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

'.

SEBM02050309

KOMATSU

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

PC200,21 0-3

PC220,240-3 -

MACHINE MODEL

SERIAL No.

20001 and up

PC200,200LC-3

K10001 and up

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

20001 and up

PC240 ,240LC ,240NLC-3

10001 and up

PC240,240LC,240NLC-3K

K10001 and up

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

-

PC200-3

PC220-3

Printed in Japan 07-88(01 )06261

21464 and up

26365 and up

Revised

•

PC200-3

•

PC210-3

• •

PC220-3 PC240-3

21464 and up

26365 and up

00-1 ®

-

CONTENTS No. of page

01 GENERAL

01-1

10 ENGINE 11

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

11-1

12

TESTING AND ADJUSTING

12-1

13

DISASSEMBLY AND ASSEMBLY

13-1

20 POWER TRAIN 21

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

21-1

22

TESTING AND ADJUSTING

22-1

23

DISASSEMBLY AND ASSEMBLY

23-1

24

MAINTENANCE STANDARD

24-1

-

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

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

31-1

33

DISASSEMBLY AND ASSEMBLY

33-1

34

MAINTENANCE STANDARD

34-1

60 HYDRAULIC SYSTEM 61

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

61-1

62

TESTING AND ADJUSTING

62-1

63

DISASSEMBLY AND ASSEMBLY

63-1

64

MAINTENANCE STANDARD

64-1

80 ELECTRIC AND ELECTRONIC SYSTEM 81

STRUCTURE AND FUNCTION

81-1

82

TESTING AND ADJUSTING

82-1

90 OTHERS 93

00-2 ®

DISASSEMBLY AND ASSEMBLy

93-1

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

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~ IMPORTANT

SAFETY NOTICE

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

it

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

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

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

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

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

-

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

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

00-3

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

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

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

-

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

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

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

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

-

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

00-4

-

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

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

.-

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

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

-

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

00-5

HOW TO READ THE SHOP MANUAL

-

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

VOLUMES

REVISED EDITION MARK

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

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

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

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

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

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

-

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

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

21 - 3

t

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

Example 2 (Engine volume):

Symbol

Item

Special safety precautions are necessary when performing the work.

~ Safety

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

¢

*

Caution

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

Weight

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

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

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

00-6

J--

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

Remarks

db ~

~.

Wi • ...:.

-

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

Places to be coated with adhesives and lubricants etc.

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

Drain

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

-

-

HOW TO READ THE SHOP MANUAL

NETWORK (Disassembly and assembly relationship drawings)

MAINTENANCE STANDARD Standard size, Tolerance

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

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

Ass'y

-

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

Example:

120- 0 .026

-0.126

Utequals 119.874 -

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

119.978 mm)

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

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

I

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

0030 Shaft-- 60-0.076

TROUBLESHOOTING CHART

-

N N



20--' oa:

Set pressure

(kg/cm

2

)

Piston type: 320 Gear type: 30

Type, number Control lever operation

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

0

:::) -5:20

Swing motor

Piston type x 1

cc

>-

o

f-

I--'2

Hydraulic cylinder

Double acting piston

Hydraulic tank

Closed box type

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled

PC200, 220-3

01-7

-

-

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

-

-

ENGINE ASSEMBLY DRAWING

GENERAL

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

•

PC220-3

FRONT VIEW

LEFT SIDE VIEW

Unit:mm

l

Direction of wind

Crankshaft center

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:1

6-IOXI.5

i

I-

205F2005

205F2006

REAR VIEW

RIGHT SIDE VIEW ~

OJ

-o~

.!: ~ c >OJ UU

-

I

i

I

Oil pres. sensor

Water temp. sensor

j'D»-

To radiator

-...

I

~I

co

~

~o cco '" C ~

OJ

U",

lOX 1.5

8-IOXI.S

I 0 X I .5

235

-

.J

205F2007-1

PC200, 220-3

205F2008·1

01-9

LIST OF WEIGHT

GENERAL

-

LIST OF WEIGHT Unit: kg Machine Model

PC200-3

PC220-3

Serial Numbers

20001 and up

20001 and up

Engine ass'y

830

850

635

655

20

20

178

175

7

10

Radiator ass'y

105

115

Hydraulic tank (without hydraulic oil)

150

150

95

95

1,500

2,255

•

Engine

•

Damper

•

Main piston pump

•

Charging pump

Fuel tank (without fuel) Revolving frame

-

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

395

395

Swing machinery

175

215

Swing motor assembly

70

70

Travel motor assembly (with brake valve)

70

70

165

165

30

30

Counterweight

2,910

3,935

Track frame assembly

3,921

5,090

•

Track frame

1,995

3,030

• •

Carrier roller assembly

24 x 2

24 x 4

Track roller assembly

37 x 14

37 x 16

Recoil spring assembly

135 x 2

135 x 2

Idler assembly

120 x 2

120 x 2

550

560

36 x 2

36 x 2

275

305

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

• •

•

Final drive assembly

• •

Sprocket Swing circle assembly

-

01-10

PC200, 220-3

-

SPECIFICATIONS

GENERAL

Machine Model

PC220-3

PC220LC-3

Serial Numbers

20001 and up

20001 and up

Engine model

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

Type

-

No. of cylinder - bore x stroke

(mm)

Total displacement

(cc)

Flywheel horsepower

(HP/rpm)

148/2,100

Maximum torque

(kgm/rpm)

56.5/1,400

High idling speed

(rpm)

2300 ± 50

Low idling speed

(rpm)

850 ± 50

Minimum fuel consumption ratio

(g/HPh)

LU

6 - 105 x 125 6,494

Z (9

Z LU

155

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

Starting motor

24V,25A

Alternator

24V (12V x 2) - 140 Ah

Battery

D-type corrugate fin

Type of radiator core LU

(9 ,« 0:_ LUO:

Carrier roller

(one side)

2

2

Track roller

(one side)

8

10

00:

z«

c..

-

Built-up triple grouser

Track shoe

=>u

:2:

=>

c..

u

Variable displacement piston type x 2 Gear type x 1

Type, number Delivery

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

(Q/min)

.-J

Gear type: 50 (at rated engine speed)

=>

«0: 0

:2:

LU

Built-up triple grouser

Set pressu re

>-

I

(kg/cm 2

)

Piston type: 320 Gear type: 30

f-

(/)

>-

...J

(/)

0 a:w

U

z...J

.-J

=>

0«

u>

«

u

>-

«a: a:o 0>>-0 I:;;

0: 0

I

Type, number

...J

::>

Control lever operation

Pilot type (Travel control lever: linkage type)

Travel motor

Piston type (with parking brake) x 2

Swing motor

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

Hydraulic cylinder

-

4-spool type and 5-spool type

>->

Double acting piston

Hydraulic tank

Closed box type

Hydraulic filter

Tank return side

Hydraulic cooler

PC200, 220-3

Air cooled

01-11 (2)

ENGINE ASSEMBLY DRAWING

GENERAL

-

ENGINE ASSEMBLY DRAWING FRONT VIEW

LEFT SIDE VIEW

Unit:mm

Water inlet

Direction of wind

:uI 'I

/

6-IQXI.5

L

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0>

1239

"O~

.=

~ c >0> U"

205F2006

205F2005

REAR VIEW

RIGHT SIDE VIEW

Water temp. sensor

Oil pres. sensor

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

Potentiometer (if equipped)

L)"

