two backup rings (14) and the O-ring. a Install the backup rings and O-ring as shown in the figure below.
5.
Install wear rings (12) (2 pieces).
6.
Install wear rings (11) (2 pieces). a Be careful not to open the end gap of the ring too wide.
50-500
31
SEN06146-00
Assembly of piston rod 1. Set piston rod assembly (2) to tool U1.
2.
Install cylinder head assembly (7).
3.
Install the O-ring and the backup rings to collar (6) and install the collar to the piston rod. a Install the two backup rings, one each in the front and rear of the O-ring. a Only the boom and arm cylinders
4.
Install plunger (5). a Only the boom and arm cylinders
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32
500 Hydraulic system Disassembly and assembly of work equipment cylinder
5.
Place plunger (10) on piston rod assembly (2). Install 12 balls (9) and cap (8). a After installing the plunger, check that there is a little play at its end. a Arm cylinder only
6.
If both of piston rod assembly (2) and piston assembly (4) are to be reused, assemble them according to the following procedure. (If either or both of them are to be replaced with new ones, see Step 7.) 1) Using tool U2, install piston assembly (4) to piston rod assembly (2). a Any burrs or sharp edges on threaded portions must be removed using files before installation.
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of work equipment cylinder
a
a
SEN06146-00 3
Fully tighten piston assembly (4) until it contacts with end face (b) of the rod. Then, at around this position, align screw holes (H) in the piston and piston rod end face. For a cylinder with a head cushion, ensure that there is a small play in plunger (5) with piston assembly (4) installed. q Only the boom and arm cylinders
a
2) 2)
Install screw (3) to lock piston assembly (4) and piston rod assembly (2). 2 Screw (3) thread portion: Adhesive (Loctite #262) 3 Screw (3): 58.9 – 73.6 Nm {6 – 7.5 kgm} a After installing screw (3), caulk the screw at four peripheral places (a).
Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} For a cylinder with a head cushion, ensure that there is a little play in plunger (5) with piston assembly (4) installed. q Only the boom and arm cylinders
Drill a screw hole across the threads of piston rod assembly (2) and piston assembly (4). a With a drill aligned with the V groove where the threads of piston assembly (4) and piston rod assembly (2) are mated, drill a hole straight. a The cylinder with the bottom cushion must not be machined in the cushion cap machining hole position. q Dimensions of screw hole (mm): Tap drill diameter Tap drill hole depth Screw hole size Screw hole depth
a
7.
10.3 27 12 x 1.75 20
After tapping the screw hole, remove chips and other dirt and thoroughly clean the area.
When replacing either or both of piston rod assembly (2) and piston assembly (4) with new ones, assemble the new ones according to the following procedure. 1) Using tool U2, screw in piston assembly (4) until it comes into contact with end face (b) of the rod. a If the cylinder has the bottom cushion, put a mark on the rod end face to indicate the tightening position of the ball cap.
PC200, 200LC, 220, 220LC-8M0
50-500
33
SEN06146-00
3)
Install screw (3) to lock piston assembly (4) and piston rod assembly (2). a After installing screw (3), caulk the screw at four peripheral places (a). 2 Screw (3) thread portion: Adhesive (Loctite #262) 3 Screw (3): 58.9 – 73.6 Nm {6 – 7.5 kgm}
500 Hydraulic system Disassembly and assembly of work equipment cylinder
2.
Install the cylinder assembly to piston rod assembly (2). a Align axial center of the cylinder tube, then insert. a Check that the ring is not broken and has not come out, then push in fully.
3.
Tighten the mounting bolts for cylinder head assembly (1). 3 Cylinder head assembly (1) mounting bolt: Boom cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm} Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5 kgm} Bucket cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm}
4.
Install piping. 3 Piping fixing band mounting bolt: Boom cylinder: 27 ± 7 Nm {2.8 ± 0.7 kgm} Arm and bucket cylinder: 89 ± 34 Nm {9.0 ± 3.5 kgm}
Connection of cylinder assembly and the piston rod assembly 1. Install piston rod assembly (2) to tool U1.
50-500
34
PC200, 200LC, 220, 220LC-8M0
500 Hydraulic system Disassembly and assembly of work equipment cylinder
PC200, 200LC, 220, 220LC-8M0
SEN06146-00
50-500
35
SEN06146-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06146-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-500
36
SEN06147-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly1 600 Work equipment Removal and installation of work equipment assembly .................................................................................. 2
PC200, 200LC, 220, 220LC-8M0
50-600
1
600 Work equipment Removal and installation of work equipment assembly
SEN06147-00
Removal and installation of work equipment assembly
5.
Part number 796-900-1200
V
Part name Remover
Essentiality Quantity
Symbol
Special tools
t 1
796-900-1210
• Sleeve
1
792-900-1520
• Plate
1
799-900-1230
• Screw
1
796-900-1240
• Adapter
1
01643-33080
• Washer
1
01803-13034
• Nut
1
790-101-4000
Puller (490 kN {50 ton} long)
t 1
790-101-1102
Pump (294 kN {30 ton})
t 1
6.
7.
Start the engine and then retract the piston rod. a Bind the piston rod with wire etc. and put it down on the blocking tools so that the piston rod does not slip out, or allot a support so that the cylinder doesn't fall down to the bottom side. If a support is allotted, remove the grease fitting at the bottom side. a Remove the boom cylinder on the other side in the same manner. a If bumping of the lifting hook against the work equipment lamp is anticipated in lifting the work equipment, the lamp must be removed. Disconnect 2 pieces of bucket cylinder hose (6) and 2 pieces of arm cylinder hose (7). a Apply the oil restraining plug and then fix the hoses to the valve side by use of ropes. Disconnect intermediate connector for working lamp A13 (8).
Removal k
k
k
1. 2. 3. 4.
Safely lower the work equipment to the ground by extending the arm and the bucket completely. Set the lock lever in the lock position, After performing step 5, release the residual pressure in the hydraulic circuit. Refer to the "Releasing residual pressure from hydraulic circuit" section in the Testing and adjusting chapter of this manual. Disconnect the cable from the negative (–) terminal of the battery. Disconnect grease hose (1). Sling the boom cylinder assembly (2). Remove lock bolt (3). Remove plate (4) and remove the head pin. [*1] a Check the number as well as locations of the shims used.
50-600
2
PC200, 200LC, 220, 220LC-8M0
600 Work equipment Removal and installation of work equipment assembly
8.
Lift the work equipment assembly, remove plate (9) and pin (10) at the foot. [*2]
SEN06147-00
Installation q
Installation is done in the reverse order of removal.
[*1]
2
Inside surface of bushing when assembling pin: Molybdenum disulfide lubricant (LMP) 2 Greasing after assembling the pin: Grease (LM-G) k When aligning the position of the pin hole, never insert your fingers into the pin hole. a st1: resin shim (thickness 1.0 mm) a Adjust the clearance (b) between cylinder rod (12) and plate (4) to 1.5 mm or less using shims: 1.0 and 2.0 mm q
a
In case to remove using tool V Remove plate (9) and remove pin (10) at the foot using tool V. Check the number as well as locations of the shims used.
[*2]
2
9.
Remove work equipment assembly (11). 4
Work equipment assembly: 3,450 kg (PC200/200LC-8M0) 4,450 kg (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
Inner surface of bushing as assembling the pin: Anti-friction compound (LM-P) 2 Feed grease after assembling pin: Grease (LM-G) a Adjust the clearance (c) between the foot's end face of boom (13) and bracket (14) to 1 mm or less by use of shims. Thickness of standard shim: 2.0, 2.5, 3.0 and 3.5 mm
50-600
3
SEN06147-00
q
Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, "Bleeding air from each part".
q
Refilling with oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
50-600
4
600 Work equipment Removal and installation of work equipment assembly
PC200, 200LC, 220, 220LC-8M0
600 Work equipment Removal and installation of work equipment assembly
PC200, 200LC, 220, 220LC-8M0
SEN06147-00
50-600
5
SEN06147-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06147-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-600
6
SEN06148-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly 700 Cab and its attachments Removal and installation of operator's cab assembly ..................................................................................... 2 Removal and installation of operator cab glass (stuck glass) ......................................................................... 5 Removal and installation of front window assembly ..................................................................................... 15 Removal and installation of floor frame assembly ........................................................................................ 22 Removal and installation of air conditioner unit assembly ............................................................................ 26
PC200, 200LC, 220, 220LC-8M0
50-700
1
SEN06148-00
Removal and installation of operator's cab assembly
700 Cab and its attachments Removal and installation of operator's cab assembly
9.
Remove rear covers (10) to (13).
Removal k
Disconnect the cable from the negative (–) terminal of the battery.
1. 2. 3.
Remove front window (1). Remove step plate (2). Remove floor mat (3).
4.
Refer to “Removal and installation of monitor assembly“, and remove monitor assembly (4).
5. 6.
Remove covers (5) and (6). Remove cover and duct assembly (7).
10. Remove duct (14). 11. Remove cover (15). a Disconnect connector H15 fixed on the back from the clip. 12. Remove plate (16).
7. 8.
Insert key (8), turn it right, and open the outside-air filter cover. Remove outside-air filter (9). 13. Remove plate (17). 14. Remove lock pin (18) and remove duct (19).
50-700
2
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator's cab assembly
SEN06148-00
15. Remove duct (20). 16. Disconnect connector L03 (21). 17. Remove plates (22) and (23) from the operator cab.
23. Remove ducts (32) and (33). 24. Disconnect wiper motor connector M05 (34). 25. Remove harness (35) and antenna (36) from the cab wall.
18. Pass over and disconnect antennas (24) and (24a) from KOMTRAX communication modem (K). 19. Disconnect connectors CK01(25) and CK02 (26). 20. Disconnect connector M10 (27) from the operator's cab. (If equipped)
26. Remove duct (37) upper and lower. 27. Remove duct (38) upper and lower.
21. Disconnect cab wiring intermediate connectors H09 (28), H08 (29), and H16 (30). 22. Disconnect radio antenna (31).
28. Disconnect window washer hose (39). 29. Disconnect harness clamp (40). 30. Haul in antenna (36).
PC200, 200LC, 220, 220LC-8M0
50-700
3
SEN06148-00
31. Disconnect harness clamp (41) from the right back side of cab.
700 Cab and its attachments Removal and installation of operator's cab assembly
35. Lift off and remove operator's cab assembly (47). 4 Operator's cab assembly: 470 kg
32. Remove bolt (42) under the cab and remove lock plate (43). [*1] 33. Remove bolt (44). [*2]
Installation q
[*1]
[*2]
Installation is done in the reverse order of removal. 3
3
Mounting bolt (42) of lock plate (43): 98 – 123 Nm {10 – 12.5 kgm} Bolt (44): 245 – 309 Nm {25 – 31.5 kgm}
34. Remove 6 mounting bolts (45) and 4 mounting nuts (46). a Check the bolt length beforehand.
50-700
4
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator cab glass (stuck
SEN06148-00
Removal and installation of operator cab glass (stuck glass)
a Among the panes of window glass on the 4 sides of the operator's cab, 5 panes (1) to (4) and (18) are stuck. a In this section, the procedure for replacing the stuck glasses is explained. a When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) a For the procedure for replacing the front window assembly, see “Removal and installation of front window assembly“.
PC200, 200LC, 220, 220LC-8M0
(1) (2) (3) (4) (5)
: Right side window glass : Left side rear window glass : Door lower window glass : Front window glass : Front window assembly (Front window glass + Front frame) (6) : Dam rubber (17) : Center trim seal (18) : Rear glass
50-700
5
700 Cab and its attachments Removal and installation of operator cab glass (stuck
SEN06148-00
X
Part number
Part name
Necessity Q’ty
Symbol
Special tools
2 793-498-1210
Lifter (Suction cup)
t 2
3 20Y-54-13180
Stopper rubber
t 2
(The figure shows the operator's cab of a wheel loader.)
Removal a Remove the window glass to be replaced according to the following procedure. 1. Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet)(8). a a
If the window glass is broken finely, it may be removed with a knife [4] and a screwdriver. Widening the cut with a flat blade screwdriver, cut the dam rubber and adhesive with knife [4].
(The figure shows the operator's cab of a wheel loader.)
a
If a seal cutter is not available, make holes on the adhesive and dam rubber with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Then, grip the both ends of the wire with pliers [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and dam rubber. Since the wire may be broken by the frictional heat, apply lubricant to the wire. 2.
50-700
6
Remove the window glass.
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator cab glass (stuck
Installation 1.
Using a knife and scraper [5], remove the remaining adhesive and dam rubber from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and dam rubber to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.)
SEN06148-00 a
1)
(The figure shows the operator's cab of a wheel loader.) 2)
Remove oil, dust, and dirt, etc. form the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at lease 5 minutes to dry. (The figure shows the operator's cab of a wheel loader.)
Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is unpacked.) Stir the primers for both of paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer and glass primer.
2.
3.
3)
Evenly apply the paint primer to the surfaces to stick dam rubber and its outside surfaces to apply adhesive on operator's cab (8). 2 Paint primer: Sunstar primer for painting plane 580 super or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
Apply primer (10). a The using limit of primer is 4 months after the date of manufacture. Do not use the primer after this limit. a Use the primer within 2 hours after unpacking it.
PC200, 200LC, 220, 220LC-8M0
50-700
7
SEN06148-00 a q
Parts to be coated with primer; Apply the primer all over dimension (a). Dimension to apply primer (a): 25 mm
700 Cab and its attachments Removal and installation of operator cab glass (stuck
a Never apply the wrong primer. If the glass primer, etc. is applied by mistake, wipe it off with white gasoline. 4)
a
q q
a
Apply the glass primer to the sticking surfaces of window glass (9). 2 Glass primer: Sunstar primer for glass 580 super or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
In addition to the above parts, additionally apply the primer to right side window glass (1) and door lower window glass (3). Range to apply primer additionally for right side window glass (1): (b) Range to apply primer additionally for door lower window glass (3): (c) After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a
a
a a
50-700
8
Parts to be coated with primer; Apply the primer to all around of sticking surface (d) of window glass (9) for dam rubber (6) installation position and operator's cab (8). Do not apply the primer to the boarder about 5mm wide between the black part and transparent part of the glass. After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Never apply the wrong primer. If the paint primer, etc. is applied by mistake, wipe it off with white gasoline.
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator cab glass (stuck
4.
SEN06148-00
Stick dam rubber (both-sided adhesive tape)(6) along the inside edge of the glass sticking section. a Do not remove the release tape of dam rubber on the glass sticking side before sticking the glass. a When sticking the dam rubber, do not touch the cleaned surface to the utmost. a Care should be taken not to float the dam rubber of each sticking corner.
2)
a
1)
Stick dam rubber (6) for left side window glass (2) to the position as shown in the figure.
When sticking dam rubber (6) around a frame, do not lap its finishing end over the starting end. Or, make clearance of about 5 mm between them (e). Stick dam rubber (6) for right side window glass (1) to the position as shown in the figure.
a q
Stick dam rubber (6a) additionally to right side window glass (1). Positions to stick additional dam rubber to the right side window glass: (f): 50 mm (g): 90 mm (h): 250 mm
PC200, 200LC, 220, 220LC-8M0
50-700
9
SEN06148-00
3)
50-700
a
Stick dam rubber (6) for door lower window glass (3) to the position as shown in the figure.
a
4)
700 Cab and its attachments Removal and installation of operator cab glass (stuck
Stick dam rubber (6b) additionally to door lower window glass (3). q Positions to stick additional dam rubber to the door lower window class: (j) : 110 mm (k) : 90 mm (m) : 200 mm
Stick dam rubber (6) for front window glass (4) to the position as shown in the figure.
10
5.
Stick dam rubber (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other dam rubbers (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)
Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then position the window glass to be the clearances evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line (n). a Stick tapes [6] for positioning to 3 points, that is, right, left and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, etc. and then remove the window glass. a Do not remove the tapes left on the window glass and the operator's cab before installing the window glass.
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator cab glass (stuck
a
6.
When positioning front window glass (4), set its horizontal position to the frame width. And set its vertical position to make the height difference (p) between the frame top and the front window glass 3 mm.
Apply adhesive. a Use either of two types of adhesives according to the season. 2 Adhesive (Apr. to Oct.): Sunstar penguine seal 580 super “S“ or equivalent 2 Adhesive (Oct. to Apr.): Sunstar penguine seal 580 super “W“ or equivalent a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part form the nozzle tip. 1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
PC200, 200LC, 220, 220LC-8M0
SEN06148-00
2)
Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. q Dimension (q): 10 mm q Dimension (r): 15 mm
3)
Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
50-700
11
SEN06148-00
4) 5)
700 Cab and its attachments Removal and installation of operator cab glass (stuck
Remove the release tape of dam rubber on the glass adhesive side. Apply adhesive (15) to the outside of dam rubber (6) of the operator's cab.
a
a a
Apply adhesive (15) with dimensions (s) and (t) for dam rubber (6) of operator's cab (8). q Dimension (s): 10 mm q Dimension (t): 15 mm Apply adhesive (15) higher than dam rubber (6). Apply the adhesive evenly with same height level.
7.
a
50-700
12
Apply adhesive (15) additionally to additional dam rubber (6a) of right side window glass and additional dam rubber (6b) of door lower window glass.
Install the window glass. 1) Install window class (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it with utmost caution. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around of it until it sticks to the dam rubber closely. a Press the corners of the window glass firmly.
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of operator cab glass (stuck
a
SEN06148-00
You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup X2.
a
After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range (s) with dimensions (t) and (u). After applying the primer to glass (4) of section A-A, apply the adhesive as caulking material. q Caulking dimension (t): 2 mm q Caulking dimension (u): 5 mm a When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. a Wipe off the projected adhesive. 2 Glass primer: Sunstar primer for glass 580 super or equivalent 2 Adhesive: SUNSTAR penguine seal 580 super “S“ or “W“ or equivalent
PC200, 200LC, 220, 220LC-8M0
50-700
13
SEN06148-00
8.
Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers X3 to 2 places (v) at the bottom of the glass to fix the glass.
700 Cab and its attachments Removal and installation of operator cab glass (stuck
9.
After installing the window glass, remove any excess of the primer and adhesive from the operator's cab and window glass. a By using the white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact on it.
10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours. (at temperature of 20°C and humidity of 60%) 2) After removing the stopper rubbers, styrene foam blokes, and rubber bands, wait at least 14 hours, that is, at least 24 hours in total, before operating the machine actually.
2)
50-700
By using styrene foam blocks [9] and rubber bands [10], fix the window glass and the dam rubber to fit them completely.
14
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of front window assembly
SEN06148-00
Removal and installation of front window assembly k
Lower the work equipment completely to the ground and stop the engine. a To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.
Removal 1.
Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides).
2.
Remove left corner block (1) and right corner block (2). [*1] a
Mounting bolt (4) and washer (3) for left corner block are used to hang the pull-up assist cable in the following step 6.
6.
3.
Release the rear lock of the cab.
4.
Lower the front window assembly carefully a little. Put out rollers (5) and (6) under the both sides of the front window through the portion from which the corner blocks were removed in the above step 2. (the portion where the rail is open) and hold them.
5.
Remove rollers (5) and (6) under the both sides of the front window.
PC200, 200LC, 220, 220LC-8M0
Remove left lower pin (7). [*2] a By removing left lower pin (7), plate (8) at the end of pull-up assist cable (9) comes off. a Hang plate (8) on the mounting bolt of left corner block (use washer) and set in place. k The return load of 58.8 N {6 kg} is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (7) to disconnect pull-up assist cable (9).
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SEN06148-00
700 Cab and its attachments Removal and installation of front window assembly
9.
7.
Pull out the bottom of front window assembly (10) though the rail opening portion and lower it gradually.
8.
Lower front window assembly (10) completely. a Do not let the front window assembly touch the monitor.
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16
Twist front window assembly (10) to the right and left to remove both upper rollers (11) and (12) from the rails, and then remove front window assembly (10).
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of front window assembly
SEN06148-00 a
Installation q
Carry out installation in the reverse order to removal.
a
[*1] q
1. 2.
Adjust opening and closing of the front window assembly according to the following procedure. Open and close the front window to check that it does not interfere with the rails and that the rollers are not hitched. If there is any problem in opening and closing of the front window, loosen the mounting bolt of roller adjustment bracket (13) and adjust the condition of the front window, and then tighten the mounting bolt again. a Make sure that bracket (13) is not mounted on the angle. 3 Mounting bolt: 34.3 Nm {3.5 kgm}
5.
3.
Raise the front window assembly and fix it with the rear locks (on both sides). a Check that the locks in the rear of the operator's cab are securely fastened.
4.
Install right corner block (2). a Fully tighten the block after adjusting the “Close“ position in the following step 6.
PC200, 200LC, 220, 220LC-8M0
Install the right corner block so that clearance (a) between the rail and right corner block (2) becomes 0 – 2.0 mm. Install the right corner block so that there is no level difference at the rolling surface (R) of the roller.
Install left corner block (1). a Fully tighten the block after adjusting the “Close“ position in the following step 6. a Install the left corner block so that clearance (b) between the rail and left corner block (1) becomes 0 – 2.0 mm. a Install the left corner block so that there is no level difference at the rolling surface (R) of the roller. (Refer to the above figure.)
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17
SEN06148-00
6.
700 Cab and its attachments Removal and installation of front window assembly
Adjust the “Close“ position of the front window assembly lock according to the following procedure. 1) Tighten left and right corner blocks (1) and (2) at roughly right positions so that front window glass (14) is attached firmly to cab-side trim seal (15).
7.
2)
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After the adjustment, splash water heavily over the front window glass and check that the water does not leak into the cab.
Check the working condition of right and left locks (16) and (17) when opening and closing the front window assembly. q If right and left locks (16) and (17) do not work normally. 1] Loosen lock fitting bolt (18), move lock (16) forward, and then tighten the bolt again. a The same applies to the right side. 2] After moving the lock, recheck the fitness of front window glass (14) and cab-side trim seal (15) which was checked in step 1). 3] Repeat the work in 1] and 2] until the fitness of the front window glass and the working condition of locks (16) and (17) are both acceptable, and then tighten the mounting bolts of the right and left corner blocks.
18
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of front window assembly
8.
Adjust the “Open“ position of the front window assembly lock. 1) After adjusting the “Close“ position of the front window assembly lock in steps 6 and 7, raise the front window assembly to the ceiling. 2) Set the front window assembly locks at the both sides of rear of the operator's cab to the “Open“ position, and then check the following items. q Check the working condition of right a nd left lo cks (1 6) an d ( 17 ) ( as explained above). q Front window assembly must be in contact with the right and left rubber stoppers (18) and furthermore, must be pushing them backward for 1.5 – 3.0 mm. q The front window assembly must be pushing the limit switch (19) backward for 4 – 7 mm. a The position of limit switch (19) cannot be adjusted. Therefore, the “Open“ position of the front window assembly is decided within the range where this switch works. a Limit switch (19) is used to prevent the windshield wiper from moving when turning the wiper switch on by m i s ta k e w h e n t h e f r o n t w i n d o w assembly is in “Open“ position. If the wiper operates when there is no glass in the front, the wiper falls down inside the cab and causes trouble. To check whether limit switch (19) is working, turn the key switch on and see that, even if the wiper switch is turned on, the wiper does not operate when the front window assembly is in “Open“ position.
SEN06148-00
4)
Loosen locknut (20) of right and left side of rubber stoppers (18), and then pull back both rubber stoppers (18) so that they won't contact with the front window assembly when it is in “Open“ position.
5)
Loosen both sides of locknuts (22), and adjust the position of striker bolt (21). a Striker bolt (21): M10 Inner diameter of plate (23): ø 14.5 mm
1]
2]
Front window assembly (10) must be pushing the limit switch (19) backward for 4 – 7 mm (at “Open“ position). Working condition of lock (17).
After checking the above items, if it becomes necessary to do the adjustment. Close front window assembly (10). q
3)
PC200, 200LC, 220, 220LC-8M0
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19
SEN06148-00
6)
700 Cab and its attachments Removal and installation of front window assembly
Adjustment of right and left rubber stoppers (18). 1] Bring front window assembly (10) (the lock should be in “Open“ position) into contact with right and left rubber stoppers (18).
4]
9. 2] 3]
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20
Close front window assembly (10). Turn right and left rubber stoppers (18) to the left for one and a half rotation. a One turn of rubber stopper (18) to the left is equivalent to squashing the rubber for approximately 1.5 mm. a When the front window assembly is in “Open“ position, the front window assembly must be pushing right and left rubber stoppers (18) for 1.5 – 3.0 mm.
Tighten locknuts (20) of the both sides of rubber stopper (18).
Adjust stopper (24) of the front window assembly. 1) Adjust and lock both sides of stopper (24) so that when pulling up the front window assembly (10), surface (d) of stopper (D) of front window assembly (10) is in contact with surface (c) of stopper (24).
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of front window assembly
SEN06148-00
10. Check the operating effort of the lock of the front window assembly. 1) After finishing the adjustment of steps 6 – 9, check that latching efforts of both right and left locks (16) and (17) are even. a Check the latching efforts on both “Close“ side (in the front of the operator's cab) and “Open“ side (in the rear of the operator's cab).
[*2]
3 2
Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm} Mounting bolt: Adhesive (LT-2)
PC200, 200LC, 220, 220LC-8M0
50-700
21
700 Cab and its attachments Removal and installation of floor frame assembly
SEN06148-00
Removal and installation of floor frame assembly
5.
Disconnect ground (2).
6.
Disconnect connectors (4a) to (7b) from travel PPC valve (3). q Connector (4a): L.H. travel reverse oil pressure sensor (P10) q Connector (4b): L.H. travel forward oil pressure sensor (P09) q Connector (5a): R.H. travel forward oil pressure sensor (P11) q Connector (5b): R.H. travel reverse oil pressure sensor (P12)
7.
Disconnect hoses (11) to (14) from travel PPC valve (6). a The hose bands are colored as follows: q Hose (6a): Red (L.H. travel forward port (P2)) q Hose (6b): Without band (L.H. travel reverse port (P1)) q Hose (7a): Blue (R.H. travel reverse port (P3)) q Hose (7b): Green (R.H. travel forward port (P4))
Removal k k
k
a a k
Disconnect the cable from the negative (–) terminal of the battery. In the case that you do not drain the coolant, if you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. In this case, wait until the coolant temperature lowers and then disconnect the heater hose. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
1.
Turn the upper structure by 90°.
2.
Drain the engine coolant. 6 Coolant : 20.3 l (PC200/200LC-8M0) 19.8 l (PC220/220LC-8M0)
3.
Remove the operator's cab assembly by referring to “Removal and installation of operator's cab assembly“.
4.
Remove cover (1).
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22
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of floor frame assembly
SEN06148-00
q Step 8 – 10 is optional (for breaker). Disconnect the following PPC hoses from the PPC valve. The color of the band is; q (8): Yellow q (9): No color a Plug the hose to stop oil flow-out. 9. Disconnect connectors S11 (10) and S10 (11). 10. Disconnect connectors P13 (12) and V30 (13).
8.
22. Disconnect connectors (27) to (29) conditioner controller assembly (B). q Connector (27): Machine main (AC01) q Connector (28): Machine main (AC02) q Connector (29): Air conditioner ness (AC04)
from air harness harness unit har-
11. Disconnect ground (14). From the left, T04, T05, T06, T07, T09, T10 12. Disconnect clamp (15). 13. Disconnect connector A08 (16) from the clip. 14. Disconnect connector P17 (17) from the air conditioner tube. 15. Remove the clamp and disconnect spacer (18). 16. Disconnect hose (19). a Check the connecting point. a Plug the hose to stop oil flow-out. a Disconnect the work equipment PPC hose (P) at joint box side. (See item 30.) 23. Remove cover (31) (3 bolts). a Disconnect connectors (32) and (33) located behind cover (31). q Connector (32): R.H. console intermediate harness (H14) q Connector (33): R.H. console intermediate harness (H15)
17. Disconnect hose (20). a Check the connecting point. a Plug the hose to stop oil flow-out. 18. Disconnect heater hose (21). a Check the connecting point. 19. Remove mounting bolt (22) and disconnect air conditioner tube (23). [*1] 20. Remove clamps (24) and (25). [*2] 21. Disconnect clamp (26). (If equipped) PC200, 200LC, 220, 220LC-8M0
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23
SEN06148-00
24. Remove grommet (34). 25. Move wiring harness (35) to the outside of the floor frame. a (SP) is made of sponge.
26. Disconnect the clamp of wiring harness (35). 27. Move plates (36) and (37) together with wiring harness (35) to the boom side.