J)~ -

. -

To radiator

4~IOXI.5

'~"-

~i

1 Engine 0 speed sensor 001 (if equipped) ~

~~~

:"'It ~j

00,

0,

12-IOX 1.5 4-12X I lOX 1.5

235

-.-4-

235

205F2007

01-12 ®

205F2008

PC200, 220-3

-

ENGINE I I STRUCTURE AND FUNCTION

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

-

. . . . .

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

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

PC200. 220-3

11-1 CZ)

ENGINE MOUNT AND ENGINE ATTACHED PARTS

STRUCTURE AND FUNCTION

-

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

~

' _ >V---'-c-ft·-

/ !

I

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

1',1

,

;

. . • .j

;j.- .'

.___

'i

j

,; ,

1'1

I

, I

-

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3

4

5

6 9

11

10

12

/

-

Section A-A View Z

11-2 ®

205F2009-1

PC200, 220-3

-

STRUCTURE AND FUNCTION

ENGINE MOUNT AND ENGINE ATTACHED PARTS

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

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

2

F20503101 -----'1 1

I I I,

\ \

-----+- 8 "

F{ \\

LU

-

View Z

PC200, 220-3

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

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

11-3 (6)

STRUCTURE AND FUNCTION

RADIATOR AND COOLER

-

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

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

11

4

2

\\ \

/

.~

~~ .

-

7

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I

'

B

3 ··~10 205F20 I I

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

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

Specifications

~

Core type

Overall heat radiation area

Radiator

CD-3

23.83 m 2

Hydraulic oil cooler (air cooled)

SF-3

12.47 m 2

Capacity

10Q

5.2Q

11-4

PC200, 220-3

STRUCTURE AND FUNCTION

DAMPER

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

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

/1

) 4cstic-=-~.\

.

l' .

~.;~.

;.. ~i

:I

,

- ' ,I ~"'/-

.

'1/.1;.'

~ .d,

"

1

1

J'

A

-

Maximum torque

E

Engi ne speed

u c co

.g

Low idling speed

l1>

kgm/rpm

47/1,600

rpm

800 - 900

-

56.5/1,400 800 - 900 -

High idling speed

rpm

2,250 - 2,350

O°C

rpm

150 min.

-

2,250 - 2,350

"-

Necessary starti ng speed

E

~

~

~

'":::Jco

-'= x

150 min.

_20° C (Using starting aid)

-

rpm

100 min. 162 max.

635 max.

162 max.

635 max.

50 max.

75

50 max.

75

650 max.

650 max.

650 max.

Intake resistance

All speed

mmH 2 0

Inta ke pressu re

All speed

mmHg

Exhaust pressure

All speed

mmHg

Exhaust temperature

All speed !intake air temp.: 20°C)

°c

650 max.

100 min.

-

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Quick acceleration

-0

c

Exhaust gas color

co

At high idling

l1>

-'" j'l

-c

Valve clearance at 20°C

Bolch scale

Intake valve

mm

Exhaust valve

mm

5.5 max.

6.0

5.5 max.

6.0

1.0 max.

2.0

1.0 max.

2.0

0.25

0.25

0.25

0.25

0.45

0.45

0.45

0.45 I

Oil temperature: 40 - 60°C

>

kg/cm

2

31.5 min.

22

31.5 min.

22

Compression pressure

-0 0 .0

(E ngi ne speed)

(rpm)

(320 - 360)

mmH 2 0

100 max.

200

100 max.

200

kg/cm 2

3.5 - 5.5

2.5

3.5 - 5.5

2.5

1.0min.

0.8

1.0 min.

0.8

°c

80 - 110

120

80 - 110

120

%

0.5 max.

1.0

0.5 max.

1.0

(320 - 360)

l1>

c

At high idling

'0,

c

Blow-by pressure

LJJ

Oil temperature: min. 80°C E

2l

~

c 0 .;::; co

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

:::J

...J

E

At low idling

kg/cm

2

Oil temperature

All speed (Oil in oil pan)

Oil consumption ratio

At continuous rated output (Ratio to fuel consumption)

Fuel injection pressure

Nozzle tester

kg/cm 2

225

180

225

180

Fuel injection timing

B.T.D.C.

Degree

20 ± 1

20

20 ± 1

20

Coolant temperature

All speed (at engine outlet)

°c

70 - 80

100

70 - 80

100

Valve cracking temperature

°c

74.5 - 78.5

74.5 - 78.5

74.5 - 78.5

74.5 - 78.5

Full opening temperature

°c

90

90

90

90

mm

10 ± 0.5

10 ± 0.5

10 ± 0.5

10 ± 0.5

kg/cm 2

0.75 ± 0.1

0.75 ± 0.1

0.75±0.1

0.75 ± 0.1

.~

.n

At high idling

_l1>

-

l1>~

:::J '"

LL~

E

~

Thermostat function

~

Full opening lift

C>

c

"6 0

u

Radiator pressure valve function

Opening pressure (Differential pressure)

Fan speed

At high idling speed

rpm

2,100

2,100

2,100

2,100

Fan belt tension

Deflect when pushed with a force of 6 kg

mm

10

5 -15

10

5 -15

12-2 ®

PC200,220-3

-

TESTING AND ADJUSTING TOOL LIST

TESTING AND ADJUSTING

TESTING AND ADJUSTING TOOL LIST No.

-

Testing and measuring item

1

Engine speed

2

Battery S.G.

3

Freezing temperature of cooling water

4

Water temperature, oil temperature, air intake temperature

Part No.

Remarks

Multi-tachometer

799-203-8000

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

Battery coolant tester

795-500-1000

Fault finding tool

1.1 00 - 1.300 -5 - -50°C

0- 200°C ThermIstor temperature gauge

799-101-6000

5

Exhaust temperature

0- 1,000°C

6

Lubrication oil pressure

0- 20 kg/em'

7

Fuel pressu re

0- 50 kg/em'

8

Intake pressure, exhaust pressure

9

Blow-by pressure

0-500mmH20

10

Intake resistance

-1,000 - 0 mmH,

11

Compression pressure

Compression gauge

795-502-1204

0- 70 kg/em'

12

Blow-by pressure

Blow-by checker

799-201-1503

0- 500mmH,O

13

Valve clearance

Feeler gauge

795-125-1330

0.25, 0.45 mm

14

Exhaust gas color

Handy smoke checker

799-201-9000

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

15

Water and fuel content in oil

Engine oil checker

799-201-6000

Provided with 0.1 and 0.2 water content standard samples

16

Fuel injection pressure Fuel injection nozzle spray condition

Nozzle tester

Commercially available

0- 300 kg/em'

17

Coolant quality

Water quality tester

799-202-7001

PH, nitrite ion concentration

18

Pressure valve function Leakage in cooling water system

Radiator cap tester

799-202-9001

0- 2 kg/em'

19

Radiator blockage (wind speed)

Anemometer (Air speed gauge)

799-202-2001

0- 40 m/s

20

Engine cranking

Cranking kit

795-610-1000

Engine with DC24V starting motor

21

Electrical circuits

Tester

Commercially available

Current, Voltage, Resistance

Engine pressu re measu ring kit

799- 203- 2002

0- 1,000 mmHg

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

PC200. 220-3

12-3 (6)

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

-

ADJUSTING VALVE CLEARANCE

*

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

Exhaust valve

0.25

0.45

At 20°C 1) 2)

3)

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

-

*

Cylinder No.

1

2

--

4

3

5

-

6

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

Exhaust valve

4)

0

0

0

0

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

5)

0

0

Lock nut:

3.2 ± 0.3 kgm

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

*

*

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

lock

nut,

confirm

4

3

5

6

valve

21KFIOI

12-4 CD

PC200. 230-3

-

-

-

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

-

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

-

MEASURING EXHAUST GAS COLOR Special tool

A

LL *

Part No.

Part Name

Q'tv

799-201-9000

Handy smoke checker

1

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

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

1) 2)

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

-

* 3)

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

5) 6)

7)

*

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

*

-

*

12-6 CD

PC200, 220-3

-

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

*

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

Intake valve

Exhaust valve

0.25

0.45

Engine at cold 1) 2)

-

3)

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

*

Cylinder No.

1

2

4

3

5

6

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

Intake valve

Exhaust valve

4)

•

a

a

a

•

a

a

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

5)

•

•

a

Lock nut:

3.2

± 0.3 kgm

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

*

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

4

*

After tightening clearance.

-

lock

nut,

confirm

3

5

6

valve

21KFIOI

PC200.220-3

12-7 CD

MEASURING COMPRESSION PRESSURE

TESTING AND ADJUSTING

-

MEASURING COMPRESSION PRESSURE

*

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

Special tool

A

Part No.

Part Name

a'ty

795·502·1204

Compression gauge

1

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

-

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

*

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

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

3.

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

* 4.

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

5.

Set the tachometer.

6.

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

-

*

* *

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

12-8 CD

PC200, 220-3

-

MEASURING BLOW-BY PRESSURE

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE Special tool

A

* 1.

-

Part No.

Part Name

a'ty

799-201-1503

Blow-by checker

1

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

2.

Connect adapter to blow-by checker A with tube.

3.

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

*

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

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

-

PC200. 220-3

12-9 CD

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

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

4. Place fuel control lever at FULL position.

-

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

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

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

BEYOND injection timing line:

Timing RETARDED

BEFORE injection timing line:

Timing ADVANCED

*

*

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

--

12-10 CD

PC200. 220-3

TESTING AND ADJUSTING

ADJUSTING FUEL CONTROL LEVER

3.

CHECKING FUEL CONTROL LEVER SENSOR

* 1)

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

205P24 I I

-

2)

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

3)

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

*

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

To controller ---+-.

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

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

eNg

205F2415

4)

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

* *

205F2416

PC200, 220-3

12-13 ®

ADJUSTING DECELERATION CYLINDER

TESTING AND ADJUSTING

-

ADJUSTING DECELERATION CYLINDER Adjustment procedure

1)

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

*

*

5

4

* *

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

2 F20503062A

4

2 F20503063A

,. 12-14 ®

PC200.220-3

TESTING AND ADJUSTING

ADJUSTING FUEL CONTROL LEVER

3.

CHECKING FUEL CONTROL LEVER SENSOR (IF EQUIPPED)

*

1)

After adjustment, check the sensor as follows.

10

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

205P24I I

-

2)

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

3)

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

*

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

Fuel control

To controller ---+.

~-----?Ieversensor

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

eN9

205F2415

4)

-

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

*

*

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

205F2416

PC200, 220-3

12-13 @

ADJUSTING DECELERATION CYLINDER

TESTING AND ADJUSTING

-

ADJUSTING DECELERATION CYLINDER Adjustment procedure 1)

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

*

*

5

4

*

*

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

2 F20503062A

4

2 F20503063A

12-14 (8)

PC200, 220-3

-

-

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION TESTING FAN BELT TENSION

Water pump pulley Approx. 10 mm

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

Alternator pulley

205F2417

-

ADJUSTING FAN BELT TENSION 1) 2)

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

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

PC200, 220-3

12-15 CD

-

-

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

-

--

ENGINE I3 DISASSEMBLY AND ASSEMBLY

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

-

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

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

*

-

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

*

After repair or long storage, follow the same procedure.

PC200. 220-3

13-1 @

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

-~

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

Open hood.

2.

Remove lower engine cover.

3.

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

4.

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

INSTALLATION OF STARTING MOTOR ASSEMBLY

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

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

2.

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

*

3.

Install lower engine cover.

4.

Close Mod and lock with catch.

5.

Connect lead to negative (-) terminal of battery.

-

13-2 cD

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

ALTERNATOR

REMOVAL OF ALTERNATOR ASSEMBLY

it

-

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

1.

Open hood.

2.

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

3.

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

4.

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

5.

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

INSTALLATION OF ALTERNATOR ASSEMBLY

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

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

2.

Fit belt (6) in pulley groove.

3.

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

* 4. 5.

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

*

6.

Close hood and lock with catch.

7.

Connect lead to negative (-) terminal of battery.

02L 05W

-.

05B

PC200. 220-3

205F2301A

13-3 CD

DISASSEMBLY AND ASSEMBLY

ENGINE OIL COOLER

-

REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1.

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

*

2.

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

3.

Remove heater relay (3) together with plate.

4.

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

5.

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

6.

Remove tube (8) between oil cooler and block.

7.

Remove engine oil cooler assembly (9).

P205C3024

-

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

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

2.

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

-

* 3.

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

4.

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

* 5.

Install heater relay (3) together with plate.

6.

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

7.

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

*

13-4 CD

9

P205C3029

PC200, 220-3

-

-

-

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

-

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

-

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

(2) and loose

4. Disconnect fuel supply hose (4).

*

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

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

-

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

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

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

205P2016

13-6

Plt From shuttle valve of arm PPC valve

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

21-9-2 (6)

STRUCTURE AND FUNCTION

TRAVEL AND BRAKE SYSTEM

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

*

-

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

From

PR

port