28. Open the engine hood and remove cover (38).
700 Cab and its attachments Removal and installation of floor frame assembly
Green Red Yellow a Prepare an oil sump.
31. Pull out PPC hose assembly (41) of the work equipment.
32. Sling floor frame assembly (42) and remove it. a Make sure that the hoses, connectors, clamps, and so on are disconnected without fail. 4 Floor frame assembly: 250 kg
29. Disconnect clamp (39). 30. Disconnect PPC hose (40) of the work equipment. From the top, the color of the band is: White Brown None Blue Black 50-700
24
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of floor frame assembly
SEN06148-00
Installation q
Installation is done in the reverse order of removal.
[*1] a When installing the air conditioner circuit hoses, take care so that dirt, water, may not enter. a Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose. a Check that there is no defect or deterioration on the O-ring. a When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (PAG 46 or equivalent)). 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm} [*2] a Make sure that the hoses do not lap over. q
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 725 ± 50 g
q
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 20.3 l (PC200/200LC-8M0) 19.8 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
50-700
25
SEN06148-00
700 Cab and its attachments Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly k
k k
k
Park the machine on a level ground, swing the upper structure by 90 deg., lower the work equipment to the ground stably, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery. If you drain the coolant or disconnect the heater hose when the coolant temperature is high, you may be scalded. In this case, wait until the coolant temperature lowers and then drain the coolant or disconnect the heater hose. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere. a Ask a qualified person for collecting, adding, and filling operations of the refrigerant (R134a). a Note connector numbers and installed positions before disconnecting wiring and hoses. a Positions of the controllers are shown below. q A: Pump controller assembly q B: Air conditioner controller assembly q C: KOMTRAX terminal controller assembly
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26
Removal 1.
Collect the refrigerant (R134a) from the air conditioner circuit. [*1] a Refrigerant to be collected: 725 ± 50 g
2.
Drain the coolant. 6 Coolant: 20.3 l (PC200/200LC-8M0) 19.8 l (PC220/220LC-8M0)
3.
Pull up front window assembly (1) to the ceiling and lock it. a Make sure that the assembly is certainly locked.
4.
Remove front lower window (2).
5.
Remove floor mat (3).
6.
Remove box (8) (five bolts). a Disconnect the hose located under box (8).
7.
Remove box (9) (three bolts). a Be careful about connectors (10) and (11) located behind box (9) (for machines equipped with 12 V power socket). q Connector (10): 12 V power socket intermediate harness (M13A) q Connector (11): 12 V power socket intermediate harness (M13B)
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of air conditioner unit assembly
8.
9.
Pull up cover (12) (three bolts) to remove. a The connectors and harnesses at the rear must not be caught.
SEN06148-00
10. Remove duct (15) (two bolts). 11. Remove cover (16) (three bolts) and bracket (41) (two bolts). a Disconnect connectors (17) and (18) located behind cover (16) . q Connector (17): R.H. console intermediate harness (H14) q Connector (18): R.H. console intermediate harness (H15)
Remove cover (13) (seven bolts). a Disconnect connector (14) located behind cover (13). q Connector (14): Cigarette lighter (M04)
12. Remove plate (19) (two bolts). 13. Pull up lock pin (20) to unlock and remove duct (21).
PC200, 200LC, 220, 220LC-8M0
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27
700 Cab and its attachments Removal and installation of air conditioner unit assembly
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14. Remove ducts (24) to (28). a Cut the cable ties holding the ducts.
[*2]
17. Remove four bolts (29) and remove pump controller assembly (A). Arrange the assembly neatly and place it on the floor apart from the operator's cab.
15. Remove cable tie (39) of the left console wiring harness. 18. Disconnect connectors (30) to (32) from air conditioner controller assembly (B). q Connector (30): Machine main harness (AC01) q Connector (31): Machine main harness (AC02) q Connector (32): Air conditioner unit harness (AC04)
16. Remove cable tie (40) of the floor wiring harness.
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28
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of air conditioner unit assembly
19. Disconnect connectors (42) to (45). q Connector (42): Communication antenna (GPS) q Connector (43): Machine main harness (CK01). q Connector (44): Machine main harness (CK02). q Connector (45): Communication antenna
SEN06148-00
24. Remove six mounting bolts (37), then remove air conditioner unit assembly (38).
20. Remove KOMTRAX terminal (C) (four bolts).
21. Remove cover (33).
22. Remove bolt (34), then disconnect tubes (35) of the air conditioner. [*3] 23. Disconnect hoses (36) of the heater core. [*4]
PC200, 200LC, 220, 220LC-8M0
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29
SEN06148-00
700 Cab and its attachments Removal and installation of air conditioner unit assembly
Installation a Perform installation in the reverse order to removal. [*1] a Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 725 ± 50 g q Refilling of air compressor oil For details, see Others "Filling compressor oil". [*2] a Removing cover (48) makes easier to install ducts (24) and (26) . a Since the mounting bolts of cover (48) are hidden by cover (47), remove cover (47) first.
[*3] a When installing air conditioner hoses and tubes, take care so that dust, dirt or water does not enter them. a When connecting the air conditioner hoses and tubes, check that O-rings are fitted to their joints. a Do not reuse an O-ring since it is deformed and deteriorated once it is used. a When removing O-rings, use a soft tool to avoid damaging hoses and tubes. a Check that there is no defect or deterioration on the O-ring. a Apply compressor oil (Denso: ND-OIL8) for R134a refrigerant to O-rings.
3
Hose clamp (M6 bolt): 8 to 12 Nm {0.8 to 1.2 kgm}
[*4] a When installing the hoses of heater core, make white line (marking) of heater hoses straight to prevent kink of heater hoses. q
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Refilling of coolant (radiator) Supply the coolant through the coolant filler port to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant (radiator): 20.3 l (PC200/200LC-8M0) 19.8 l (PC220/220LC-8M0)
PC200, 200LC, 220, 220LC-8M0
700 Cab and its attachments Removal and installation of air conditioner unit assembly
PC200, 200LC, 220, 220LC-8M0
SEN06148-00
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31
SEN06148-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06148-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-700
32
SEN06149-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
50 Disassembly and assembly
1
800 Electrical system Removal and installation of machine monitor assembly ................................................................................. 2 Removal and installation of engine controller assembly ................................................................................. 4 Removal and installation of pump controller assembly ................................................................................... 6 Removal and installation of KOMTRAX terminal assembly ............................................................................ 8
PC200, 200LC, 220, 220LC-8M0
50-800
1
800 Electrical system Removal and installation of machine monitor assembly
SEN06149-00
Removal and installation of machine monitor assembly k
k
a
4.
Remove three mounting screws of cover (4). a One of the three screws is covered with cap (5).
5.
Remove connector (6) and then remove cover (4). a Connector (6): Sunlight sensor (P31)
6.
Remove duct (10) (one bolt).
1
Park the machine on a level ground, lower the work equipment to the ground, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery. Note connector numbers and installed positions before disconnecting wirings and hoses.
Removal 1.
Pull up front window assembly (1) to the ceiling and lock it. a Check that the front window is securely locked.
2.
Remove front lower window (2).
3.
Remove rubber panel (3) (two bolts).
50-800
2
PC200, 200LC, 220, 220LC-8M0
800 Electrical system Removal and installation of machine monitor assembly
7.
Insert a flat-head screwdriver in slit (7) and pull it upward to remove cover (9) while releasing lug (8).
a
8.
Hook (17) beneath cover (9) unites cover (9).
SEN06149-00
9.
Remove four mounting bolts (11) of machine monitor (12).
10. Disconnect connectors (13) to (16). a Disconnecting connector (15) first makes easier to disconnect the other connectors. q Connector (13): Machine monitor (CM01) q Connector (14): Machine monitor (CM02) q Connector (15): Machine monitor (not used) (CM03) q Connector (16): Machine monitor (for camera connection) (CM04)
Loosen mounting bolts (19) of cover and duct assembly (18). a Loosening mounting bolts (19) first makes easier to remove machine monitor mounting bolts.
Installation q
PC200, 200LC, 220, 220LC-8M0
Perform installation in the reverse order to removal. 50-800
3
800 Electrical system Removal and installation of engine controller assembly
SEN06149-00
Removal and installation of engine controller assembly
1
Removal k
Disconnect the cable from the negative (–) terminal of the battery.
1.
Turn the upper structure by 90°.
2.
Remove cover (1).
Installation q
Carry out installation in the reverse order to removal
[*1]
3.
Open the engine hood.
4.
Disconnect connectors CE02 (2) and (3) from the engine controller. [*1] a The connector is locked with the inside hexagonal head bolt L6 (4 mm).
5.
Disconnect connector (4) from the engine controller by pushing the lock. [*1]
6.
Remove the mounting bolt and engine controller (5). a Ground (E) and harness clamp are tightened together with.
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4
q
Check that there is no sand, dust or water inside the controller connector (especially on the bottom). If any of them is found, completely remove them using a blower, etc. (Sand, dust or water may cause defective contact in connectors or defects by entering water.)
a
Reference How to replace the seal of O-ring of power source connector (4). Seal of O-ring: 1010-074-0406 (NIHON-DEUTSCH Ltd.) or equivalent
q
1) Remove cover (6) by nipping the tab with tweezers [1].
PC200, 200LC, 220, 220LC-8M0
800 Electrical system Removal and installation of engine controller assembly
SEN06149-00
2) Remove O-ring (7) with tweezers [1].
PC200, 200LC, 220, 220LC-8M0
50-800
5
SEN06149-00
800 Electrical system Removal and installation of pump controller assembly
Removal and installation of pump 1 controller assembly Removal k
1.
Disconnect the cable from the negative (–) terminal of the battery. Remove cover (1).
Installation
2.
Disconnect relay R08 (4) from the clip.
3.
Disconnect bracket (5) and put it to the right side.
4.
Disconnect wiring connectors C01 (6) and C02 (7) as follows. q Tilt lock (L2) inside while pressing lock (L1). a Bar (B) comes out and the lock is released.
5.
Remove the 4 mounting bolts and pump controller assembly (8).
q
Installation is done in the reverse order of removal.
a 1.
Reference Procedure for removing connector cover (1) 1) Cut and remove cable tie (2). 2) Move lever (3) up.
3) 4)
50-800
6
Lightly push part (A) of connector cover (1) from both sides to unfasten claw (B). Remove connector cover (1) around claw (C).
PC200, 200LC, 220, 220LC-8M0
800 Electrical system Removal and installation of pump controller assembly
a
2.
Connector without connector cover (1)
Procedure for installing connector cover 1) Push in right and left sliders (4) as far as possible.
SEN06149-00
3)
Set claw (C) to the connector and place connector cover (1). a Take care that wiring harness (5) will not be caught.
4)
Set claw (B) and install connector cover (1).
5)
Bind connector cover (1) and wiring harness with a new cable tie. (See 1. 1).)
a
2)
Right and left sliders (4) pushed in as far as possible (Left figure) Move lever (3) of connector cover (1) from the upper position to the left position (lock position) in the figure. a (B), (C): Claws a If the sliders and lever are not set as shown in the following figure, the connector is not disconnected or locked securely with the lever. Accordingly, check their positions again.
PC200, 200LC, 220, 220LC-8M0
50-800
7
SEN06149-00
Removal and installation of KOMTRAX terminal assembly k
k
a a
800 Electrical system Removal and installation of KOMTRAX terminal assembly
4.
Remove cover (6) (seven bolts). a Be careful about connector (7) located behind cover (6). q Connector (7): Cigarette lighter (M04)
5.
Disconnect connectors (8) to (11). q Connector (8): Communication antenna (GPS) q Connector (9): Machine main harness (CK01). q Connector (10): Machine main harness (CK02). q Connector (11): Communication antenna
6.
Remove KOMTRAX terminal (C) (four bolts).
1
Park the machine on a level ground, lower the work equipment to the ground, and stop the engine. Disconnect the cable from the negative (–) terminal of the battery. Note connector numbers and installed positions before disconnecting wiring and hoses. The position of the KOMTRAX terminal is shown below. q C: KOMTRAX terminal
Removal 1.
Remove box (1) (five bolts). a Disconnect the hose located under box (1).
2.
Remove box (2) (three bolts). a Be careful about connectors (3) and (4) located behind box (2) (for machines equipped with 12 V power socket). q Connector (3): 12 V power socket intermediate harness (M13A) q Connector (4): 12 V power socket intermediate harness (M13B)
3.
Remove cover (5) (three bolts).
Installation q
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8
Perform installation in the reverse order to removal.
PC200, 200LC, 220, 220LC-8M0
800 Electrical system Removal and installation of KOMTRAX terminal assembly
PC200, 200LC, 220, 220LC-8M0
SEN06149-00
50-800
9
SEN06149-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06149-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
50-800
10
SEN06151-00 SEN06002-00
PC200, 200LC, 220, 220LC-8M0
HYDRAULIC EXCAVATOR PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Shop Manual
Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
80 Appendix 100 Air conditioner Precautions for refrigerant ..........................................................................................................................
3
Air conditioner component ..........................................................................................................................
4
Configuration and function of refrigeration cycle.........................................................................................
6
Outline of refrigeration cycle .......................................................................................................................
7
Air conditioner unit ......................................................................................................................................
9
Air conditioner controller ............................................................................................................................. 15 Compressor ................................................................................................................................................ 16 Condenser and Modulator .......................................................................................................................... 17 Sensor......................................................................................................................................................... 18 Procedure for testing and troubleshooting .................................................................................................. 20 Circuit diagram and arrangement of connector pins ................................................................................... 22 System diagram .......................................................................................................................................... 24 Parts and connectors layout ....................................................................................................................... 26 Testing air leakage (duct)............................................................................................................................ 29 Testing with self-diagnosis function............................................................................................................. 31 Testing vent (mode) changeover................................................................................................................. 33 Testing FRESH/RECIRC air changeover.................................................................................................... 34 Testing sunlight sensor ............................................................................................................................... 35 Testing (dual) pressure switch for refrigerant.............................................................................................. 36 Testing relays .............................................................................................................................................. 37
PC200, 200LC, 220, 220LC-8M0
80-100
1
SEN06151-00
100 Air conditioner
Troubleshooting chart 1............................................................................................................................... 38 Troubleshooting chart 2............................................................................................................................... 40 Information in troubleshooting table ............................................................................................................ 42 Failure code list related to air conditioner ................................................................................................... 43 Failure code [879AKA] A/C Inner sensor Open Circuit ............................................................................... 44 Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................... 45 Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................. 46 Failure code [879BKB] A/C Outer sensor Short Circuit............................................................................... 48 Failure code [879CKA] Ventilating sensor Open Circuit.............................................................................. 50 Failure code [879CKB] Ventilating sensor Short Circuit.............................................................................. 51 Failure code [879DKZ] Sunlight sensor Open or Short Circuit.................................................................... 52 Failure code [879EMC] Ventilating Damper Abnormality ............................................................................ 54 Failure code [879FMC] Air Mix Damper Abnormality.................................................................................. 55 Failure code [879GKX] Refrigerant Abnormality ......................................................................................... 56 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate).... 58 Troubleshooting for compressor and refrigerant system (Air is not cooled)................................................ 60 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................................ 63 Troubleshooting for FRESH/RECIRC air changeover................................................................................. 65 Troubleshooting with gauge pressure ......................................................................................................... 67 Connection of service tool........................................................................................................................... 69 Precautions for disconnecting and connecting air conditioner piping ......................................................... 71 Handling of compressor oil.......................................................................................................................... 73 Desiccant replacement procedure .............................................................................................................. 75
80-100 2
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Precautions for refrigerant
SEN06151-00
Precautions for refrigerant k
Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, condenser, air conditioner compressor or receiver drier and so on.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmok
sphere.
If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working cloth with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC200, 200LC, 220, 220LC-8M0
80-100
3
SEN06151-00
100 Air conditioner Air conditioner component
Air conditioner component
80-100 4
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Air conditioner component
1. Compressor 2. Condenser 3. Modulator * 4. Hot water piping 5. Hot water return piping 6. Refrigerant piping 7. Dual pressure switch 8. Sight glass 9. Air conditioner controller 10. Air conditioner unit 11. Recirculation air filter 12. Fresh air filter 13. Machine monitor 14. Sunlight sensor
SEN06151-00 Specifications Refrigerant
R134a
Refrigerant refilling level (g)
725 ± 50
A. Front vent B. Rear vent C. Foot vent D. Defroster air vent E. Recirculation air inlet F. Fresh air inlet
*: Receiver drier and condenser are integrated on this product. The existing receiver drier unit is called "modulator" here.
PC200, 200LC, 220, 220LC-8M0
80-100
5
100 Air conditioner Configuration and function of refrigeration cycle
SEN06151-00
Configuration and function of refrigeration cycle Cycle (Component)
Compression (Compressor)
Condensation (Condenser)
Location
Engine compartment
Front of radiator
Function
State of refrigerant
80-100 6
Circulates refrigerant gas and increases its temperature and pressure so that it can be liquefied easily in condenser. (Compression of refrigerant) Gas o Gas Adiabatic compression
Condenses refrigerant to discharge heat absorbed in evaporator. (condensation of refrigerant) Gas o Liquid Cnstant pressure change
Expansion (Expansion valve) In operator cab (Built in air conditioner unit)
Evaporation (Evaporator) In operator cab (Built in air conditioner unit)
Lowers temperature and pressure of refrigerant liquid and gas for easy evaporation with throttle. Controls flow rate, too. (Throttle of refrigerant)
Evaporates refrigerant to absorb heat from air around evaporator, and cool the air. (Evaporation of refrigerant)
Liquid o Liquid and gas
Liquid and gas o Gas
Adiabatic expansion
Cnstant pressure change
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Outline of refrigeration cycle
SEN06151-00
Outline of refrigeration cycle The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and liquefying. 1. Compression (Compressor) The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into a state where it can be easily liquefied at the ambient temperature. The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and pressure at which it can be easily liquefied when cooled to the ambient temperature. 2. Condensation (Condenser) The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from the compressor. The heat released to the outside from the condenser is called condensation heat. The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor. The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed. In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist. The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. Reference: The pressure varies depending on the condensation temperature of the refrigerant. 3. Expansion (Expansion valve) The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1). The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it is sent to the evaporator is called expansion. The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate simultaneously. The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
PC200, 200LC, 220, 220LC-8M0
The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is supplied to the evaporator. (*1) Throttle action If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow will be generated. The liquid expands when it passes through the narrow section and rushes into the passage where the sectional area is larger, and consequently, its pressure and temperature are reduced. No heat is transferred from or to the outside during the throttle action. 4. Evaporation (Evaporator) The evaporator evaporates the liquid refrigerant (superheated vapor). The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab). After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the temperature inside the cab. The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant in the evaporator The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other. The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature. Relationship between refrigerant and defective air conditioning q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab. q If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
80-100
7
SEN06151-00
q
q
100 Air conditioner Outline of refrigeration cycle
If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the compressor in liquid form, which will cause the compressor to compress the liquid and may damage the components. If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the refrigerant flow, and may result in defective air conditioning.
80-100 8
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Air conditioner unit
SEN06151-00
Air conditioner unit a This air conditioner unit is auto temperature control type.
PC200, 200LC, 220, 220LC-8M0
80-100
9
100 Air conditioner Air conditioner unit
SEN06151-00 A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to compressor) C: Hot water inlet D: Hot water outlet E: Recirculation air hole F: Fresh air hole G: Front air vents H: Rear air vents J: Foot level air vents K: Defroster vents 1. Evaporator 2. Heater core 3. Expansion valve 4. Blower fan, blower motor 5. Air mix servomotor 6. Air mix door 7. Vent (mode) changeover servomotor 8. Rear door 9. Foot door 10. Defroster door 11. FRESH/RECIRC air changeover servomotor 12. FRESH/RECIRC air changeover servomotor 13.Power transistor 14. Evaporator temperature sensor 15. Inner sensor (inside air temperature sensor) Outline q The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or warm up the air in the cab. Temperature control Whenever a temperature control switch is operated on the machine monitor, temperature setting data is sent to the air conditioner controller, which is located behind the operator seat. The air conditioner controller controls the air mix servomotor (5) and changes the angle of the air mix door (6) in order to adjust the temperature.
q
Over-cooling (Freezing) prevention Evaporator temperature sensor (14) varies its electrical resistance according to temperature. q The air conditioner controller detects the temperature of the evaporator (1) by converting the changes in the resistance of the evaporator temperature sensor (14) into voltage changes. q The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the compressor clutch relay (*) to stop the compressor. q
80-100 10
*: See "Parts and connectors layout" for details regarding the compressor clutch relay. Air flow adjustment q Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the air conditioner controller. The air conditioner controller controls blower motor (4) using power transistor (13) in order to adjust the air flow. Vent (mode) changeover Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner controller. The air conditioner controller controls mode changeover servomotor (7) to adjust the opening angle of mode changeover doors (8) to (10) and thus perform vent changeover.
q
FRESH/RECIRC air changeover Whenever a FRESH/RECIRC air changeover switch is operated on the machine monitor, FRESH/RECIRC air changeover setting data is sent to the air conditioner controller. The air conditioner controller controls FRESH/RECIRC air changeover servomotor (11) to open and close FRESH/RECIRC air changeover door (12).
q
Automatic air conditioner Inside air temperature sensor (15) detects the internal temperature based on changes in resistance. The air conditioner controller detects the internal temperature by converting the changes in the resistance of inside air temperature sensor (15) into voltage changes. The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the internal temperature so that it matches the setting made on the machine monitor. Data from the sunlight sensor and the outside air temperature sensor is also taken into consideration when adjusting the internal temperature.
q
a The door is the same as the damper.
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Air conditioner unit
SEN06151-00
Changeover pattern of the vent (mode) changeover door Rear door (8)
Front
Air vent mode
Opening and closing door Close
Foot door (9)
0
Opening and closing door Close
Angle
Defroster door (10)
0
Opening and closing door Close
Angle
Angle 0
Front and rear Front, rear and foot Foot
Open
25
Close
0
Close
0
Open
25
Open
35
Close
0
Open
25
Open
53
Close
0
Foot and defroster
Open
25
Open
23
Open
38
Defroster
Open
25
Open
0
Open
38
Selection pattern of air mix door (6) Set temperature
Opening and closing door
Angle
Max. Cool
Close
0
Max. Hot
Open
80
PC200, 200LC, 220, 220LC-8M0
80-100
11
100 Air conditioner Air conditioner unit
SEN06151-00 Functions of major components a For details of the numbers in the following sentence, see "Air conditioner unit". Evaporator q Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion valve (3). q Air from blower motor (4) is cooled and dehumidified when passing through the fins of the evaporator (1). Heater core Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. q Air from blower motor (4) is warmed when passing through the fins of the heater core (2). q
Evaporator temperature sensor Evaporator temperature sensor (14) is installed on evaporator (1) with the holder. Its resistance changes in response to the temperature change of the evaporator (1). q The air conditioner controller determines the evaporator temperature from the voltage value of the evaporator temperature sensor (14) and turns the compressor on/off to prevent freeze of the evaporator (1).
When the door (damper) reaches the position specified by each switch, the air conditioner controller stops the supply of current to the servomotor, then the corresponding door stops. q When the potential difference fails to reach a predefined voltage for control of the servomotor, the air conditioner controller notifies the machine monitor of an abnormality. [879EMC] or [879FMC] is displayed in the "Electrical System" (electrical systems abnormality record) screen in service mode of the machine monitor. a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore, does not have a self-diagnosis function. a When attempting to operate a servomotor during inspecting, do not supply power directly between servomotor terminals (6) and (7). q
q
Servomotors
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover. q Whenever a switch on the machine monitor is operated, the air conditioner controller delivers power to the servomotor by raising the voltage between terminals (6) and (7) to 24 V. (The rotation direction changes based on the supply polarity.) q The servomotor contains a variable resistance, and its resistance value changes as the motor turns. q The air conditioner controller delivers voltage at 5 V to the variable resistance and detects motor rotation angle based on the potential difference. 80-100 12
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Air conditioner unit
SEN06151-00
Expansion valve
A: When evaporator outlet temperature is high B: When evaporator outlet temperature is low C: From receiver drier (high-pressure refrigerant) D: To compressor (low-pressure refrigerant) 1. Expansion valve 1a. Needle valve 1a-1. Diaphragm 1a-2. Thermoprobe 1b. Spring 2. Refrigerant gas 3. Evaporator
Structure q Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc. q Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of needle valve (1a).
Outline q The expansion valve converts high-pressure and high-temperature liquid refrigerant from the receiver drier to low-pressure, low-temperature misty refrigerant through the throttle action. q It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in the cab. q The temperature of the air blown out of the air vent is adjusted depending on the volume of refrigerant circulating in the evaporator (3).
PC200, 200LC, 220, 220LC-8M0
80-100
13
100 Air conditioner Air conditioner unit
SEN06151-00 Operation q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3). q After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched area) through the thermoprobe (1a-2). q The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg) pushing the needle valve (1a). q The opening level of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. q The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the opening level of needle valve (1a). When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure] q The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve (1a) moves leftward. q As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the evaporator (3) is increased to improve cooling capacity.
Dual pressure switch a The dual pressure switch is mounted on the air conditioner hose under the floor. q The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or abnormally high. q When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are protected. Function
a LA or lower: Abnormally low pressure a HA or higher: Abnormally high pressure LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure] q The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve (1a) is moved rightward by the spring force (1b). q The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity.
80-100 14
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Air conditioner controller
SEN06151-00
Air conditioner controller
a See "System Diagrams" for details regarding input/output signals.
PC200, 200LC, 220, 220LC-8M0
80-100
15
100 Air conditioner Compressor
SEN06151-00
Compressor
A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser) 1. Pulley 2. Magnetic clutch 3. Relief valve
Function q The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated (liquefied) at the normal temperature. q Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller activates magnetic clutch (2) built in the compressor. q When the magnetic clutch is engaged, the power of the engine rotates the compressor shaft along with pulley (1) to drive the compressor. Specifications Number of cylinder – Bore x Stroke (mm) Piston capacity (cc/rev)
80-100 16
10 - 32 x 20.8 157.3
Allowable maximum speed (rpm)
6,000
Compressor oil
Denso: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc)
180
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Condenser and Modulator
SEN06151-00
Condenser and Modulator
A: Refrigerant inlet (from compressor) B: Refrigerant outlet (to air conditioner unit) 1. Condenser 2. Modulator Function q Condenser (1) It cools and liquefies the high-pressure, high-temperature misty refrigerant from the compressor. a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible. As a result, pressure in refrigerant circulation circuit is increased, applying extra load to the engine or reducing cooling effect. Take extreme care not to crush or damage the fins when handling them or checking them in daily inspection.
Function q Modulator (2) a This has desiccant in it. See "Desiccant replacement procedure". It is used to store liquefied high-pressure, high-temperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. It eliminates foreign substances in the circulation line and moisuture in the refrigerant by use of the built-in filter and desiccant.
Specification
Specification
Fin pitch (mm) Height x Width x Thickness (mm) Weight (kg)
4.0 421 x 540 x 16
PC200, 200LC, 220, 220LC-8M0
Weight of desiccating agent (g)
290
3.2
80-100
17
100 Air conditioner Sensor
SEN06151-00
Sensor Sunlight sensor
Outside air temperature sensor
1. Connector 2. Sensor
1. Connector 2. Sensor
Outline q The sunlight sensor is mounted on top of the machine monitor. q It detects the strength of incident sunlight and sends signals to the air conditioner controller. q When performing automatic air conditioning, the air conditioner controller controls the blower motor and the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
Outline q The outside (air) temperature sensor is installed on the bracket in the cooling unit. (See "Parts and connectors layout".) q The outside air temperature sensor has feature of change in resistance by temperature change, therefore, can detect the ambient temperature. q The air conditioner controller detects the ambient temperature by converting the changes in the resistance of the outside air temperature sensor into voltage changes. q When performing automatic air conditioning, the air conditioner controller controls the blower motor and the air mix servomotor with the data of the outside (air) temperature sensor in order to adjust the temperature and air flow.