To arm throttle valve

From port PL

From travel shuttle valve

From port PL

From port PR

205F2034

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

From

From travel shuttle valve

PR

...

port

To arm throttle valve

From port PL

...

From port PL

From port PR

205F2035

21-10 @

-

PC200, 220-3

-

-

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

3.

TRAVEL CONTROL VALVE

Port Pl ,

Port P4 PortP1Al

Port PAA

E Port B1L

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

-

\ \ Port P3Al Port B3l Port B2l

Port A3l

A

Port P3BA

B

Port A2l

5-spool valve

4-spool valve

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

1.

F20503004

Travel shuttle valve

PC200, 220-3

21-11 (2)

STRUCTURE AND FUNCTION

TRAVEL AND BRAKE SYSTEM

•

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

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

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

/

6

/

8

9

Section A-A

10

11

12 14

9

~15

3

-

13

Section C-C Section G-G

1. 9. 10. 11. 12.

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

21-12 (6)

F20503005

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

PC200, 220-3

-

-

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

•

5-SPOOL VALVE (RIGHT TRAVEL CONTROL VALVE)

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

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

16~.

17 18

20

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

6

23

22 Section B-B

24

-

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

25

10

Section D-D F20503006

PC200, 220-3

21-13 (~

STRUCTURE AND FUNCTION

TRAVEL AND BRAKE SYSTEM

MAIN RELIEF VALVE

9

1.

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

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

F20503032

-

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

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

•

-

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

•

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

F20503035

21-14 @

PC200, 220-3

-

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

1)

Counterbalance valve

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

-

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

c,

c MA

MB

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

205F2041

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

MA

MB

205F2042

-

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

MA

MB

205F2043

PC200, 220-3

21-15

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

2)

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

Setting pressure 320

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

Control valve

-

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

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

205F2044

11

205F2045

G

21-16

PC200, 220-3

-

-

-

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

-

STRUCTURE AND FUNCTION

FINAL DRIVE SYSTEM

-

FINAL DRIVE SYSTEM

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

4

3 1. Coupling 2. Shaft

'I -

8~ 9"

" 10~

3. Hub

4. 5. 6. 7.

~

~

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

12

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

13/ /

11. 12. 13. 14. 15.

11--

-

1

/ 14

15

17

16 Section A-A

21-18

205F2046

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

PC20D,220-3

-

FINAL DRIVE SYSTEM

STRUCTURE AND FUNCTION

STRUCTURE • • •

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

•

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

•

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

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

Reduction ratio: 1

PC200-3:

32

72

32

72

31

72

31

72

+13 x n

-69.892

1 - 27 x 7i 1

PC220-3:

+14x2j

1 - 27 x

-78.714

m

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

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

www. k omat s upar t s book . c om •

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

•

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

Volume of lubricating oil (each side): 4£

(engin~ oil CLASS-CD SAE30)

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

-

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

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

-

205F2047

PC200, 220-3

21-19

STRUCTURE AND FUNCTION

SWING SYSTEM

-

SWING SYSTEM 1. OUTLINE

-

2

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

F205C3008

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

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

-

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

*

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

21-20

PC200, 220-3

-

2.

-

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

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

12

Counterbalance valve spool

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

2

F

3 (Plate)

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

(Disc)

6

Travel brake valve

c 205F2039

PC200, 220-3

21-21 ~

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

(2) TRAVEL BRAKE VALVE

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

~,

I~j I

I~' ill.

•

-

~I

':j

l 'I'CC C--1 -10

F20503007

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

7

8

9

10

11

\

-

°

/ / - - ......

--,OJ' ~_/

Section 0-0

Section C-C

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

+g kg/cm

2

(at 5 Q/min) 2

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

21-22 (6)

1. 2. 3. 4. 5.

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

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

_-

205F2040

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

PC200, 220-3

-

TRAVEL AND BRAKE SYSTEM

STRUCTURE AND FUNCTION

1)

Counterbalance valve

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

-

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

c MA

MB

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

205F2041

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

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

205F2042

-

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

Dl

MB

205F2043

PC200, 220-3

21-23

STRUCTURE AND FUNCTION

TRAVEL AND BRAKE SYSTEM

2)

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

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

Control valve

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

-

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

205F2044

11

205F2045

G

21-24 (6)

PC200, 220-3

-

-

SWING SYSTEM

STRUCTURE AND FUNCTION

2

I I I I

I I I I

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

3

4

7

6

5

B

Section A-A

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

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

F205C3013

*

Theoretical delivery: 87.8 cc/rev

PC200, 220-3

21-25

STRUCTURE AND FUNCTION

SWI NG SYSTEM

(1) SWING BRAKE AND SAFETY VALVE

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

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

2

_---3

-

4

----5 6

www. k omat s upar t s book . c om 7

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

B

9

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

1. 2. 3. 4. 5.

Adjustment screw Lock nut Sleeve Safety valve spring Piston

21-26

6. 7. 8. 9.

Safety valve Housing Check valve Check valve spring

-

205F2055

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

PC200, 220-3

STRUCTURE AND FUNCTION

SWING SYSTEM

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

-

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

lever

•

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

from

Cs Return oil from another circuit

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

MB Control valve 205F2056

•

-

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

PC200, 220-3

•

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

•

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

21-27

STRUCTURE AND FUNCTION

SWING SYSTEM

2.

When returning the swing control lever to "Neutral":

Cs Return oil from another circuit

B

A

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

MB

MA Control valve

205F2057

•

•

•

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

•

•

-

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

21-28

PC200, 220-3

STRUCTURE AND FUNCTION

SWI NG SYSTEM

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

r---

5-spool control valve

Accumulator

I

I r'ARt--:

L.H. PPC valve

lj!

I

I

-

!

+-

I

I

I

I,

I

- - +- '-j

:

I~P1BRl

1

I

,

I

I

:

: I

l- __ I

C·,

I

I I I

I

I

I

I

I

- -r- ~'_JI I

Swing motor safety valve

Main relief valve

I

Set pressure 320 kg/em'

I

I I

I

Shuttle valve

-tn

I

Charging pump

I I I

--Jtr :

I

I

JJ

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

II

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

,----------...-+_

I Hydraulic. filter

D

L

P5a

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

Oil cooler

L-

-

-

_

II

I

4-spool control valve

I Hydraulic tank

IP5

I

Solenoid valve for swing mechanical brake

I I

t - - -----1 I

205F2049-2

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

PC200, 220-3

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

21-29 (~)

STRUCTURE AND FUNCTION

SWING SYSTEM

(2) Operating to "SWING RIGHT"

5-spool control valve

1--

Accumulator

~1.AR}

;- _ ____ __ _,

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

I

_

i

I

i-fIr'--i :' :

LH. PPC valve

I

,

tf>lB~ ~

Swing

-~

I

•

~J

-t

"

-t - - -- -- ~"-

Shutti~'valve:

Charging pump

L

-

L

-

-

~~;~ i""'

-

'

-

-

-

-

, -

-

priority

:

:

valve

:,

I

i

:

i

:

I,

"

PR

'L__

-,

,

:

,

,

---H

i

MB

I

I

Front main pump

Swing motor safety valve

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

T,---'~

:

I

-

0

nf- ~ 0~ I~

When the arm control lever is operated to "A RM IN", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P4AR. It acts on the tip of the spool of the arm-Lo and arm-Hi control valves, and moves the spools. When this happens, the pressure oil from the front main pump and rear main pump enters port PR and port PL, passes through arm-La and arm-Hi control valves, and merges. The oil from port B4R acts on the bottom end of the arm cylinder, and extends the arm cyl inder. The oil returning from the arm cyl inder head passes through port A4 R to port T. It then flows through the hydraul ic filter and oil cooler, and is drained to the hydraul ic tank.

PC200, 220-3

•

•

When the arm control lever and swing control lever are operated at the same time, the pilot pressure from the PPC valve (for swing) actuates the swing priority valve. This regulates the flow of pressure oil to the arm-La control valve. Therefore priority is given to supply of oil to the swing circuit. This im'proves ease of operation when using arm and swing together. If the arm control lever is operated to "ARM IN" when there is no load, the weight of the arm and bucket will make the cylinder move more quickly than oil can be supplied to the cylinder bottom, so negative pressure will be formed at the bottom end of the cylinder To prevent this, there is a throttle (modified spool) in the return circuit of the arm-La control valve.

61-15

STRUCTURE AND FUNCTION

WORK EQUIPMENT CONTROL

b.

Arm control lever operated to ARM OUT:

Control valve (5-spool)

A'R

Safety valve Set pres. 340 kg/cm 2

AccumUlator

B'R

j-----~----I

.----------_+_~

I

I I

Arm cylinder

frt ----t-- _!,-'~R_ ~-----

From swing PPC - ~ shuttle valve

~ To oil - - - -r-+-- pres. : -, I

I

-

switch

I

~--~~-I-

~ P4BR - - - - -rl-- - - - - - I

Charging pump

Shuttle valve Front main pump

I

I

Main relief valve Set pres. ~---------~r__~--+'~~_ _--..J 320 kg/cm 2 :

~

L-Jr--r-L'--'--_-'

PR

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

Rear main pump

I

I

I l

PL

I

I

I

r-,,

..I

T

I

I

I

I

r

r---- ----- -

•

I

1~

I

r--

I ------~ '---.J

I

------~---------~

Arm throttle valve

I

I

'-

Hydraulic filter N

"Qj

~ c

•

•

•

:--~I

c.~

'co ~ a;~

Oil cooler

L-....:......_ _

OJ

E ~~

::;;; > Ul M ' - - - - - - - - - - '

I I

Hydraulic tank

When the arm control lever is operated to "AR M OUT", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P4B R. It acts on the tip of the spool of the arm-Lo and arm-Hi control valves, and moves the spools. When this happens, the pressure oil from the front main pump and rear main pump enters port PR and port PL, passes through arm-Lo and arm-Hi control valves, and merges. The oil from port A4R acts on the head end of the arm cylinder, and retracts the

Control valve (4-spool)

•

F205C3022

When the arm control lever and swing control lever are operated at the same time, the pilot pressure from the PPC valve (for swing) actuates the swing priority valve. This regulates the flow of pressure oil to the arm-Lo control valve. Therefore priority is given to supply of oil to the swing circuit. This improves ease of operation when using arm and swing together.

arm cylinder. The oil returning from the arm cylinder bottom passes through port 84 R to port T. It then flows through the hydraulic filter and oil cooler, and is drained to the hydraulic tank.

61-16

-

PC200, 220-3

WORK EQUIPMENT CONTROL

STRUCTURE AND FUNCTION

c.

Arm throttle valve Function • When the arm control lever and boom control lever are operated at the same time, most of the pressure oil flows to the arm circuit, where the load is less. The amount of oil flowing to the boom circuit drops, so the arm speed is faster than boom speed. This makes combined operations difficult. (Particularly when using "ARM OUT" and "BOOM RAISE" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier.

-

•

The arm is actuated by the merged oil flow from two pumps, and the bucket is actuated by the flow from one pump. For this reason, when the arm and bucket are operated together, the flow of oil to the arm circuit is greater, so the arm moves much faster than the bucket. This makes combined operations difficult. (Particularly when using" ARM OUT" and "BUCKET CURL" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier.

www. k omat s upar t s book . c om Operation • When only arm control lever operated: Pilot pressure oil from the boom and bucket PPC shuttle valve does not flow to the arm throttle valve, so the arm throttle valve is not actuated. Pressure oil from the rear main pump passes through port PL and then flows to the arm-Hi control valve.

-

•

To arm-Hi control valve

...

From swing PPC shuttle valve

c;),,""""

...

When arm control lever and boom (or bucket) control lever operated together: The pilot pressure oil from the boom and bucket PPC shuttle valve passes from port P4 to port P4 a. It acts on the right end of the spool of the arm throttle valve, and pushes the spool to the left. When this happens, the pressure oil flowing from the rear main pump to the arm-Hi control valve is restricted, and the arm speed is regulated to make combined operations easier.

From port PL

From boom. bucket PPC shuttle valve

20SF21S0

To arm-Hi control valve

l' From swing PPC shuttle valve

Throttle

*", ':"'. t From port PL

From boom, bucket PPC shuttle valve

20SF21S1

PC200, 220-3

61-17

STRUCTURE AND FUNCTION

WORK EQUIPMENT CONTROL

(4) Operation of bucket control lever

a.

Bucket control lever operated to BUCKET CURL

1--Control valve (5-spool)

Accumulator

r------------,

t - - - - - - - - - - - + -, '., R.H. PPC valve

:

~ck~t--r=i ~

-n

I I

I

-----~~~-:

Safety-suction valve Set pres. 340 kg/cm 2

I I I

I I

I I

:

_ i---i~J l~ Charging pump

Shuttle valve

Front main pump

I

~~Ll

______ _

..I

V

'-

Bucket control valve

,-''--...,.--'-----,

,

~

---

1----1---- CU R L