Output characteristics
80-100 18
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Sensor
PC200, 200LC, 220, 220LC-8M0
SEN06151-00
80-100
19
SEN06151-00
100 Air conditioner Procedure for testing and troubleshooting
Procedure for testing and troubleshooting The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main components. Specifically, the operation of sensors and servomotors can be examined. If a troubled section is detected, every part of that section must be inspected. 1. After basic check, find the troubled section according to the detected trouble of the air conditioner. 2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”). If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to the air conditioner controller and with CAN communication between the machine monitor and the air conditioner controller. If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is receiving power normally and that CAN communication between the machine monitor and the air conditioner controller is normal. 3. After finding out the troubled section, inspect the component parts in that section and repair the troubled part. Basic testing and troubleshooting sequence
80-100 20
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Procedure for testing and troubleshooting
SEN06151-00
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor. *2: Simple checking of refrigerant volume through sight glass. Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with the inspection. A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant. B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient. C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no refrigerant at all. The above should be treated as general guidelines as certain exceptions do exist. See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the condition is normal. S: Sight glass condition R: Receiver drier internal condition LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will definitely be leaking from the same point. In such a case, retighten in accordance with the table of retightening torques from "Precautions for disconnecting and connecting air conditioner piping." *4: Start the engine and perform the check with the air conditioner switch set to ON.
PC200, 200LC, 220, 220LC-8M0
80-100
21
SEN06151-00
100 Air conditioner Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-100 22
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Circuit diagram and arrangement of connector pins
SEN06151-00
a Diffuser servomotor means vent (mode) changeover servomotor. a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor. a Frost sensor means evaporator temperature sensor.
PC200, 200LC, 220, 220LC-8M0
80-100
23
SEN06151-00
100 Air conditioner System diagram
System diagram a This air conditioner unit is auto temperature control type.
80-100 24
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner System diagram
SEN06151-00
Input and output signals of the air conditioner controller Controller connector: AMP 025 - 32PM Wiring harness connector: ACECU (AMP025 32PF) AMP025 - 32PF Pin No.
Symbol
1 2 3 4
+Bback – SS THOUT
5
THF
6
THI
7
POT5 V
8 9
BWFB PTRB
10
CAN_H
11
CAN_L
12
–
13
MRFA
14
MRFB
15 16 17 18
MAMA MAMB +24 V –
19
SAM
20
SVI
22 23 24 25 26 27 28 29 30
PRESS SW – – – GNDS GND – – RLCC –
31
MV1A
32
MV1B
21
Input/ OutSignal name put signal Backup power supply Input (*1) – Sunlight sensor Input Outside air temperature sensor Input Evaporator temperature senInput sor Inside air temperature sensor Input Servomotor potentiometer Output power supply (5 V) Blower feedback signal Input Power transistor control signal Output Input/o CAN communication signal (H) utput Input/o CAN communication signal (L) utput (*1) – Fresh/recirculated air servomoOutput tor terminal A Fresh/recirculated air servomoOutput tor terminal B Air mix servomotor terminal A Output Air mix servomotor terminal B Output 24 V power supply Input (*1) – Air mix servomotor potentiomInput eter signal Vent (mode) changeover serInput vomotor potentiometer signal Dual pressure switch (*1) (*1) (*1) Sensor GND GND (*1) (*1) Compressor clutch relay (*1) Vent (mode) changeover servomotor terminal A Vent (mode) changeover servomotor terminal B
Input – – – Input Input – – Output –
Operation of air conditioner controller 1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air conditioner unit by inputting switches associated with air conditioning. 2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air changeover. 3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch for activating the compressor). 4. The air conditioner controller controls the air flow volume using the power transistor. a The power transistor has an overcurrent prevention fuse in it. 5. The air conditioner controller detects the evaporator temperature using the evaporator temperature sensor. 6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by turning the compressor clutch relay ON and OFF. a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating. 7. When performing automatic air conditioning, the air conditioner controller controls the inside (air) temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor, the outside air temperature sensor, and the inside air temperature sensor. 8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on the "Electrical Systems" screen of the electrical system on the machine monitor.
q
Output Output
*1: Never connect these pins. Malfunctions or failures may occur.
PC200, 200LC, 220, 220LC-8M0
80-100
25
100 Air conditioner Parts and connectors layout
SEN06151-00
Parts and connectors layout q
q
k
k
Three fuses related to the air conditioner are in the fuse box at the right rear of the operator's seat. The air conditioner unit is mounted inside the rear cover of at the rear cover of the operator's seat. Park the machine on a level surface, swing the upper structure by 90 degrees, lower the work equipment to the ground so that it is stable, and stop the engine. Turn the battery disconnect switch to the "OFF" position and pull out the key.
Connector No.
a Note the connector numbers and installed positions before disconnecting wiring and hoses.
Remarks
Location
Reference item
AC01
Intermediate connector
Right rear of cab
2.
AC02
Intermediate connector
Right rear of cab
2.
AC03
Air conditioner compressor
Engine
7.
ACECU
Engine controller
Rear of cab
2.
CM01*
Machine monitor
Front of cab
5.
CM02
Machine monitor
Front of cab
5.
CM03*
Machine monitor
Front of cab
5.
CM04*
Machine monitor
Front of cab
5.
F01
Fuse box
Right rear of cab
1.
P17
Dual pressure switch aSwing upper structure 90 deg.
Under cab
6.
P18
Outside air temperature sensor
Cooling unit
8.
P31
Sunlight sensor
Machine monitor
4.
R21
Relay
Rear of cab
2.
[2]
Power transistor
Air conditioner unit
3.
[5]*
FRESH/RECIRC air changeover servomotor
Air conditioner unit
3.
[6]*
Inside air temperature sensor
Air conditioner unit
3.
[7]*
Evaporator temperature sensor (frost sensor)
Air conditioner unit
3.
*: Connectors that are not involved in the troubleshooting
80-100 26
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Parts and connectors layout
1. Each fuse in fuse box F01: Open the cover of the fuse box at the right rear of the operator's cab. q No. 11 (20 A): Fuse for the power supply of blower (fan) and the air conditioner compressor q No. 10 (5 A): Fuse for the primary power supply of the air conditioner unit, air conditioner controller, and the air conditioner compressor electromagnetic clutch relay q No. 18 (5 A): Fuse for the power supply (backup power supply) of the air conditioner controller
SEN06151-00 2. Air conditioner controller: *1 q AC01: Intermediate connector q AC02: Intermediate connector q ACECU: Air conditioner controller connector q R21: Connector for air conditioner compressor electromagnetic clutch relay
3. Air conditioner unit a Connectors [2], [5], [6], and [7] do not have labels. a Rear side of air conditioner unit (Only connector [2] can be removed while installed on machine) [2]: Power transistor (*2) connector [5]: FRESH/RECIRC air changeover servomotor connector [6]: Inner sensor (inside air temperature sensor) connector [7]: Evaporator temperature sensor connector *2: Power transistor
PC200, 200LC, 220, 220LC-8M0
80-100
27
SEN06151-00 4. Sunlight sensor P31: Sunlight sensor connector
5. Machine monitor q CM01 to CM04: Machine monitor connector a Connector CM03: (Not used) a Connector CM04: (For camera connection)
100 Air conditioner Parts and connectors layout
7. Air conditioner compressor a Open the engine hood. q AC03: Air conditioner compressor connector
8. Outside air temperature sensor P18: Outside (air) temperature sensor connector
6. Dual pressure switch a Rotate cab undercover 90 degrees and remove it. q P17: Dual pressure switch connector
80-100 28
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Testing air leakage (duct)
SEN06151-00
Testing air leakage (duct) k
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. k Turn the battery disconnect switch to the "OFF" position and pull out the key. a Note connector numbers and installed positions when disconnecting wiring and hoses. Testing 1. Lift front window assembly (1) to the ceiling and lock it. a Check that the front window is securely locked. 2. Remove front lower window (2). 3. Remove floor mat (3). 4. Remove cover (4) first, and remove cover (5). 5. Remove cover (6).
8. Remove drink box (8) (five bolts). a Disconnect the hose under drink box (8). 9. Remove magazine box (9) (three bolts). a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V power socket). q Connector (10): 12 V power socket intermediate harness (M13A) q Connector (11): 12 V power socket intermediate harness (M13B) 10. Pull up cover (12) (three bolts) to remove. a The connectors and wiring harnesses at the rear must not be caught.
6. Remove cap (7-1). 7. Remove cover (7). a Disconnect the sunlight sensor connector from the rear of cover (7).
PC200, 200LC, 220, 220LC-8M0
80-100
29
SEN06151-00
100 Air conditioner Testing air leakage (duct)
11. Remove cover (13) (seven bolts). a Be careful about connector (14) behind box (13). q Connector (14): Cigarette lighter (M04)
12. Check whether any of the following ducts or pins are disconnected. q Front duct (15) q Defroster duct (16) q Rear duct (17) q Fresh air inlet duct (18) and pin (19)
80-100 30
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Testing with self-diagnosis function
SEN06151-00
Testing with self-diagnosis function Testing outline The air conditioner controller performs various self-diagnosis such as sunlight sensor, inside air temperature sensor, outside air temperature sensor, evaporator temperature sensor, temperature control system, vent (mode) changeover system, and refrigerant pressure with the pressure switch. If an error is detected on the temperature control system, vent (mode) changeover system, or refrigerant, the machine monitor momentarily shows "L01" (2) and then "Air conditioner system state monitor" is displayed continuously. a The machine monitor displays the system state monitor "!" when an error occurs in the communication between the machine monitor and the air conditioner controller.
How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor. q
Overview of machine monitor operating procedure Normal screen O While pressing number key (4), press (1), (2), and (3) in this order. Service menu (Mode) O Press [F3] twice. Press [F6]. 03 Abnormality record O Press [F3] once. Press [F6]. 02 Electrical Systems screen
Detailed description of machine monitor operating procedure 1. On the normal operation screen, while pressing number key (4), press (1), (2), and (3) in this order.
q
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not automatically be reset. To reset the failure condition, the starter switch must be set to OFF. a On the "Electrical System" screen in the service mode of the machine monitor, the system performs self-diagnosis for various sensors. If a problem is detected, failure information is displayed. a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.
PC200, 200LC, 220, 220LC-8M0
80-100
31
100 Air conditioner Testing with self-diagnosis function
SEN06151-00 2. On the service menu screen, press [F3] (R) twice, and then select "03 Abnormality Record". 3. Press [F6] ( ) to confirm.
4. On the Abnormality Record screen, press [F3] (R) once, and then select "02 Electrical Systems". 5. Press [F6] ( ) to confirm.
a For details, see the failure code list related to air conditioner Failure Failure (Displayed on Remarks code screen) A/C Inner Sensor Open 879AKA Circuit * A/C Inner Sensor Short 879AKB Circuit A/C Outer Sensor Open 879BKA Circuit A/C Outer Sensor Short 879BKB Circuit Ventilating Sensor Open 879CKA Circuit * Ventilating Sensor Short 879CKB Circuit Sunlight Sensor Open or 879DKZ Short Circuit Ventilation Dumper 879EMC * Abnormality Air Mix Dumper Abnor879FMC * mality 879GKX
Refrigerant Abnormality
DAZ9KQ
A/C Model Selection Abnormality
DAZQKR
CAN2 Discon (Aircon ECU)
See Chapter 40, "Troubleshooting by failure code" **
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector cannot be checked. **: Troubleshooting is not performed by the air conditioner unit but by the machine monitor. a The air conditioner inner sensor means the inside (air) temperature sensor. a The air conditioner outer sensor means the outside (air) temperature sensor. a The ventilating sensor means the evaporator temperature sensor (frost sensor). a The ventilation damper means the vent (mode) changeover damper (door). a The air mix damper means the temperature adjustment (air mix) damper (door).
80-100 32
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Testing vent (mode) changeover
SEN06151-00
Testing vent (mode) changeover k
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. k Turn the battery disconnect switch to the "OFF" position and pull out the key. a Note connector numbers and installed positions when disconnecting wiring and hoses. Testing 1. Remove drink box (1) (five bolts). a Disconnect the hose under drink box (1). 2. Remove magazine box (2) (three bolts). a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V power socket). q Connector (3): 12 V power socket intermediate harness (M13A) q Connector (4): 12 V power socket intermediate harness (M13B) 3. Remove cover (5) (three bolts).
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the "ON" position. 7. Start the engine and turn the air conditioner power "ON". 8. Operate the vent changeover switch on the machine monitor. 9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
4. Remove cover (6) (seven bolts). a Be careful about connector (7) behind box (6). q Connector (7): Cigarette lighter (M04) 10. After finishing the inspection, turn the starting switch to the OFF position.
PC200, 200LC, 220, 220LC-8M0
80-100
33
SEN06151-00
100 Air conditioner Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover k
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. q FRESH/RECIRC air is selected by changing the door (damper) angle in the air conditioner unit with the servo motor. Check the opening and closing operations of the door (damper) visually. a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor. Testing 1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON". 3. Operate the FRESH/RECIRC air selector switch on the machine monitor. 4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
80-100 34
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Testing sunlight sensor
SEN06151-00
Testing sunlight sensor k
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. k Turn the battery disconnect switch to the "OFF" position and pull out the key. a Note connector numbers and installed positions when disconnecting wiring and hoses. Testing If [879DKZ] "Sunlight sensor disconnection or short circuit" is displayed by the self-diagnosis ("Air-conditioning System" screen on the machine monitor), test sunlight sensor connector P31. q To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. a If the sunlight sensor is measured with the resistance range of the tester, the sunlight sensor may be destroyed, so do not measure with the resistance range of the tester. q
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7. 2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.) 3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals on the sensor side using a circuit tester in voltage range. q Approximate voltage of sunlight sensor unit 0.55 V: Direct sunlight 0.45 V: Cloudy 0.4 V: Indoors
PC200, 200LC, 220, 220LC-8M0
80-100
35
100 Air conditioner Testing (dual) pressure switch for refrigerant
SEN06151-00
Testing (dual) pressure switch for refrigerant k
Park the machine on a level surface, lower the work equipment to the ground so that it is stable, and stop the engine. k Turn the battery disconnect switch to the "OFF" position and pull out the key. a Note connector numbers and installed positions when disconnecting wiring and hoses. Testing If [879GKX] "Refrigerant Abnormality" is displayed by the self-diagnosis (on "03 Electrical System" screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17. q To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. q The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal. a As the refrigerant pressure will drop when the ambient temperature is below 0 °C, there is a possibility that the dual pressure switch is OFF. In such a case, the dual pressure switch is actually normal (i.e., not defective). q
1. Swing by 90 deg.. 2. Remove the cab undercover. 3. Disconnect the dual pressure switch connector P17.
80-100 36
4. Ensure that the resistance between the switch-side terminals from connector P17 is shorted (ON). (If not shorted (OFF), the dual pressure switch will detect a refrigerant pressure abnormality.) a When the dual pressure switch is OFF, connect a pressure gauge to the high-pressure side of the air conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and "Troubleshooting with gauge pressure." a If the refrigerant pressure is normal, the dual pressure switch is defective. q
(Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2} k When replacing the dual pressure switch, refrigerant must be collected in advance. a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform "Troubleshooting for compressor and refrigerant system".