~~~~--~3I'cl

Bucket cylinder

I

-

: I

To arm-Hi control valve Arm throttle valve

,I

t

I

I

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----'

I

'--,

I I

I

Rear main pump

I I I I

PL

L

I

,--------------1

T

I

r

Main relief valve Set pres.

I

Hydraulic filter

I I

I I

320 kg/cm:-----------i'

I I

I I

Oil cooler

, , ,

Control

I I

V~;;(4-SPOOI)! ~f>"-t----l I

, ,

_____-'1

Hydraulic tank

---

--------r-

L~

~

P.

F205C3023

•

•

•

When the bucket control lever is operated to "BUCKET CURL", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P3 AL and acts on the tip of the spool of the bucket control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL and passes through the bucket control valve. The oil from port B3 R acts on the bottom end of the bucket cylinder, and extends the bucket cyl inder. The oil returning from the bucket cylinder head passes through port A3 R to port T. It then flows through the hydraul ic filter and oil cooler and is drained to the hydraulic tank.

61-18

•

•

-

The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and bucket together. If the bucket control lever is operated to "BUCKET CU RL" when there is no load, the weight of the bucket will make the cylinder move more quickly than oil can be suppl ied to the cyl inder, so negative pressure will be formed at the bottom end of the cylinder. To prevent this, there is a throttle (modified spool) in the return circuit of the bucket control valve.

PC200, 220-3

WORK EQUIPMENT CONTROL

STRUCTURE AND FUNCTION

b.

Bucket control operated to BUCKET DUMP

Control valve (5-spool) Accumulator

,----------,

,

t----------_+___ 1 R. H. PPC valve

I

Bucket

,

:

,'

~--r- -:-m-----i~--~ ~

"

I

-

L

, I

I

j'

-----ri : : I I

:

I I

~

IP3BL

L

-

J

Safetysuction valve Set pres. 340 kg/cm 2

_

CURL

~-1- --t--~ ----~.~:~ __f>3~L

-------

I

I

Shuttle valve Charging pump Front main pump

,I

,

,

, , I I

Bucket cylinder

I

, ,

To arm-Hi control valve Arm throttle valve

I I , I I

, , ,I

- -

---'

'--,

www. k omat s upar t s book . c om Rear main pump

I

,I ,

, ,

l

I

PL

,

,I , , ,I ,I

(

I

1 Hydraulic filter:

Contr-;;I-;;~Ive

Oil cooler

(4-spool)

;--i-------=-n~-I ~f>,~t--:

-----+- -_ . --

'---

'--_1

L_

'p,

.J

~

Hydraulic tank

-

F205C3024

•

•

•

-

When the bucket control lever is operated to "BUCKET DUMP", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows from port P3 BL and acts on the tip of the spool of the bucket control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL and passes through the bucket control valve. The oil from port A3 L acts on the head end of the bucket cylinder, and retracts the bucket cyl inder. The oil returning from the bucket cylinder bottom passes through port B3 L to port T. It then flows through the hydraulic filter and oil cooler and is drained to the hydraulic tank.

PC200, 220-3

•

The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and bucket together.

61-19

WORK EQUIPMENT CONTROL

STRUCTURE AND FUNCTION

(5) a.

BOOM CONTROL Boom control lever operated to BOOM RAISE

Accumulator Control valve (5-spool)

:------T-------iB~~HT~trOivi~=-~It-----------+,

I

'

I

:: I

__J

I

'

~,I t~, -----1 I

I

~

+--l i

I

._ LJ=d--hJ-tl i I

L

tI

:

Main relief valve

"----~~~.L ~

;.-p':':'R';-'+---)----;;>--.=:.._...J

I

Charging Shuttle valve I pump Front main pump I I

I

L i

Set pres.

}3~_k~/~r.r2~_

-- -

+---+-~~~

--._._-

RAISE

p~j- -~~~%IL~a~v~----...-----4---+4-JL.*=----4

~

P'AL

-

I

I

Boom cylinder

www. k omat s upar t s book . c om To arm-Hi control valve

Rear main pump

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ JI

Ll\J:~j~.Q!.!~~'!!~-- - - l

T

I

Main relief val/ve 320 kg cm

I

Control valve

Oil cooler

~~-P!.~"---------J

:

I

(4~s~~;;I)T

I

1

Lp·~t---l

~_------------------

J

P. t -~

Hydraulic tank F205C3025

•

•

When the boom control lever is operated to "BOOM RAISE", the spool of the PPC valve connected directly to ~ the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows to port P2 BLand acts on the tip of the spool of the boom-Lo and boom-Hi control valve, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom-Lo. control valve, and goes to port A2L. At the same time, the pressure oil from the front main pump enters port PR, passes through the boom-Hi control valve, and goes to port A2 L. The oil acts on

•

•

the bottom end of the boom cylinder, and extends the boom cylinder. The oil returning from the boom cylinder head passes through port B2 L to port T. It then flows through the hydraulic filter and oil cooler and is drained to the hydraulic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together.

61-20

PC200, 220-3

WORK EQUIPMENT CONTROL

STRUCTURE AND FUNCTION

b.

Boom control lever operated to BOOM LOWER

Accumulator

1-

Control valve (5-spool)

,-----, I

I I I

l

.-

I I I

!l-----, I

I

I

I

I

I I

+_,

-

l____ ,-1 J

8l i!

I L;,-

Charging Shuttle valve pump Front main pump I I I

I I

I

I

I I

I I

p~,_

-

- - - - - - - - - - - - - '--"'---I

Bo-;;-m~L~

- - - - - - - - - -

RAISE

~

cont rol va~.lrver+.l_r_rrTT"_rr"..

P'AL

Boom cylinder

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I I

Rear main pump

I

I I

I

__________________ J

--,

I

L~r!!:,..!hIP!!I~I/il~e ~IL+---..,

T

Main rei ief valve Set pres.

320 k,lcm'

Con~rol Oil cooler

r

I

valve

,

~

(4-~-

Lp'1---: I

I

'

J

L I

'j.

I ,

-- -----

H

__

p.

Hydraulic tank

-

F205C3026

•

•

-

•

When the boom control lever is operated to "BOOM LOWER", the spool of the PPC valve connected directly to the control lever is actuated. Pilot pressure oil (set pressure: 30 kg/cm 2 ) from the charging pump flows to port P2A L and acts on the tip of the spool of the boom-Lo, and moves the spool. When this happens, the pressure oil from the rear main pump enters port PL, passes through the boom-Lo control valve, and goes to port B2 L. The oil acts on the head end of the boom cylinder, and retracts the boom cylinder. The oil returning from the boom cylinder bottom passes through port A2 L to port T. It then flows

PC200, 220-3

•

•

through the hydraulic filter and oil cooler and is drained to the hydraulic tank. The pilot pressure oil divided from the shuttle valve passes through port P4 to_port P4a, and actuates the arm throttle valve. This regulates the flow of pressure oil to the arm-Hi control valve. This improves ease of operation when using the arm and boom together. For BOOM LOWER there is a throttle (modified spool) in the return circuit. This controls the lowering speed of the work equipment and also acts to prevent negative pressure from being formed at the head end of the boom cylinder.

61-21

STRUCTURE AND FUNCTION

HYDRAULIC TANK

-

HYDRAULIC TANK

]

2 To oil cooler

From oil cooler

. ,From filter



c

LU

Condition

Engi ne rated speed Engine speed when auto-deceleration acts. (If equipped)

• At two pump relief: Bucket and arm circuits relief

-

2100

• Fuel control lever at "Full" • Work equipment control lever at "Neutral"

1200 ± 50

I

Boom control valve

a

1200 ± 50

b

I

a

b

-

Arm control valve

www. k omat s upar t s book . c om Bucket control valve

-E E

OJ > ~

£

Swing control valve

L. H. travel control valve

~~

u..

00

~

-

0 0 0-

(/)

R. H. travel control valve

.,..,.. 'In

()

°oC~

I

35

9.5 ± 0.5 9.5 ± 0.5

35

9.5 \ 0.5 9.51 0.5

205F2401

Boom-Hi control valve

Straight-travel valve

Service valve Neutral ~ Raise and Lower

65 ± 10

65 ± 10

Neutral ~ Arm IN and OUT

65 ± 10

65 ± 10

Neutral ~ Curl and Dump

65 ± 10

65 ± 10

Neutral -+ R.H. and L.H. Swing

65 ± 10

65 ± 10

Neutral ~ Forward and Reverse

130 ± 15

130 ± 15

F

45 ± 5

45 ± 5

R

40 ± 5

40 ± 5

Stop .... Low idling

45 ± 20

45 ± 20

Low idling .... Full speed

175 ± 30

175 ± 30

Boom control lever Arm control lever

-E

Bucket control lever

OJ >

Swing control lever

E

• At center of lever knob

• Measure at end of travel

~

~

Q;

Travel control lever • Do not start engine

> .!"

eC

Travel pedal

0

u

Neutral ~ Forward and Reverse

-

Fuel control lever

62-2 (8)

PC200, 220-3

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Classification

Standard value

Condition

Item Boom control

30+0·5 · -0.8

3.4

Arm control

25+0·5 · -0.8

2.7

Buc ket control

25+0·5 · -0.8

2.7

3 0 +0.5 · -0.8

3.4

Forward

2.5 ± 1.0

3.8

Reverse

2.5 ± 1.0

3.8

Forward

5.5 ± 1.1

8.3

Reverse

6.0 ± 1.2

9

C,

::£

'" OJ

.2

Swing control

Ol

c .;::; co

Permissible value

Travel control

Q;

Q.

• At engine full speed • Hydraulic oil tem peratu re : 45 - 55°C • Hook pushpull scale on center of lever knob to measure

0 ~

'" ~ >

e ~

c 0

Lever

Pedal

u Low idling ... Stop

12.0~~:g

Low idling ... Full speed

10.0~~:~

Fuel control lever

15

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

Arm circuit

• Hydraulic oil temperature: 45 - 55° C

Bucket circuit

Travel circuit

320 +10 -6

320 +25 0

297 +15 -10

275 +25 0

30 +5 0

30 ± 3

• Relief pressure at engine full speed (Be relieved oil in only measuring circuit)

Swing circuit Charging circuit

-

"'E -.

-"'"

TVC valve outlet pressure

• Hydraulic oil temperature: 45 - 55°C • At engine full speed

E

~ '"C-

Lever at neutral At one pump relief (320 kg/cm 2 ) Average pressu re of two pump (160 - 170 kg/cm 2

PC200-3

PC220-3

PC200-3

PC220-3

23 ± 1

24 ± 1

Min.18

Min.18

16 ± 1

17 ± 1

15 ± 1.5

16 ± 1.5

)

.>!

-::l co

-0 I

>-

NC valve outlet pressure

• Hydraulic oil temperature: 45 - 55°C • At engine full speed

Max. 7

Max. 7

Min.18

Min.18

Lever at neutral

15 ± 1.0

15 ± 1.0

Lever at full stroke

Max. 2

Max. 2

Max. 5

Max. 5

Lever at neutral Lever at stroke end Raise track on one side then rotate sprocket

Difference pressure of jet sensor

• Hydraulic oil temperature: 45 - 55°C • At engine full speed

Lowered hydraulic pressure

• Hydraulic oil temperature: 45 - 55°C • Difference oil relief pressure between at engine full speed and at engine a half speed (Measure pressure in one circuit only) .

PC200, 220-3

62-3 @

-

._~----------------------

TESTING AND ADJUSTING

Classification

TABLE OF JUDGEMENT STANDARD VALUE

Item

Standard val ue

Condition

PC200-3 PC220-3

• Engine speed: Full speed • Hydraulic oil temperature: 45 -55°C

(sec,)

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE) • Measure time taken from cylinder fully extended to bucket tooth touching the ground (LOWER)

(sec.)

• Top of boom is in horizontal, and bucket cylinder fully extended • Measure time taken from cylinder fully retracted position to cylinder fully extended position (I N) • Measure time taken cylinder fully extended position to cylinder fully retracted position (OUT)

Boom

Permissible value PC200-3

PC220-3

w (fl

3.2 ± 0.3 3.4 ± 0.3

4.0

4.1

s: o

2.8 ± 0.3

3.4

4.2

z

4.0 ± 0.4 5.0 ± 0.5

5.1

5.9

3.2 ± 0.3 3.2 ± 0.3

3.5

3.9

,(.

o

s:

Top of boom horizontal I Arm cylinder

1~~~,,,

Total work equipment

(Fig. 2)

Max. 600

Max. 960

Max. 30

Max. 45

Max. 110

Max. 165

Max. 20

Max. 30

205F575

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C • Bucket unloaded • Work equipment in posture in Fig. 2 • Measure amount bucket tooth moved down (distance "a") in 15 min. • Measure immediately after setting (mm) Boom cylinder

(mm)

Arm cylinder

(mm)

Bucket cylinder (mm)

62-6 @

• Measure amount each cylinder retracted in 15min.

PC200, 220-3

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Classification

Item

Condition

Standard value

Permissible value

0

1.2 (Time lag is 0 sec, run the engine at min 1500 rpm)

• Engine speed: Low idling • Hydraulic oil temperature: 45 - 55°C Boom

C OJ

(sec.)

E

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measure time taken from bucket tooth touching the ground to the machine raised

Cl

c.

~

:J

OJ

0-

• Top of boom is in horizontal, bucket cylinder fully retracted

E

OJ

i=

.>t.

0

Arm

s:

-

(sec.)

• Measure time taken from arm stopped when arm came into vertical to arm moved again

(sec.)

• Arm is in vertical • Measure time taken from bucket stopped when bucket tooth came in bottom to bucket moved again

Bucket

OJ

u c co

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C

Cl

c

.~

E

2.8 (Time lag is 0 sec, ru n the engi ne at min 1500 rpm)

0

3.6 (Time lag is 0 sec, ru n the engi ne at min 1000 rpm)

0

PC200-3

PC220-3

PC220-3

PC200-3

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

-0

c co c 0 .;::;

OJ

C.

c 0 .;::;

~

~

OJ

c.

OJ

c.

0

0

E co

c 0 .;::; co c

0 E

:0

Arm and Swing 90°

• Bucket unload • Arm is in vertical and boom cylinder is extended fully • Operate at "Boom raise" and in "Swing" at the same time, and measure the time taken and the amount arm top pin moved up when swing for 90°

E 0

Time

3.5 ± 0.4

3.5 ± 0.4

(sec.)

Height of arm top pin (mm) Time

3700 ± 370

4400 ± 440

Min. 2700

Min. 3400

(sec.)

Height of arm top pin (mm)

0 0 aJ

U

-

Boom and Swing 90°

• Engine speed: 2100 rpm • Hydraulic oil temperature: 45 - 55°C • Relief pressure is 30 kg/cm 2

Charging pump discharge

Min. 44.5

40.5

Max. 100

Max. 1.00

Max. 100

Max. 100

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

(li/min.) Hydraulic oil temperature

• Oil levels and coolant level within specifications • Convert the atmospheric temperature reading in ° F to ° C, using the formula ~ (F - 32) = C.

Engine coolant temperature OJ

u c co co .n co ~

Engine oil temperature

OJ

I

Swing gear case oil temperature

Final drive case oil temperature

Estimate the temperature inside the cab on the basis of the known temperature difference between the atmospheric temperature • Drain the antifreeze and use a forcibly open type thermostat. • Wind velocity, maximum 5 m/sec.: Do not conduct the test in extremely bad weather • Surface conditions: Flat and sandy soils with Nd Value 10 - 20 Nd: niobium .With engine running at full speed, dig a ditch whose width is about the same as the machine and whose depth is about 2/3 the max. digging depth, swing 90°, and dump. Continue until the heat balance is achieved. • As far as possible, keep the oil pressure below the set pressure of the relief valve and use simultaneous operations while digging.

PC200, 230-3

62-7 @

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

FLOW CONTROL FEATURE TVC VALVE

*

The following table shows the reference values for use when troubleshooting.

Classification

Item

Condition

S position

Posture of work equipment

L position

PC200-3

PC220-3

PC200-3

PC220-3

3.6 ± 0.4

3.6 ± 0.4

3.8 ± 0.4

3.8 ± 0.4

OJ



c co

E

.E Q;

0.

c

,2 ~

E OJ

Boom and swing 90°

0.

a c a

~

205F2407

•. Engine speed: Full speed

-

• Hydraulic oil temperature: 45 - 55°C

~

co c

:0 E a u (sec.)

• Bucket loaded • Operate at "Boom raise" and in "Swjng" at the same time, and measure the time taken when swing for 90°

www. k omat s upar t s book . c om Posture of work equipment

l~)

j)f>f

,,-);:i

V

Minimum engine speed (rpm) at boom raise, and boom raise speed

~

3co

.e -

e

(sec.)

205F242I

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C

3.2 ± 0.3 (2050 ± 50)

3.5 ± 0.3 (2150±50)

3.8 ± 0.4 (2190 ± 50)

4.0 ± 0.5 (2200 ± 50)

3.5 ± 0.5

3.4 ± 0.5

4.0 ± 0.5

3.9 ± 0.5

• Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE)

~

c

a

Posture of work equipment

:5: a u.. Note. Bucket dump speed when relieving oil in swing circuit

~S;

-;:7=~=

(_l

--~)

-

205F2426

(sec.)

Note:

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C

With the control performance check of the TVC valve, it becomes the control position (approximately position A on the curve) when (swing relief pressure 297

o

~~5 + bucket operation

pressure) -:- 2

=

average pressure.

S, L position

:5: a

;;::

'0 ~

c

:>

a

E

a;

www. k omat s upar t s book . c om -a c. E :J

c..

50

Pump del ivery pressure

PI + P2

2

(kg/em 2 )

Check point

Test pump del ivery pressure (kg/em 2 )

Other pump delivery pressure (kg/em 2 )

Average pressure (kg/em 2 )

Standard value for delivery Q (new machine) (Q/min)

Judgement standard for del ivery Q (Q/min) (bottom level)

(1)

PI

P2

PI + P2 --2-

See graph

See graph

(2)

320

0-20

Note

15 +20 -10

0

(3)

180

320

250

50 ± 20

30

(4)

200 - 180

0-20

100

130 +30 -20

110

(5)

120 - 100

0-20

60

170 +30 -20

150

(6)

0-20

0-20

195 + 5 -10

185

0:... 20

-

Note: The CO valve is working, so the average pressure is unnecessary.

62-12 ®

PC200, 220-3

-

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

PC220-3 Main piston pump (5 mode)

150 c

-

~ 0< d

..., C

::J

a

E co

100

>

'"

.~

a:;

www. k omat s upar t s book . c om "0

0.

E ::J

a..

50

OL.-.l...-L......J---'---l.---l.--'---L.--'--'--'---'--.l...-.l--L......J---l.---l.---l......L--'---'---L.--'--'--'---'--.l--L......JL......J---l.---l.---l.....J

50

100

1 50

200

Pump delivery pressure

P, + pz

-

2

250

300

350

(kg/em Z )

Standard value for delivery Q (new machine) (Q/min)

Judgement standard for delivery Q (Q/min) (bottom level)

--2-

See graph

See graph

0-20

Note

27 ± 20

0

280

320

300

70 ± 20

50

(4)

180

320

250

100 ± 20

80

(5)

300 - 280

0-20

150

170 ± 20

150

0-20

0-20

0-20

195 + 5 -10

185

Check point

Test pump del ivery pressure (kg/em Z )

Other pump del ivery pressure (kg/em Z )

Average pressure (kg/em Z )

(1)

PI

Pz

(2)

320

(3)

(6)

P, + pz

Note: The CO valve is working, so the average pressure is unnecessary.

PC200, 220-3

62-13 @

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

PC220-3 Main piston pump (L mode)

150 1 - - - - - - 1 - - - -

-

d

C ::l o E

100 f - - - - - I - - - - - - t - - - - - - t - - - - =

r:'" ~

www. k omat s upar t s book . c om a; "'C

Co

E ::l

c..

501-----f-----t-----+-------j------1"

Pump delivery pressure

P, + P, 2

(kg/em' )

Check point

Test pump delivery pressure (kg/em' )

Other pump del ivery pressure (kg/em' )

Average pressure (kg/em' )

Standard value for delivery Q (new machine) (Q/min)

Judgement standard for delivery Q (Q/min) (bottom level)

(1)

P,

P,

PI + P, --2-

See graph

See graph

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

40 ± 20

20

(4)

80

320

200

100 ± 20

80

(5)

100 - 80

0-20

100

160 +30 -20

140

(7)

0-20

0-20

0-20

195 + 5 -10

185

-

Note: The CO valve is working, so the average pressure is unnecessary_

62-14 ®

PC200, 220-3

TROUBLESHOOTING Circuit diagram 62-16 62-19 Connection table for connector pins Connector position for troubleshooting 62-21-1 Troubleshooting procedure 62-22 62-23 Checks before troubleshooting Troubleshooting (except troubleshooting for machine monitor) 62-24 62-24 1) How to use the judgement table 2) Judgement table 62-26 3) Method of using the troubleshooting chart. . . . . . . . .. 62-28 Troubleshooting for electric system (E1 - E6) 62-29-1 Troubleshooting for hydraulic and mechanical 62-76 system (H1 - H16)

-

www. k omat s upar t s book . c om Failure mode and components

62-105

-

PC200, 220-3

62-15 Q)

TROUBLESHOOTING

CIRCUIT DIAGRAM

-

CIRCUIT DIAGRAM E. OLSS AND AUTO-DECELERATION SYSTEM (IF EQUIPPED) PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20364) CN33 Engine speed sensor Swing oil pressure sensor

CN32

Potentiometer

Limit switch (neutral)

TVC solenoid

eNII 02n

Auto-decelerator

028

Control box

solenoid

-

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

:Mode selec-:

~S_~i~

Auto"decelerator switch

D5W

Fuse box CN40

PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up) 02YB 02 02LG 02LG

CN33

-

Potentiometer

Control box

~ai=n~===J~CN38 02P 02V

OlP 02V

Resistor

02W

028

Mode selector switch connection OPPOSlW term",,,1 No

~'E

Battery relay

Q.5W

Fuse box

62-16 @

OFF

0

ON

o

M

H

0

F20503064

PC200, 220-3

-

-.