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Testing relays
SEN06151-00
Testing relays a If the air conditioner compressor is normal (air is cooled), omit this test since the relays are normal. q Compressor clutch relay R21: Turns the air conditioner compressor (clutch) ON/OFF. a See Step 2 on "Parts and connectors layout". Testing 1. Check contact R21 of connector (for disconnection). 2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether its clicks. a The air conditioner controller will not turn on the compressor clutch relay in the following cases. 1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator temperature sensor). 2) When the dual pressure switch detects abnormality (it is turned OFF).
PC200, 200LC, 220, 220LC-8M0
Checking relay unit a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil actually.
q
Compressor clutch relay (RLCC), connector (R21) 1) The coil resistance between terminals (1) and (2) is approximately 300 to 500 z. 2) While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are connected. 3) While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are connected.
80-100
37
100 Air conditioner Troubleshooting chart 1
SEN06151-00
Troubleshooting chart 1 The numbers in the boxes are the item numbers in the troubleshooting table. 1. Cooling trouble
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PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting chart 1
SEN06151-00
2. Heating trouble
PC200, 200LC, 220, 220LC-8M0
80-100
39
100 Air conditioner Troubleshooting chart 2
SEN06151-00
Troubleshooting chart 2 1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow setting. Probable cause
Check method
Remedy Repair broken parts and connect correctly
Wire breakage or defective con- Check the connector for disconnection. nection See "Parts and connectors layout".
Operate the fan switches in order and check the fan speed. See Replace "Air conditioner unit". Defective power transistor (PTR) Operate the fan switches in order and check the fan speed. Replace Defective blower fan motor
2. During cooling, the blower fan motor is normal but the flow of air is very light. Probable cause Large duct resistance Air leakage through duct joints Obstruction at evaporator inlet
Check method
Remedy
Check the filter for clogging and the duct for crushing. Check duct joints. See "Testing air leakage (duct)".
Repair Repair Remove obstruction and clean
Check evaporator for stain and obstruction
Evaporator is frozen. Sensor fixing clip inspection, sensor contaminated Inspect the air conditioner hose around the dual pressure Repair or replace switch for frost. (when freezing has advanced even further) *: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit. Defective evaporator temperature sensor, defective contact of evaporator temperature sensor, defective expansion valve*
3. Pressure abnormality (high-pressure/low-pressure) during cooling. Probable cause
Check method
Insufficient refrigerant Check the refrigerant volume through sight glass. Specifically, perform checking with the gauge manifold connected. Overcharge with refrigerant
Judgment by pressure at inlet/outlet of compressor
80-100 40
Normal pressure range Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} High pressure: Approx. 1.5 - 1.7 MPa {15 – 17 kg/cm2} Temperature in operator's cab: 30 to 35 °C, Engine speed: Approx. 1,500 rpm
Remedy Repair leaking part, then charge with proper quantity of refrigerant again Collect refrigerant, then fill up with proper quantity of refrigerant again See Troubleshooting with gauge pressure
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting chart 2
SEN06151-00
4. During cooling, the compressor will not operate smoothly, or at all. a See "Troubleshooting of compressor system (Air is not cooled)". Troubled part Compressor belt
Compressor
Magnet clutch
Relay Refrigerant pressure Dual pressure switch
Probable cause Slack of belt Trouble in compressor Insufficient compressor oil Seizing on compressor Drop of battery voltage
Check method Remedy Deflection of belt is large. See "Testing and adjusting of Air conditioner Adjust tension compressor belt tension" in the "Testing and adjusting" in Chapter 30 of the shop manual. Slip of clutch Repair or replace See "Handling comHeating of compressor pressor oil". Slip of clutch Charge battery
Inspect with multimeter (10 - 20 z) Check ground cable and joints. Wire breakage or defective conSee "Troubleshooting for compressor and nection of ground wire refrigerant system". Defective compressor clutch relay See "Testing relays" Low/high pressure (Operation of See "Troubleshooting with gauge pressure". pressure switch) See "Troubleshooting for compressor and refrigerant system". Defective dual pressure switch See "Testing refrigerant (dual) pressure switch". Open or short circuit in coil
Replace Repair Replace See "Troubleshooting with gauge pressure". Replace
5. During heating, blower fan motor is normal but air flow alone is insufficient. Probable cause
Check method
Large duct resistance
Check the filter for clogging and the duct for crushing. Check the duct joints by referring to "Testing air leakage Air leakage through duct joints (duct)." Clogging of heater core fins Check heater core fins for clogging
Remedy Repair Repair Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling Probable cause Low engine coolant temperature Low engine coolant level Insufficient circulation of engine coolant The connection of IN and OUT heater hoses is in reverse.
Check method
Remedy
Warm up engine, and then check engine coolant temperature
Find out cause
Check coolant level in radiator Check engine coolant piping for clogging. (Hose, pipe and core)
Add coolant
Check the destination of heater hoses
Correct
Bleed air and correct
7. Fan speed abnormalities during cooling Probable cause Fan speed is low
Check method Remedy See "Testing and adjusting of fan belt and alternator belt tension" in "Testing and adjusting" in Chapter 30 of the shop man- Correct ual.
8. Other abnormalities Probable cause Temperature cannot be controlled Vent (mode) changeover is not possible. FRESH/RECIRC air cannot be changed over Excessive compressor oil
Check method
See "Handling of compressor oil".
Water leakage into the cab
Clogging of drain hole
Remarks
Select manual mode and change temperature setting. See "Testing vent (mode) changeover".
Common to cooling and heating
See "Testing FRESH/RECIRC air changeover".
PC200, 200LC, 220, 220LC-8M0
Cooling only
80-100
41
100 Air conditioner Information in troubleshooting table
SEN06151-00
Information in troubleshooting table Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Failure Related information
Problem on machine Information related to detected failure or troubleshooting
Cause
1
2
Probable causes of failure (Perform troubleshooting according to these.)
3 - defective
Procedure, measuring location, criteria and remarks q Procedure q Measuring location a "Between A and B" means "Measure voltage or resistance and so on between A and B". q Standard value in normal condition to judge probable causes q Remarks required for judgement (1) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) tester leads as shown below unless otherwise specified. q Connect the plus (+) lead to a pin or harness indicated in the front. q Connect the minus (–) lead to a pin or harness indicated in the rear. (2) Example of troubleshooting by inspection of multiple items a Normal in 1 but abnormal in 2 At this time “- defective” shown at left is applied
a If a wiring harness is burnt, replace it. q Open circuit Connection of connector is defective or wiring harness is broken. q Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. q Hot short circuit A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit An independent wire in the harness abnormally comes into contact with one of another wire. (Defective insulation in connector or others) Related circuit diagram This is the excerpted circuit diagram related to failure q Indicates connector No., and pin No. q See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for connector location q The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are two colors Example: WY: Yellow line on white background a The number before the wire color indicates the wire size. q N.C.: Normally closed (Normally ON) q [1], [2],··· are numbers of unlabeled connectors. q Arrow (↔): Roughly indicates their mounting place on the machine.
80-100 42
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code list related to air conditioner
SEN06151-00
Failure code list related to air conditioner Failure code
Component in charge
Action level
879AKA
A/C Inner Sensor Open Circuit
MON
–
879AKB
A/C Inner Sensor Short Circuit
MON
–
MON
–
MON
–
MON
–
MON
–
MON
–
MON
L01
879BKA 879BKB 879CKA 879CKB 879DKZ 879EMC
A/C Outer Sensor Open Circuit A/C Outer Sensor Short Circuit Ventilating Sensor Open Circuit Ventilating Sensor Short Circuit Sunlight Sensor Open or Short Circuit Ventilation Dumper Abnormality
879FMC
Air Mix Dumper Abnormality
MON
L01
879GKX
Refrigerant Abnormality
MON
L01
MON
–
MON
L01
DAZ9KQ DAZQKR
a a a a a
Failure (Displayed on screen)
A/C Model Selection Abnormality CAN2 Discon (Aircon ECU)
Category of record
Remarks
Electrical Troubleshooting cannot be system performed while the controller is mounted on the machine Electrical since the connector cannot be system checked. Electrical system Electrical system Electrical Troubleshooting cannot be system performed while the controller is mounted on the machine Electrical since the connector cannot be system checked. Electrical system Electrical Troubleshooting cannot be system performed while the controller is mounted on the machine Electrical since the connector cannot be system checked. Electrical system Electrical system See Chapter 40, "TroubleElectrical shooting by failure code" system
The air conditioner inner sensor means the inside (air) temperature sensor. The air conditioner outer sensor means the outside (air) temperature sensor. The ventilating sensor means the evaporator temperature sensor (frost sensor). The ventilation damper means the vent (mode) changeover damper (door). The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes q Troubleshooting for power supply system (Air conditioner does not operate) q Troubleshooting for compressor and refrigerant system (Air is not cooled) q Troubleshooting for blower motor system (No air comes out or air flow is abnormal) q Troubleshooting for FRESH/RECIRC air changeover
PC200, 200LC, 220, 220LC-8M0
80-100
43
100 Air conditioner Failure code [879AKA] A/C Inner sensor Open Circuit
SEN06151-00
Failure code [879AKA] A/C Inner sensor Open Circuit Action level
Failure code
–
879AKA
Detail of failure Action of controller Problem on machine
Open circuit in air conditioner inside air temperature sensor (Machine monitor system)
q
Air conditioner controller detected open circuit in inside (air) temperature sensor.
q
The air conditioner controller sends information about the inside (air) temperature sensor open circuit to the machine monitor via CAN communication. Stops the air conditioner if it is in automatic mode. The air conditioner does not operate in automatic mode because of an open circuit in the air conditioner inside air temperature sensor. (The air conditioner can be operated in manual mode) Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air) temperature sensor cannot be checked while the controller is installed on the machine.
q q
q
Related information
Failure
q q
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
80-100 44
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879AKB] A/C Inner sensor Short Circuit
SEN06151-00
Failure code [879AKB] A/C Inner sensor Short Circuit Action level
Failure code
–
879AKB
Detail of failure Action of controller Problem on machine
Short circuit in air conditioner inside air temperature sensor (Machine monitor system)
q
Air conditioner controller detected short circuit in inside (air) temperature sensor.
q
The air conditioner controller sends information about the inside (air) temperature sensor short circuit to the machine monitor via CAN communication. Stops the air conditioner if it is in automatic mode. The air conditioner does not operate in automatic mode because of a short circuit in the air conditioner inside air temperature sensor. (The air conditioner can be operated in manual mode) Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of the air conditioner inside (air) temperature sensor cannot be checked while the controller is installed on the machine.
q q
q
Related information
Failure
q q
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
80-100
45
100 Air conditioner Failure code [879BKA] A/C Outer sensor Open Circuit
SEN06151-00
Failure code [879BKA] A/C Outer sensor Open Circuit Action level
Failure code
–
879BKA
Detail of failure Action of controller Problem on machine
Open circuit in air conditioner outside air temperature sensor (Machine monitor system)
q
An open circuit is detected in the air conditioner controller outside air temperature sensor
q
The air conditioner controller sends information about the outside air temperature sensor open circuit to the machine monitor via CAN communication. Continues control of air conditioner in automatic mode, ignoring data of outside air temperature sensor. Since there is an open circuit in the air conditioner outside temperature sensor, outside temperature is not counted in automatic mode. (does not have any effect to the air conditioner in manual mode) Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. For connectors etc., see "Parts and connectors layout". Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced.
q q
q q
Related information
Failure
q q
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective outside air temperature 2. Disconnect connector P18. 1 sensor Resistance Between P18 (male) (1) and (2)
25 °C
1. Turn starting switch to OFF position. 2. Disconnect connector AC01. Open or short circuit in wiring har2 a Same as above, if resistance is normal. ness Resistance Between AC01 (female) (7) and (8)
25 °C
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
Approx. 1.7 kz
Approx. 1.7 kz a If no failure is found by check for cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors P18 and AC01. Resistance
Between AC01 (female) (7) and P18 (female) (1)
Max. 1 z
Between AC01 (female) (8) and P18 (female) (2)
Max. 1 z
If no failures are found by the above checks, the air conditioner controller may 4 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) 5 Defective air conditioner unit
80-100 46
If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879BKA] A/C Outer sensor Open Circuit
SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0
80-100
47
100 Air conditioner Failure code [879BKB] A/C Outer sensor Short Circuit
SEN06151-00
Failure code [879BKB] A/C Outer sensor Short Circuit Action level
Failure code
–
879BKB
Detail of failure Action of controller Problem on machine
Short circuit in air conditioner outside air temperature sensor (Machine monitor system)
q
Air conditioner controller detected short circuit in outside air temperature sensor.
q
The air conditioner controller sends information about the outside air temperature sensor short circuit to the machine monitor via CAN communication. Continues control of air conditioner in automatic mode, ignoring data of outside air temperature sensor. Since there is a short circuit in the air conditioner outside air temperature sensor, outside temperature is not counted in automatic mode. (does not have any effect to the air conditioner in manual mode) Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. For connectors etc., see "Parts and connectors layout". Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced.
q q
q q
Related information
Failure
q q
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective outside air temperature 2. Disconnect connector P18. 1 sensor Resistance Between P18 (male) (1) and (2)
25 °C
1. Turn starting switch to OFF position. 2. Disconnect connector AC01. Open or short circuit in wiring har2 a Same as above, if resistance is normal. ness Resistance Between AC01 (female) (7) and (8)
25 °C
3 Short circuit in wiring harness
Approx. 1.7 kz
Approx. 1.7 kz a If no failure is found by check for cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors P18 and AC01. Resistance
Between AC01 (female) (7) and (8), or between P18 (female) (1) and (2)
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors P18 and AC01. Between ground and AC01 (female) (8) or P18 Resistance Min. 1 Mz (female) (1) If no failures are found by the above checks, the air conditioner controller may 5 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Ground fault in wiring harness 4 (contact with ground circuit)
6 Defective air conditioner unit
80-100 48
If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879BKB] A/C Outer sensor Short Circuit
SEN06151-00
Circuit diagram related to air conditioner outside air temperature sensor
PC200, 200LC, 220, 220LC-8M0
80-100
49
100 Air conditioner Failure code [879CKA] Ventilating sensor Open Circuit
SEN06151-00
Failure code [879CKA] Ventilating sensor Open Circuit Action level
Failure code
–
879CKA
Detail of failure Action of controller Problem on machine
Open circuit in temperature (frost) sensor (Machine monitor system)
q
Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
q
The air conditioner controller sends information about the evaporator temperature (frost) sensor open circuit to the machine monitor via CAN communication. Stops the air conditioner.
q q q
Related information
Failure
q q
The air conditioner does not operate due to an open circuit in the evaporator temperature (frost) sensor. Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of the evaporator temperature (frost) sensor cannot be checked while the air conditioner unit is installed on the machine.