-

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

-

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

-

TABLE OF JUDGEMENT STANDARD VALUE

*

Standard value and permissible value in following table are the value when 3-stage mode selector switch is at H position.

Classification

Item

Condition

Standard value

Permissible value

Engine low idling speed

• Engine oil temperature: in correct range

730 - 820

-

Engine high idling speed

• Engine water temperature: in correct range

2250 - 2350

-

2150 - 2250

Min.2150

-E

-e"0 Q) Q)

~ c: '", c: w Q)

• Hydraulic oil temperature: 49 - 55°C

Engine speed when one or two main pump circuit oil is relief

Engi ne rated speed

Engine speed when auto-deceleration acts.

Boom control valve

• Engine coolant temperature: incorrect range • Engine oil pressure: incorrect range • At one pump relief: Bucket circuit relief • At two pump relief: Bucket and arm circuits relief • Fuel control lever at "Full" • Work equipment control lever at "Neutral"

e

1200 ± 50

1200 ± 50

A) R.H. and L.H. travel control lever spool (Linkaged type)

Arm control valve

-

2100

Q

b

a

Q

b

a

-

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

Bucket control valve

E E a; >

0

Cl. Cfl

I

I

'

i I

--~4Jr

Swing control valve

Neutral

L.H. travel control valve

....~

-0

-....,

a ' b r--+---j

R. H. travel control valve

204F 173

35

B) Control lever spools excepting A) (With PPC valve) Q

9.5 ± 0.5 9.5 ± 0.5

35

9.5 ± 0.5 9.5 ± 0.5

~~ Boom-Hi control valve 00

Straight-travel valve

Il'"

°OO~

r

Service valve

205F2401

Li n kaged tYpe With PPC valve Linkaged type With PPC valve Boom control lever

Arm control lever

E E a; >

....~ ~

Q)

>

• At center of lever knob

Bucket control lever Swing control lever Travel control lever

~

• Measure at end of travel • Do not start engine

-

g c: 0

Neutral .... Raise and Lower

150 ± 15

65 ± 10

150 +30 0

65 ± 10

Neutral .... Arm I N and OUT

110 ± 15

65 ± 10

110 +22 0

65 ± 10

Neutral .... Curl and Dump

110 ± 15

65 ± 10

110 +22 0

65 ± 10

Neutral .... R.H. and L.H. Swing

150 ± 15

65 ± 10

150 +30 0

65 +10 0

Neutral .... Forward and Reverse Neutral .... Forward and Reverse

Travel pedal

u

Stop -

Low idling

130 ± 15

130 ± 15

F

45 ± 5

45 ± 5

R

40 ± 5

40 ± 5

45 ± 20

45 ± 20

175 ± 30

175 ± 30

-

Fuel control lever Low idling - Full speed

62-16

PC200. 220-3

-

CIRCUIT DIAGRAM

TROUBLESHOOTING

SWING BRAKE SYSTEM (IF EQUIPPED)

Timer

Swing mechan ical "--'-_ _---' brake solenoid

02Yf.,

Oil pressure sensor

1J)(jY

-

I --~I--~

L...:.""----

I

NC valve outlet pressure

Difference pressu re of jet sensor

Lowered hydraulic pressu re

• Hydraulic oil temperatu re: 45 - 55°C • At engine full speed • Hydraulic oil temperatu re: 45 - 55°C • At engine full speed

320 +25 0

PC200·3

PC220·3

PC200-3

PC220-3

Lever at neu tral

23 ± 1

24 ± 1

Min.18

Min.18

At one pump relief (320 kg/cm 2 ) Average pressu re of two pump (160 - 170 kg/cm 2

16 ± 1

17 ± 1

15.5 ± 1.5

16.5 ± 1.5

)

Lever at neutral

Max. 7

Lever at stroke end Raise track on one side then rotate sprocket

Min.18

Lever at neutral

15 ± 1.0

15 ± 1.0

Lever at full stroke

Max.2

Max.2

Max. 5

Max. 5

• Hydraulic oil temperature: 45 - 55°C • Difference oil relief pressure between at engine full speed and at engine a half speed (Measure pressure in one circuit only)

Max.7

18

pe200, 220-3

62-17

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

Classification

Item

Condition

• Hydraulic oil temperature: 45 - 55°C • Open filler cap and run engine for 5 minutes. Fix filler cap and operate work equipment. And position work equipment to measure air pressure in tank.

In hydraulic tank

«

(kg/cm 2

Standard value

Permissible value

Max. 0.39

± 0.15

)

Bucket cylinder fully extended

Arm cylinder fully retracted

PC200-3

PC220-3

PC200-3

PC220-3

/

tt~-~~I ./-//

(Fig. 1) Swing brake angle

-

)

(

.. '

/-/h

"/

203F419 85 ± 10

• Engine speed: Full speed

85 ± 10

95

120

• Work equipment in posture in Fig. 1 • Hydraulic oil temperature: 45 - 55°C • Bucket unloaded

www. k omat s upar t s book . c om (degree)

• Braking angle after swing work equipment 180° with boom horizontal, arm cylinder fully retracted and bucket empty. (angle)

• • • •

Time taken to start swing (sec.)

Time taken to swing

• • • •

(sec.)

Engine speed: Full speed Hydraulic oil temperature: 45 - 55°C Bucket unloaded Measure time taken for 90° and 180° swing from starting point with work equipment in posture in Fig. 1

(mm)

Leakage from swing motor (Q/minJ

3.0 ± 0.3

3.2 ± 0.3

3.6

3.8

180°

4.3 ± 0.4

4.6 ± 0.5

5.2

5.5

Engine speed: Full speed Hydraulic oil temperature: 45 - 55° C Work equipment in posture in Fig. 1 Measure time taken to swing for 5 turns, after swinging one turn as an approach swing

• • • • •

Hydraulic drift of swing

90°

Engine speed: Stopped Hydraulic oil temperature: 45 - 55°C Work equipment in posture in Fig. 1 Bucket unloaded Stop the machine on 15° slope and set boom at 90° angle across the slope • Write the mach marks on the swing circle outer race and track frame. After 5 minutes, measure the lag of match marks. • • • •

Engine speed: Full speed Hydraulic oil temperature: 45 - 55°C Relieve oil in swing circuit Measure leakage from swing motor with measuring cylinder

24 ± 2

30

o

o

Max. 2.5

4

-

62-18 ®

PC200, 220-3

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

Classification

Item

Condition

T ravel speed (1)

(sec.)

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Raise track on one side, then measure time taken to rotate for 5 turns after rotating one turn as an approach travel • Repeat same way with track on other side • • • •

Travel speed (2) (sec.)

-

Standard value

Engine speed: Full speed Hydraulic oil wmperature: 45 - 55°C Machine is On level ground Measure time taken to travel for 20 m after traveling '10 m as an approach travel

~ ?Om

a; >

~

PC200-3 STD

Permissible value

PC220-3 STD

LC

LC

PC200-3 STD

PC220-3 STD

LC

LC

4 39±2 43±2 46±2 50±3 39 +4 43 +4 46+ 50 +5 -2 -2 -2 -3

4 19±2 21±2 21±2 21±2 19+ 21 +4 21 +4 21 +4 -2 -2 -2 -2

l

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

205F2402

Travel deviation

Imm)

Hydraulic drift of travel

-

(mm)

Leakage from travel motor (Q/min.)

Max. 200

220

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Run the machine for about 30 m on firm and level ground. Layout a 20 m string from a point 5 - 6 m from the start, and measure the deviation (a) of the machine at the midway point (10 m mark)

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C • Stop the machine on 12° slope with setting sprocket on uphill • Measure distance moved by machine in 5 min. • Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C • Relieve oil in travel circuit with lock track shoe

0

0

Max.3

4

PC200, 220-3

62-19 @

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

Classification

Item

Condition

Standard value

(sec.)

Engine speed: Full speed Hydraulic oil temperature: 45 -55°C Bucket unloaded Arm and bucket cylinder fully retracted Measure time taken from bucket tooth touching the ground to cylinder fully extended (RAISE) • Measure time taken from cylinder fully extended to bucket tooth touching the ground (LOWER)

(sec.)

• Top of boom is in horizontal, and bucket cylinder fully extended • Measure time taken from cylinder fully retracted position to cyl inder fully extended position (IN) • Measure time taken cylinder fully extended position to cylinder fully retracted position (OUT)

PC200-3 PC220-3

• • • • •

Boom

Permissible value PC200-3

PC220-3

w

Ul

ll>

c.

...

E

c. :> 0-

Arm

ll>

..><

(;

~

• Top of boom is in horizontal, and arm cylinder fully retracted • Measure time taken from cylinder fully retracted position to cylinder fully extended position (CURL) • Measure time taken from cylinder fully extended position to cylinder fully retracted position (DUMP)

z

-

l:::l

0

-

..J

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

...

a: :::l u

3.5 ± 0.4 4.2 ± 0.4

4.2

4.9

2.2 ± 0.2 2.6 ± 0.3

2.7

3.5

Cl.

~ :::l Cl

E

c.

:> 0ll>

Bucket cylinder fully extended \

..><

(;

~

Top of boom horizontal ! Arm cylinder / fully retracted

~~ -~. ---~ ~

-.

Total work equipment

.

(Fig. 2)

...

c=-:)

. .'.'

.

,-

~

.GL

205F575

1440 (960)

Max. 960 (600)

-

.....;: -0 .~

-:>

~ -0

>-

I

(mm) Boom cylinder Arm cylinder

• Engine speed: Stopped • Hydraulic oil temperature: 45 - 55°C PC200: 1260 kg • Buc ket loaded PC220: 1620 kg • Work equipment in posture in Fig. 2 • Measure amount bucket tooth moved down (distance "a") in 15 min. • Measure immediately after setting Max. 50 (30)

(mm) (mm)

Bucket cylinder (mm)

60 (45) "_._-

• Measure amount each cylinder retracted in 15 min. (

): Unloaded

Max. 248 (110) Max. 30 (20)

300 (165) 45 (30)

62-20

PC200. 220-3

-

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Classification

Item

Condition

Standard value

Permissible value

0

1.2 (Time lag is 0 sec, run the engine at min 1500 rpm)

0

2.8 (Time lag is 0 sec, ru n the engi ne at min 1500 rpm)

0

3.6 (Time lag is 0 sec, ru n the engi ne at min 1000 rpm)

• Engine speed: Low idling • Hydraulic oil temperature: 45 - 55°C Boom

~

c

(sec.)