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
80-100 50
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879CKB] Ventilating sensor Short Circuit
SEN06151-00
Failure code [879CKB] Ventilating sensor Short Circuit Action level
Failure code
–
879CKB
Detail of failure Action of controller Problem on machine
Evaporator temperature (frost) sensor short circuit (Machine monitor system)
q
Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
q
The air conditioner controller sends information about the evaporator temperature (frost) sensor short circuit to the machine monitor via CAN communication. Stops the air conditioner.
q q q
Related information
Failure
q q
The air conditioner does not operate due to a short circuit in the evaporator temperature (frost) sensor. Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of the evaporator temperature (frost) sensor cannot be checked while the air conditioner unit is installed on the machine.
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
80-100
51
100 Air conditioner Failure code [879DKZ] Sunlight sensor Open or Short Circuit
SEN06151-00
Failure code [879DKZ] Sunlight sensor Open or Short Circuit Action level
Failure code
–
879DKZ
Detail of failure Action of controller Problem on machine
Sunlight sensor open or short circuit (Machine monitor system)
q
Air conditioner controller detected open or short circuit in sunlight sensor.
q
The air conditioner controller sends information about the sunlight sensor open or short circuit to the machine monitor via CAN communication. Continues control of air conditioner in automatic mode, ignoring data of sunlight sensor. Since there is an open or short circuit in the air conditioner sunlight sensor, sunlight strength is not counted in automatic mode. (does not have any effect to the air conditioner in manual mode). Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. For connectors etc., see "Parts and connectors layout". Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced.
q q q q
Related information
Failure
q q
q
Cause
Procedure, measuring location, criteria and remarks 1. See "Testing sunlight sensor".
1 Defective sunlight sensor
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
Voltage
Between sunlight sensor terminals
Direct sunlight
Between sunlight sensor terminals
Cloudy
Between sunlight sensor terminals
Indoors
Approx. 0.55 V Approx. 0.45 V Approx. 0.4 V
1. Turn starting switch to OFF position. 2. Disconnect connector P31. a See "Testing sunlight sensor". Resistance
Between P31 (female) (1) and AC01 (female) (10)
Max. 1 z
Between P31 (female) (2) and AC01 (female) (9)
Max. 1 z
If no failures are found by the above checks, the air conditioner controller may 3 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) 4 Defective air conditioner unit
80-100 52
If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879DKZ] Sunlight sensor Open or Short Circuit
SEN06151-00
Circuit diagram related to sunlight sensor
PC200, 200LC, 220, 220LC-8M0
80-100
53
100 Air conditioner Failure code [879EMC] Ventilating Damper Abnormality
SEN06151-00
Failure code [879EMC] Ventilating Damper Abnormality Action level
Failure code
L01
879EMC
Detail of failure Action of controller Problem on machine Related information
Failure
Abnormality in vent (mode) changeover damper servomotor (Machine monitor system)
q
Air conditioner controller judged from potentiometer voltage of servomotor that vent (mode) changeover damper servomotor is not operating.
q
The air conditioner controller sends information about the abnormality in vent (mode) changeover damper to the machine monitor via CAN communication.
q
Vent (mode) cannot be changed but air conditioner can be operated.
q
Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of vent (mode) changeover damper servomotor cannot be checked while the air conditioner unit is installed on the machine.
q q
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
80-100 54
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879FMC] Air Mix Damper Abnormality
SEN06151-00
Failure code [879FMC] Air Mix Damper Abnormality Action level
Failure code
L01
879FMC
Detail of failure Action of controller Problem on machine Related information
Failure
Abnormality in air mix (temperature regulation) damper servomotor (Machine monitor system)
q
The air conditioner controller judged from the potentiometer voltage of the servomotor that the air mix (temperature regulation) damper servomotor is not operating.
q
The air conditioner controller sends information about the air mix damper abnormality to the machine monitor via CAN communication.
q
The air conditioner does not operate since temperature cannot be regulated.
q
Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. Troubleshooting cannot be performed since the connector portion of the air mix damper servomotor cannot be checked while the air conditioner unit is installed on the machine.
q q
Cause
Procedure, measuring location, criteria and remarks
If no failures are found by the above checks, the air conditioner controller may 1 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be 2 Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC200, 200LC, 220, 220LC-8M0
80-100
55
100 Air conditioner Failure code [879GKX] Refrigerant Abnormality
SEN06151-00
Failure code [879GKX] Refrigerant Abnormality Action level
Failure code
L01
879GKX
Detail of failure
Failure
Refrigerant (dual) pressure switch abnormality (Machine monitor system)
q
Air conditioner controller detected that dual pressure switch was OFF (abnormal).
q
Action of controller
q
The air conditioner controller sends information about the refrigerant pressure abnormality to the machine monitor via CAN communication. The air conditioner controller turns OFF compressor clutch relay, since refrigerant pressure is abnormal. (air conditioner compressor stops)
Problem on machine
q
Air conditioner (cooling) does not work
q
Method of reproducing failure code: Turn starting switch to ON position. Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. For connectors etc., see "Parts and connectors layout". Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced.
q
Related information
q q
q
Cause 1
Defective refrigerant (dual) pressure switch
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. See "Testing (dual) pressure switch for refrigerant". When replacing the dual pressure switch, be sure to collect refrigerant in advance. See "Caution for refrigerant"
k
1. Turn starting switch to OFF position. 2. Disconnect connectors AC01 and AC05. Between P17 (female) (1) and AC01 (female) (6)
Max. 1 z
Resistance Between P17 (female) (2) and ground Max. 1 z a Looseness and rust of T06 If no failures are found by the above checks, the air conditioner controller may 3 Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) 4 Defective air conditioner unit
80-100 56
If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Failure code [879GKX] Refrigerant Abnormality
SEN06151-00
Circuit diagram related to refrigerant (dual) pressure switch
PC200, 200LC, 220, 220LC-8M0
80-100
57
SEN06151-00
100 Air conditioner Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) Failure Problem on machine
Air conditioner does not operate due to power supply system failure.
[DAZQKR] is displayed on the operation screen of machine monitor. No air blows out (Blower motor does not rotate). q If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting first. a The machine monitor, engine controller, pump controller, and air conditioner controller are connected via CAN communication. q "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In this section, 1) and 2) of the following are explained. 1) The air conditioner controller is receiving no power. 2) The air conditioner controller is malfunctioning. 3) No communication is possible between the air conditioner controller and the machine monitor. a For 3), see failure code [DAZQKR]. q Turn starting switch to ON position and check whether failure code [DAZQKR] is displayed on machine monitor and whether CAN communication condition is abnormal. This type of abnormal status indicates that CAN communication cannot be performed between the air conditioner controller Related inforabove the air conditioner unit and the machine monitor. mation q Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse box F01 for breakage. q Ground cable of air conditioner is connected in machine wiring harness together with electrical equipment of machine. q For each connector, see "Parts and connectors layout". q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compressor and refrigerant system." q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). q To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced. q q
Cause
1
2
3
4
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. Defective wiring harness (ground) 3. Disconnect connector AC02. Between (1) (black) on harness side of connector Resistance Max. 1 z AC02 and chassis ground 1. Turn starting switch to OFF position. Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 10 (5 A) in fuse box F01 for breakage. a If fuse described in related information is blown, replace it. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Disconnect connector AC02. Defective wiring harness 4. Turn battery disconnect switch to ON position. 5. Turn starting switch to ON position. Between connector AC02 (female) (4) (red) and (1) Voltage 20 to 30 V (black) a If the fuse is blown again during the above test, carry out the following procedure. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. Ground fault in wiring harness 3. Disconnect connector AC02. (contact with ground circuit) 4. Remove fuse No. 10 of fuse box F01. Between ground and connector AC02 (female) (4) Resistance Min. 1 Mz (red) or F01-10
80-100 58
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Cause
5 Open circuit in wiring harness
SEN06151-00
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Turn starting switch to OFF position. Turn battery disconnect switch to OFF position. Disconnect connector AC02. Remove fuse No. 10 of fuse box F01. Between connector AC02 (female) (4) (red) and Resistance F01-10
Min. 1 Mz
6 Defective air conditioner controller Replace air conditioner controller. 7 Defective air conditioner unit
If no failure is found by above checks, air conditioner unit may be defective.
8 Defective machine monitor
If no failure is found by above checks, machine monitor is defective.
Circuit diagram related to power supply
PC200, 200LC, 220, 220LC-8M0
80-100
59
SEN06151-00
100 Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for compressor and refrigerant system (Air is not cooled) Failure
Air is not cooled due to compressor or refrigerant system failure.
When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is not cooled as displayed on screen. q Air conditioner compressor does not operate. q Referring to "Testing with self-diagnosis function", display "Electrical Systems" screen on the machine monitor and check to see if the refrigerant pressure is abnormal by checking whether failure code [879GKX] is displayed. If the refrigerant pressure is abnormal, the compressor will not be turned ON and air will not subsequently not be cooled. a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the dual pressure switch is not grounded". q In certain cases, the air conditioner will not turn on at 3 °C or lower (normal). Related inforq If no air comes out, see "Troubleshooting for blower motor system". mation q For each connector and fuse, see "Parts and connectors layout". a A T-adapter is provided only for the connector AC03. q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). q To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced. Problem on machine
q
Cause
1
Defective dual pressure switch system
2
Defective air conditioner compressor
Defective compressor 3 clutch relay (does not turn ON)
80-100 60
Procedure, measuring location, criteria and remarks a Perform this check when failure code [879GKX] is displayed on "Electrical Systems" screen of machine monitor. See failure code [879GKX]. a In certain cases, the dual pressure switch may be operating normally and set to OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a pressure gauge to the air conditioner compressor and check the refrigerant pressure. (See "Troubleshooting with gauge pressure.") k Before replacing pressure switch, collect refrigerant. 1. Turn starting switch to OFF position. 2. Disconnect the connector AC03 from the air conditioner compressor and connect a T-adapter to the male side. a Ensure connection of air conditioner compressor ground cable (E). (See "Parts and connectors layout".) Between connector AC03 (male) (1) and the chassis Resistance Approx. 15 z ground (i.e., air conditioner compressor coil resistance) q Referring to "Testing relays", check sound when compressor clutch relay is turned ON. Click is heard -----------------------------------------A a When A above is abnormal and B below is abnormal and C is normal (if the relay is normal), go to cause 4. 1. Turn starting switch to OFF position. 2. Disconnect connector R21. 3. Use a wire to short-circuit (3) (white) and (5) (red on yellow) of connector R21 (wiring harness side) . (This forces the compressor to operate without using the relay.) 4. Turn starting switch to ON position. Air is cooled -----------------------------------------B 1. Turn starting switch to OFF position. 2. Disconnect connector R21 and troubleshoot in that condition. Between (1) and (2) of connector R21 300 – Resistance C (male) (i.e., coil resistance) 500 z
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Cause
SEN06151-00
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector R21 and carryout troubleshooting without turning starting switch ON. a Ensure that test result for cause 2 (air conditioner compressor is normal) is normal. Between connector R21 (female) (5) and F01-11 Max. 1 z Open circuit in wiring har(Dual pressure switch is turned ON) 4 ness Between connector R21 (female) (3) and chassis Resistance ground Approx. 15 z (Air conditioner compressor coil resistance) Between F01-10 and AC01 (female) (4) 300 – 500 z a Relay coil resistance a If the fuse is not blown, skip troubleshooting. Ground fault in wiring har- 1. Turn starting switch to OFF position. 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the female side 5 ness of AC03. (contact with ground circuit) Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
6
Short circuit in wiring harness
7
Defective air conditioner controller
1. Turn starting switch to OFF position. 2. Disconnect connectors AC01, AC02, and R21. a Ensure that test result for cause 2 is normal. Between wiring harness side (2) of connector R21 and Resistance Min. 1 Mz AC02 (female) (2), (3), and (4) 1. Turn starting switch to OFF position. 2. Disconnect connector R21. 3. Turn starting switch to ON position. 4. Display the air conditioner operation screen on the machine monitor and press the A/C switch. Voltage
Between connector R21 (female) (2) and ground
Max. 1 V
8
1. Turn starting switch to ON position. Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor. (defective switch) Press A/C switch. "A/C ON" is displayed
9
Defective air conditioner unit
If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
80-100
61
SEN06151-00
100 Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Circuit diagram related to compressor and refrigerant system
80-100 62
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
SEN06151-00
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) Failure
No air comes out or air flow is abnormal due to blower motor system failure.
LCD of machine monitor on air conditioner operation screen lights up normally but air does not come out. q Air flow does not match fan switch setting on air conditioner operation screen. q This failure is not checked with self-diagnosis function. q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain while during cooling, freezing of the evaporator is a likely cause. This may be due to the followings. 1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 3-A from "Troubleshooting for compressor and refrigerant system") 2) Detachment of the evaporator temperature sensor's mounting holder (Replace the air conditioner unit) 3) Incorrect adjustment of expansion valve (Replace air conditioner unit) Related infor- q If air comes out, fuse and motor are normal, and also wiring harness is normal. q For each connector and power transistor, see "Parts and connectors layout". mation a The power transistor is on the rear side of the air conditioner unit. q If air comes out but its flow is abnormal in heating mode, replace power transistor. (When no air comes out, the power transistor may also be defective.) a The blower motor cannot be replaced unless the air conditioner unit is removed once. q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate connector does not have a T-adapter either, it does have large pins). q To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced. Problem on machine
q
Cause Defective fuse No. 11 in 1 fuse box F01
Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault.