OJ

E

• Bucket unloaded • Arm and bucket cylinder fully retracted • Measu re time taken from bucket tooth touching the ground to the machine raised

en

~

0::J

OJ

0-

E

OJ

f=

"'0"

• Top of boom is in horizontal, arm cylinder fully retracted

Arm

S

-

(sec.)

• Measure time taken from arm stopped when arm came into vertical to arm moved again

(sec.)

• Arm is in vertical • Measure time taken from bucket stopped when bucket tooth came in bottom to bucket moved again

Bucket

OJ

u

en

c

• Engine speed: Full speed • Hydraulic oil temperature: 45 - 55°C

c

ro

PC200-3

PC220-3

PC200-3

PC220-3

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

E

(;

-0

c

ro

OJ

0-

c

c

0

0

~

~

~

OJ

00

OJ

00

c

§

0

ro

roc

(; E

:n

Arm and Swing 90°

• Bucket unload • Arm is in vertical and boom cylinder is extended fully

3.5±0.4

Height of arm top pin (mm)

• Operate at "Boom raise" and in "Swing" at the same time, and measure the time taken and the amount arm top pin moved up when swing for 90°

Time

3.5 ± 0.4

3700 ± 370

4400 ± 440

Min. 2700

Min. 3400

(sec.)

Height of arm top pin (mm)

co

0

Time

(sec.)

0 0

E

U

-

Boom and Swing 90°

• Engine speed: 2100 rpm • Hydraulic oil temperature: 45 - 55°C

Charging pump discharge

Min. 50

43

Max. 100

Max. 100

Max. 100

Max. 100

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

Max. 120

• Relief pressure is 30 kg/em' (Q/min.) Hydraulic oil temperature

• Oil levels and coolant level within specifications • Convert the atmospheric temperature reading in ° F to ° C, using the formula

Engine coolant temperatu re •

OJ

u

c

ro ro

.0 ~

Engine oil temperature

ro

• •

OJ

I

Swing gear case oil temperature

Final drive case oil temperature

•

•

~ (F

- 32) = C.

Estimate the temperature inside the cab on the basis of the known temperature difference between the atmospheric temperature Drain the antifreeze and use a forcibly open type thermostat. Wind velocity, maximum 5 m/sec.: Do not conduct the test in extremely bad weather Surface conditions: Flat and sandy soils with Nd Value 10 - 20 Nd: niobium With engine running at full speed, dig a ditch whose width is about the same as the machine and whose depth is about 2/3 the max. digging depth, swing 90°, and dump. Continue until the heat balance is achieved. As far as possible, keep the oil pressure below the set pressure of the relief valve and use simultaneous operations while digging.

PC200, 220-3

62-21 (~

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

-

TABLE OF S, L POSITION VALUE

*

The following table indicates the reference values for various actions when the mode selector switch is changed over from H position to S or L position. Classification

Item

Conditions

S position

Posture of work equipment

Boom

L position

PC200-3

PC220-3

PC200-3

PC220-3

3.6 ± 0.4

3.7 ± 0.4

3.8 ± 0.4

3.9 ± 0.4

3.1 ± 0.3

3.4 ± 0.3

3.2 ± 0.3

3.5 ± 0.4

w (/)

~

Bucket teeth on the ground

a:

Cylinder fully extended

a:

205F2421

(sec.)

w

~

0

• Engine speed: High idling • Oil temp.: 45 - 55°C

-l

_.

Posture of work equipment

z

"0

....c

:E

Arm

E

o:

Cylinder fully retracted

:::l

.~

g-

Cl>

=

4.6 ± 0.5

5.4 ± 0.5

4.8 ± 0.5

5.7 ± 0.6

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

Cl>

0Cl>

5-

~

t

Cylinder fully extended

Cl>

o

.><

~

o

(

~

(sec.)

• Engine speed: High idling • Oil temp.: 45 - 55°C

)

I6

3.3 ± 0.3

3.8 ± 0.4

3.5 ± 0.4

3.9 ± 0.4

3.6 ± 0.4

4.3 ± 0.4

3.7 ± 0.4

4.3 ± 0.4

205F2422

Posture of work equipment -l

g;

u

Bucket Cylinder fully retracted

t

-

Cylinder fully extended

a..

205F2423 (sec.)

~

2.5 ± 0.3

2.7 ± 0.3

2.5 ± 0.3

2.7 ± 0.3

10.6 ± 0.6

9.8 ± 0.5

11.2±0.610.1±0.5

Cl

• Engine speed: High idling • Oil temp.: 45 - 55°C Posture of work equipment Max. reach

Cl

C .~

Normal swing speed

(/)

(sec.)

62-22 @

• Engine speed: High idling .Oil temp.: 45 - 55°C • Measure time taken to swing for :! turns, after swinging one turn as an approach swing.

PC200, 220-3

-

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Classification

Conditions

Item

S position PC200-3

Travel posture

L position

PC220-3

PC200-3

4'6° :

147

\jjP iff {If>,

c

'\ ifi;;

..§. DI

::ii

126

!f!:~

;'i

i'"

d

..., c

'\iJf!!

:;)

0

E co

105

"'-

> Q;

> tii

84

-

;;~~ !8

~~""" II~

rl www. k omat s upar t s b o o k . c o m ~I "tJ

c.

E :;)

c..

63

42

t00

21

50

()

:SCJ

10[)

;)00

Pump delivery pressure

):J(J

P, + P, 2

)O(J ) 0

(kg/em' )

205F2405A

Check point

Test pump delivery pressure (kg/em' )

Other pump delivery pressure (kg/em' )

Average pressure (kg/em' )

Standard value for delivery Q (new machine) (Q/min)

Judgement standard for del ivery Q (Q/min) (bottom level)

(1)

P,

P,

P, + P, 2

See graph

See graph

(2)

320

0-20

160 - 170

27 ± 20

0

(3)

305

0-20

152.5 - 162.5

100 ± 20

80

(4)

180

320

250

119 ± 20

99

(5)

300 - 280

0-20

150

192 + 5 -20

172

0-20

25 - 35

195 + 5 -10

185

(6)

50

-

62-28 (5)

PC200, 220-3

JUDGEMENT TABLE

TROUBLESHOOTING

2. Does NORMAL display appear) 1)

21

During deceleration (H, Sand L modes)

0

H\'cj

0

Ila'[,'"9

Green

.}-

. Is voltage at inlet of

auto-deceleration solenoid correct?

OFF

r

flashing

1)

-

21

All control levers at neutral Engine at full throttle

I 1) Lever NEUTRAL solenoid A (3~pjn side) 20 - 30V 2) Lever operation solenoid B (2-pin

Auto-deceleration switch at OFF Engine at half throttle Operate mode switch H ---+ S ---+ L.

21 3)

Lever at

ncutra,l

["" When operating

times per second)

1)

chart

3. Does problem disappear 4. Is voltage at inlet when prolix circuit port of swing brake switch is operated? solenoid normal?

Other than decele· ration (H and L modes)

Rc(1

Of'F

Troubleshooting

Checking swing brake solenoid voltage

Checking by switching prolix circuit

Checking voltage of auto·deceleration solenoid

Check self·testing display

11

~wlng

1

23

I

30V

I

ov

Go to E -60 for abnormal ities in electrical system; go to H - OX for abnormalities in hydraulic or mechanical system.

1} Disconnect connector of swing brake solenoid 2) Run engine for about 10 sec. 3) Stop engine, and turn starting switch to ON. 4} Move swing lever between neutral and sWing.

Engine at half throttle or above

side) 20 - 30V 3) Engine at half

throttle or more 4) Measu re solenoid A after about 5 seconds

- - - - - - - - " E-l

YES

_

E .

- -'l

II

---------'l

H

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -'l

H

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~2!;-~r

1---------

(Step 91

H - 1

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

-

-

-

-

-

-

-

-- -

-

-

4

- - - - - - - - - - - - - - - - - 1 - - - - - - - - - 0 ) II 1 - - - - - - - - - - " F:

-----

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

--

-

-- - - - - - -

AYES --

f-- _

~--~ NO

-- -

-

-

-

-- -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-"

H E

E

-

-

-

-

-

-

-

-

-

-

-

-

-

-

YES

-----------.--i~

--------

{Step 91

3 3

--------+-------- -------

2

6

-

-

-

-

-

-

-

I- -

-

-

-

-

---'

{Step 81

r:

--------1---------

II

----------------'

E

8 (Step 5)

(Step 41

1---------

II

10

+----------------1--------"

II

11

p.~--,

II

- - ~L'.'J~--,

13

r:

+ --------1- --------------------

--~---

I

!

---------1-------

------- -

I-- - - - - - - - -

1----------------- ------- ----

-

6 H - 6

------- ----------------' -------1--------

PC200. 220-3

- - - - - - - - - - - - - - - - - ; : II

16

62-27-2 Q)

METHOD OF USING THE TROUBLESHOOTING CHART

TROUBLESHOOTING

3) METHOD OF USING THE TROUBLESHOOTING CHART (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED)(See "Example 1")

CD

Problem number and symptoms The problem number and symptoms are written at the top left of the toubleshooting chart.

Location of failure

Problem No.

E-M

Electrical system of electronic 0 LSS, auto-deceleration, swing brake

H-XX

Hydraulic or mechanical system of electronic OLSS, auto-deceleration, swing brake

M-OO

Machine monitor (use symptom to go immediately to troubleshooting; Judgement Table not used)

®

Troubleshooting tools Prepare the tools listed under "Troubleshooting tools" at the bottom left or right before starting troubleshooting.

®

Categories for same symptom Even though the symptom is the same, if the machine model or component is different, the method of using the troubleshooting chart may be different. In such cases, the symptom is divided into sections a), b), etc. Select the appropriate section and start toubleshooting from that point. If there are no sections, start troubleshooting from the beginning.

®

Following the troubleshooting chart • Carry out the check or measurement inside the box. If the result is "YES", follow the YES arrow; if the result is "NO", follow the NO arrow. • If the YES or NO arrow leads direcly to the Cause column, take the action given in the Remedy column; if the arrow leads to another box, carry out the check listed in the box. (Note: The number at the top right corner of each box is only a list number; it does not necessarily indicate the order for troubleshooting.) • Any instructions given below the box are work to be carried out before making the check listed in the box. These instructions include preparatory work, operations to be carried out, and judgement values. If the preparatory work is not carried out, or the operations are carried out wrongly, mistakes will be made in judgement, or the machine may be damaged. Therefore, before making the check or measurement in the box, read these instructions carefully and carry them out in the order listed. Then go on to the check or measurement.