1. Turn starting switch to OFF position. 2. Replace power transistor. 2 Defective power transistor a If air comes out and air flow can be adjusted, the original power transistor is defective. 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connector AC02. ness 3 3. Remove fuse No. 11 of fuse box F01. (wire breakage or defective contact of connector) Resistance Between AC02 (female) (2) and F01-11 Max. 1 z 1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Disconnect connectors AC02 and R21. 4 ness 3. Remove fuse No. 11 of F01. (contact with ground circuit) Resistance Between AC02 (female) (2) or F01-11 and ground Defective air conditioner controller Defective air conditioner 6 unit 5
Max. 1 z
If no failures are found by the above checks, the air conditioner controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, air conditioner unit may be defective.
PC200, 200LC, 220, 220LC-8M0
80-100
63
SEN06151-00
100 Air conditioner Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Circuit diagram related to blower motor system
80-100 64
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting for FRESH/RECIRC air changeover
SEN06151-00
Troubleshooting for FRESH/RECIRC air changeover Failure
FRESH/RECIRC air cannot be changed over
When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or fresh air does not change over. (FRESH/RECIRC air changeover door (damper) does not rotate) q FRESH/RECIRC air changeover is not checked with self-diagnosis function. q Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air selector switch and check operation of FRESH/RECIRC air changeover door (damper). q For each connector, see "Parts and connectors layout". a The T-adapter is not prepared for the connector. q Since connector ACECU of the air conditioner controller has small pins and does not have a T-adapter, perform troubleshooting by using the intermediate connector (Although the intermediate Related inforconnector does not have a T-adapter either, it does have large pins). mation q To replace the air conditioner harness between air conditioner controller connector ACECU and intermediate controller, the air conditioner unit must be replaced. q Method of reproducing failure code: Turn starting switch to ON position. q Check whether this failure code is displayed in the "Electrical Systems" (electrical systems abnormality record) screen in the service mode of the machine monitor. q Troubleshooting cannot be performed since the connector portion of the servomotor cannot be checked while it is installed on machine. Problem on machine
q
Cause 1
Defective fuse No. 18 in fuse box F01
Open circuit in wiring harness 2 (wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault. a Connector [5] installed on machine cannot be disconnected since it is on the rear side of the air conditioner unit. 1. Turn starting switch to OFF position. 2. Disconnect connector AC02. 3. Remove fuse No. 18 of F01. Resistance Between F01-18 and AC02 (female) (3)
3
4 5
6
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector AC02. Ground fault in wiring harness 3. Remove fuse No. 18 of F01. (contact with ground circuit) Between F01-18 and ground, or between AC02 Resistance Max. 1 z (female) (3) and ground If no failures are found by the above checks, the air conditioner controller may Defective air conditioner controller be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failures are found by the above checks, the air conditioner unit may be Defective air conditioner unit defective. (Since this is an internal defect, troubleshooting cannot be performed.) 1. Turn starting switch to ON position. 2. Display the air conditioner operation screen on the machine monitor. Defective machine monitor (defective switch) Display of Recirc/Fresh Press FRESH/RECIRC air selector switch. changes.
PC200, 200LC, 220, 220LC-8M0
80-100
65
SEN06151-00
100 Air conditioner Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
80-100 66
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Troubleshooting with gauge pressure
SEN06151-00
Troubleshooting with gauge pressure Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see "Connection of service tool". a The gauge pressure varies largely with the weather condition and operating condition of the machine. Check the gauge pressure under the pressure measurement conditions. q High-pressure line pressure is too high: Above approx. 2.5 MPa {25 kg/cm2} q High-pressure line pressure is too low: Below approx. 1 MPa {10 kg/cm2} q Low-pressure line pressure is too high: Above approx. 0.3 MPa {3 kg/cm2} q Low-pressure line pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2} a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or low-pressure line is abnormal.
Item Condition value Ambient temperature 25 to 50 °C Engine speed 1,500 rpm Air conditioner switch ON Fan switch HI Set temperature Full cool
Dual pressure switch a The swiths is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor operation.
q
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
PC200, 200LC, 220, 220LC-8M0
80-100
67
100 Air conditioner Troubleshooting with gauge pressure
SEN06151-00
Indicated gauge pressure Pressure is normal
Cause
Check method
Air conditioner cycle is operating normally. If there is any trouble (cooling trouble), there is another cause. High-pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2}
Remedy
–
2
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm } Collect refrigerant, then Bubble can be seen through sight glass. *1, fill up with proper quanInsufficient refrigerant *3 tity of refrigerant again *2 There is a temperature difference between Replace Clogging of receiver drier inlet and outlet pipes of receiver drier. *2 Tank is frosty Clean or replace sion valve *2 Repair or replace Evaporator is frozen Low-pressure gauge Replace receiver drier Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to reads vacuum Collect refrigerant, then or defective contact of sensor (coming off freezing. fill up with proper quanof mounting clip) (At Cool Max. and HI speed of fan, later it tity of refrigerant again becomes not to cold.) *2 Piping between receiver drier and compressor is clogged or crushed. Clean or replace Clogged or crushed piping If clogged completely, low-pressure gauge *2 reads vacuum Collect refrigerant, then fill up with proper quanFilling too much with refrigerant Connect gauge manifold tity of refrigerant again *2 Clean, repair fins, or Dirty condenser, clogging or crushing of repair or replace con Improper adjustment of expansion valve Replace Bubble can be seen through sight glass. *3 (Valve is opened too wide) *2 Evacuate and then fill up with proper quantity of Air in cycle parts Bubble can be seen through sight glass. *3 refrigerant again *2 Clean inside of cycle or hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check mainly on pipe joints and dirty parts with oil. *2: k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again. *3: Sight glass is on the air conditioner hose near condenser.
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100 Air conditioner Connection of service tool
SEN06151-00
Connection of service tool Symbol
Part number
Part name
X
799-703-1200
Service tool kit
a Use the service tool kit for R134a. Service tool kit X (1): Gauge manifold (2): Red high-pressure charging hose (red) (3): Blue low pressure charging hose (blue) (4): Quick joint for HI side (large diameter) (5): Quick joint for LO side (small diameter)
Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. Close high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1). 2. Connect the red charging hose (2) to the HI side of the gauge manifold and the blue charging hose (3) to the LO side. 3. Connect quick joints (4) and (5) to each hose. 4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
(a): As the thread is coarse, care should be taken with regard to loosening.
PC200, 200LC, 220, 220LC-8M0
80-100
69
SEN06151-00
100 Air conditioner Connection of service tool
A: From Cab B: To Condenser
80-100 70
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100 Air conditioner Precautions for disconnecting and connecting air conditioner piping
SEN06151-00
Precautions for disconnecting and connecting air conditioner piping Precautions for disconnecting k Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, condenser air conditioner compressor or receiver drier and so on. a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working cloth with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. q
q
When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches. Use one wrench to fix and use the other one to loosen the nuts. Cover the air conditioner piping connections not to enter dust, water or moisture.
PC200, 200LC, 220, 220LC-8M0
Precautions for connecting q Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. q When connecting piping check that there is no damage and deterioration. q Apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of "Handling compressor oil") a Do not apply oil to the threads of a bolt, nut or union, however. q Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers. q Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). a Example of O-ring installation There are O-rings at all the connections of the air conditioner piping.
q
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71
100 Air conditioner Precautions for disconnecting and connecting air conditioner piping
SEN06151-00
Table of tightening torque for refrigerant pipe joint. Thread size
Tightening torque Nm {kgm}
M6 x 1.0
8 – 12 {0.8 – 1.2}
1. Engine 2. Compressor 3. Condenser 4. Modulator 5. Air conditioner unit
80-100 72
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100 Air conditioner Handling of compressor oil
SEN06151-00
Handling of compressor oil 1. Compressor oil management (DENSO: ND-OIL8 for R134a) Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following types of problem can occur if the amount in the system is too high or too low. Condition Content Insufficiency of Lubrication trouble and seizure of comoil pressor Cooling trouble Excess of oil (Excessive oil stick to parts and lower heat exchange performance)
Air conditioner unit, evaporator
Quantity to be added (cc) Approx. 40
Condenser (including modulator)
Approx. 60
Modulator (desiccant) only
Approx. 20
Hose (between compressor and cab) Hose (between compressor and condenser) Hose (between condenser and cab)
Approx. 35
Air conditioner part
Approx. 30 Approx. 10
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant. 2. Filling compressor oil k
Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for connecting air conditioner piping." a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use an oil suitable for R134a (DENSO: ND-OIL8). a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after use to limit contact with air. Store the oil can in a dry and ventilated place. a Precautions for using oil Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except a baked finish) as it may dissolve these plastics. Check compressor oil in the following cases, and then add new oil if necessary. q When much refrigerant is discharged because of leakage. q When the compressor is troubled and replaced. (See 3 below) q When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced. q Quantity of oil to be added when cycle part is replaced
PC200, 200LC, 220, 220LC-8M0
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SEN06151-00 3. Replacement of compressor q
In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (180 cc) filled in it.
100 Air conditioner Handling of compressor oil
4. Applying compressor oil to O-rings Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to prevent the leakage of refrigerant.
Other cases a New compressor contains compressor oil of 180 cc in it. 1) Prepare an oil container and drain oil from the old compressor. 2) Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
q
3) Drain below-mentioned quantity of oil from the new compressor. Quantity to be drained = 180 cc - "Noted quantity" Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new compressor would be 150 cc (i.e., 180 - 30 cc).
80-100 74
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100 Air conditioner Desiccant replacement procedure
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Desiccant replacement procedure a Prepare desiccant (20Y-810-1250).
replacement
kit
Taking out desiccant (D) 1. Remove snap ring (SR) from receiver drier (2). 2. Remove cap (C) from receiver drier (2). Hold boss (B) of cap (C) with pliers etc. to remove. a Cap (C) may be hard to remove. When removing it, take care not to damage or deform the seal or receiver drier (2). 3. Remove filter (F) from receiver drier (2) 4. Take desiccant (D) out of receiver drier (2). a Removed snap ring (SR), cap (C), filter (F), desiccant (D) will be replaced with the parts of the drier (desiccant replacement kit) and will not be necessary any more.
k
When replacing the desiccant, be sure to collect the refrigerant from the air conditioning cycle. If the desiccant is replaced without collecting the refrigerant, the refrigerant may blind you or cap (C) may fly out and injure you because of the refrigerant pressure in the cycle. 1. Condenser 2. Receiver drier a The desiccant is in receiver drier (2).
PC200, 200LC, 220, 220LC-8M0
80-100
75
SEN06151-00
100 Air conditioner Desiccant replacement procedure
Installing new desiccant (D) 1. Apply ND-OIL 8 to the periphery of O-ring (OR) of cap (C). 2. Install filter (F) to cap (C).
3. Insert desiccant (D) in receiver drier (2). 4. Install cap (C) with filter (F) to receiver drier (2). 5. Install snap ring (SR) to receiver drier (2). a Install snap ring (SR) to the groove in receiver drier (2) securely. If it is not installed securely, cap (C) may come off.
80-100 76
PC200, 200LC, 220, 220LC-8M0
100 Air conditioner Desiccant replacement procedure
PC200, 200LC, 220, 220LC-8M0
SEN06151-00
80-100
77
SEN06151-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06151-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
80-100
78
SEN06153-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
90 Diagrams and drawings
1
100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram............................................................................................................... 2 Hydraulic circuit diagram................................................................................................................................. 5
PC200, 200LC, 220, 220LC-8M0
90-100
1
SEN06153-00
Symbols in hydraulic circuit diagram
90-100
2
100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram
1
PC200, 200LC, 220, 220LC-8M0
100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram
PC200, 200LC, 220, 220LC-8M0
SEN06153-00
90-100
3
SEN06153-00
90-100
4
100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram
PC200, 200LC, 220, 220LC-8M0
Hydraulic circuit diagram
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 a
Hydraulic circuit diagram PC200, 200LC, 220, 220LC-8M0
1
This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06153-00
PC200, 200LC, 220, 220LC-8M0
5
100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram
PC200, 200LC, 220, 220LC-8M0
SEN06153-00
90-100
7
SEN06153-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06153-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
90-100
8
SEN06154-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Machine model
Serial number
PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0
400001 and up 400001 and up 100001 and up 100001 and up
90 Diagrams and drawings
1
200 Electrical diagrams and drawings Symbols in electric circuit diagram.................................................................................................................. 2 Electrical circuit diagram ................................................................................................................................. 5
PC200, 200LC, 220, 220LC-8M0
90-200
1
SEN06154-00
Symbols in electric circuit diagram
90-200
2
200 Electrical diagrams and drawings Symbols in electric circuit diagram
1
PC200, 200LC, 220, 220LC-8M0
200 Electrical diagrams and drawings Symbols in electric circuit diagram
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
90-200
3
SEN06154-00
90-200
4
200 Electrical diagrams and drawings Symbols in electric circuit diagram
PC200, 200LC, 220, 220LC-8M0
Electrical circuit diagram (1/5) PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
Electrical circuit diagram PC200, 200LC, 220, 220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00 PC200, 200LC, 220, 220LC-8M0
5
Electrical circuit diagram (2/5) PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
Electrical circuit diagram PC200, 200LC, 220, 220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00 PC200, 200LC, 220, 220LC-8M0
7
Electrical circuit diagram (3/5) PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
Electrical circuit diagram PC200, 200LC, 220, 220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00 PC200, 200LC, 220, 220LC-8M0
9
Electrical circuit diagram (4/5) PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
Electrical circuit diagram PC200, 200LC, 220, 220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00 PC200, 200LC, 220, 220LC-8M0
11
Electrical circuit diagram (5/5) PC200-8M0,PC200LC-8M0, PC220-8M0, PC220LC-8M0
Electrical circuit diagram PC200, 200LC, 220, 220LC-8M0
★ This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN06154-00 PC200, 200LC, 220, 220LC-8M0
13
200 Electrical diagrams and drawings Symbols in electric circuit diagram
PC200, 200LC, 220, 220LC-8M0
SEN06154-00
90-200
15 5
SEN06154-00
PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic excavator Form No. SEN06154-00
© 2012 KOMATSU All Rights Reserved Printed in Japan 07-12 (01)
90-200
16 6