-

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

®

General precautions In the troubleshooting chart some precautions apply to the whole troubleshooting procedure for that symptom. Such symptoms are marked and are listed below the symptom. The precautions marked are not usually repeated in the instructions under each box, but they apply in each case and must not be forgotten.

*

®

*,

The page following the Troubleshooting Chart (See Example 2) gives the places to be checked or measured, and the connector pin numbers. • Photograph showing location of connector, fuse or plug for measuring • Diagram showing location of connector pin number

62-28

PC200, 220-3

-

-

TABLE OF JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

PC220-3 Main piston pump (5 mode)

150 c

-

.§. 0<

d

c: :l

0

100

E co

> Q;

>

Qj "0 C.

www. k omat s upar t s book . c om E :l a.

50

Pump delivery pressure

-

-

PI + P2

2

(kg/em 2 )

Standard value for delivery Q (new machine) (Q/min)

Check point

Test pump delivery pressure (kg/em 2 )

Other pump de, ivery pressu re (kg/em 2 )

(1)

P,

P2

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

55 ± 20

35

(4)

80

320

200

120 ± 20

100

Average pressure (kg/em 2 ) P, + P2

2

See graph

Judgement standard for del ivery Q (Q/min) (bottom level) See graph

(5)

80 - 100

0-20

100

185 +15 -20

165

(6)

0-20

0-20

0-20

195 + 5 -10

185

Note: The CO valve is working, so the average pressure is unnecessary.

PC200. 220-3

62-29 (~

TESTING AND ADJUSTING

TABLE OF JUDGEMENT STANDARD VALUE

PC220-3 Main piston pump (L mode)

200 ~~~~mmtim~~~l~~~~1~~~~1~~~~T~~~~T~~~1

150

C

:§: ~

-

0

c " E 0

co

100

~ CIJ > Qi "0

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

"

0-

50

Pump delivery pressure

Pi + P, 2

(kg/em' )

Standard value for delivery Q (new machine) (12/min)

Judgement standard for delivery Q (12/min) (bottom level)

See graph

See graph

Check point

Test pump delivery pressure (kg/em' )

Other pump delivery pressure (kg/em' )

(1 )

PI

P,

(2)

320

0-20

Note

27 ± 20

0

(3)

280

320

300

40 ± 20

20

(4)

80

320

200

105

20

85

(5)

180 - 200

0-20

100

170 ± 20

150

0-20

0-20

0-20

195 + 5 -10

185

(6)

Average pressure (kg/em' ) P, + P,

2

±

Note: The CO valve is working, so the average pressure is unnecessary.

62-30 @

PC200, 220-3

-

METHOD OF USING THE TROUBLESHOOTING CHART

TROUBLESHOOTING

Example 1

CD

Troubleshooting Chart No. E-2 Failure mode: Work equipment, swing, travel speeds extremely slow, or lack of power.

Tester T-adapter or socket adapter (forEKONOJ

@

a)

T-adapter or socket adapter (forMICI T-adapter or socket adapter (forDLII

Self-testing display shows abnormality

-

YES

YES

Is voltage between eNl0 (female) (l) and {2120 ~ 30 V 7

';.:.(:....J

OFF

OOFF

O

Is voltage between fuse 4 and chassis ground 20 - 30 V?

1)

Connect T -adapter

2)

Turn starting switch ON. (Do not start engine)

'::.,'1

n:s

Is voltage between eN 10 (female} (2) and chassis ground

Abnormality in power supply

(socket) to eNl 0

QV?

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

Green

Turn starting switch ON. (Do not start engine)

,)

2)

Connect T -adapter (socket) to eN' 0 Turn starting switch ON (Do not start engine)

r! ! J - - - - - - Abnormality

®

* *

In

control box

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket), For T -adapters. connect to both the male and female ends; for the socket, connect to the connector marked in (

),

Example 2

®

2,

3,

Measure voltage between CN10 (female) (1) and (2). Measure voltage between CN10 (female) (2) and chassis ground,

PC200. 220-3

62-29 CD

TROUBLESHOOTING

E-'

-

Troubleshooting Chart No. E-1 (2-STAGE MODE SELECTOR OLSS) Failure mode: Machine deviates excessively (always deviates)

*

All work equipment. swing, and travel speeds extremely slow or lack power.

* Mode selector switch (5)

Cause

YES

Remedy

For travel deviation, See H-1 For lack of power, see H-6

3

YES

1) Turn starting switch ON. 21 Turn mode selector switch (S),

2

YES 1 Is resistance between CN13 (female) (1) and (2) 10 - 25 iP

Is voltage between CN13 (male) (1) (2) OV?

Is CN13 female (1), (2) - chassis ground insulated?

4Y~ NO

Is there continuity between CNP4 (female) (31 and (4)? 1)

1)

Connect Tadapter (socket) to CN13 (female). 2) Leave female disconnected. 31 Turn starting switch OFF.

Turn starting switch OFF. Leave female disconnected. Turn mode switch (S).

Mode selector switch defective

Replace

-

-

ToA

NO

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

2) 3)

ConnectTadapter (socket) to CN13 (female) Leave female disconnected. Turn starting switch OFF.

21

3)

NO

NO

YES 6

YES 5

From A

Is there continuity between CN20 (male) (6) and (12)? 1)

Connect Tadapter (socked to CN20 (male). 2) Leave female disconnected. 3) Turn starting switch OFF.

, Cl

~c:

Tester

fQ';:;

::>0'"

T -adapter or socket adapter (forEKONO)

o~£ ~.

-'1:, , Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

1) 2)

1)

Connect T -adapter (socket) to CN9. Turn starting NO switch ON.

2) r

ConnectT -adapter to CNI o. 2 g L-_)_T_u_rn_s_t_a_rt_in_ _s_w_it_c_h_O_N_.

Measurement conditions same as in previous step. Take voltage between CN9 (1) and (3) as Vcc.

Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V? 1)

•

NO

1)

NO

I 2)

YES\

Is voltage between CN 10 (6) and (7) Vcc/2?

3

Is resistance between CN9 (male)

K n ? Is it insulated from chassis ground?

~c

Tester

..c'.;::;

:l0~

000

~~E

T-adapter or socket adapter (forEKONO)

62-30 @

1) Disconnect CN9. 2) Do not start engine. 3) Governor lever at FULL.

Is difference in resistance between CN9 (male) (1) and (21. and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

YES

Is difference in resistance between eN 10 (fern aIel (6)

YES

(1) and (3) 5 ± 1

-

NO

When using socket adapter

2

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DLI)

I

Connect T -adapter to CN10. Turn starting switch ON.

YES

_

YES

3

, O'l

I

and (7), and res istance between (7) and (81 less than ~.ll?

1) 2) 3)

Connect CN9. Disconnect CNI O. Do not start engine.

NO

NO

I I

I i

NO

pe200.220-3

-

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

TESTING AND ADJUSTING

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

-

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE Component

System

Connector No.

Testing method

~

B (J

'"cc

Measurement conditions

Judgement table

1) When using the short connector,

1) Starti ng switch ON

the following results show that the sensor is defective

0

(J

t::

Short connector connected

Monitor goes out

CN2 disconnected

Monitor I ights up

0 .J::

en

--

Coolant level sensor

CN2 (Male) 1) When carrying out a continuity test,

.~

the following results show that the sensor is normal

c c

Coolant level normal

Continuity

Coolant level abnormal

No continuity

:J

~

1) Starting switch OFF

-

0

()

B (J

1) When using the short connector,

1) Starti ng switch ON

the following results show that the sensor is defective

www. k omat s upar t s book . c om '"cc

0

(J

~

0 .J:: en

.~c

Engine oil level sensor

Short connector connected

Monitor goes out

CN4 disconnected

Mon itor Iights up

CN4 (Male) 1) Starting switch OFF

1) When carrying out a continuity test,

0

E

.~

0>

c

:J

the followi ng reSults show that the sensor is normal

c:

.J:: (J

~

'" ~

c: 0

Engine oil level normal

Continuity

Engine oil level abnormal

No continuity

()

1) Starting switch OFF

The following results show that the sensor is normal "'0>

Engine water temperature sensor (engine water temperature gauge)

C

(J

'= CN5 (Male)

c

:J '" V> ~

Normal temperature (25° C)

Approx. 37-50kr2

~~

100°C

Approx.3.5-4.0kr2

ro.~ 0> V>

B (J

0>

C

1) When using the short connector, the following results show that the sensor is defective

-

1) Engine started

c: 0

(J ~

0

Short connector connected

Monitor goes out

CN6 disconnected

Monitor I ights up

.J::

en

Engine oil pressure sensor

CN6 (Male) 1) When carrying out a continuity test,

.~ :J

the following results show that the sensor is normal

1) Engine started

.~ ~

C

0 ()

62-32

Engine oil pressure over 1 kg/cm 2 Engine oil pressure under 0.3 kg/cm 2

Continuity No continuity

PC200, 220-3

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

System

Component

Connector No.

Testing method

B u

Measurement conditions

Judgement table

1) Starting switch ON

1) When using the short connector, the following results show that the sensor is

(l)

defective

c c

0 u ~

0

Short connector connected

Monitor goes out

CN 14 disconnected

Monitor lights up

.r=

(/)

Hydraulic oil level sensor

CN14 (Male)

~

2) When carrying out a continuity test, the following resu Its show that the sensor is normal

:::J

-

c .;::;

CN14 (Male) 1 - 2

1) Starting switch OFF 2) Disconnect CN14

c 0

U

Hydraulic oil level normal

Continuity

Hydraulic oil level abnormal

No continuity

(l)

u

1) Starting

The following results show that the sensor is normal (Normal temperature 25° C)

c

.;

switch OFF 2) Disconnect CN15

www. k omat s upar t s book . c om Fuel level sensor (fuel gauge)

'" ~

CN15 (Male)

CN15 (Male) 1 - 2

Cl

c

'C:

~

co

Full

Approx.12n or less

Empty

Approx.85-110n

(l)

::2'

8c

(l)

Cl

0

(l)

c

.r: u co

Engine running (over half throttle)

-~ 0 >

E

Cl

Alternator

-

c

'C:

~ co

::2'

(l)

~

*

1) Engine started

27.5 - 29.5V

I n cold areas or when the battery is dete'riorated, the voltage may not rise for some time after the engine is started.

::2'

Monitor module The voltages for Hand L in the table are as follows, *1 Engine oil pressure signal H 3.5 - 30V L Approx.OV *2 Starting signal from starting motor H 3 - 30V L Approx.OV *3 Alternator signal H

27.5 - 29.5V

L Max.5V *4 Sensor signal H 3.5 - 30V L Approx.OV

PC200, 220-3

If the resu Its are as in Tables 1 and 2, the monitor module is normal.

>;: Monitor Items

Monitor auxiliary signal input Engine oil pressure signal *1

Starting signal of starting motor *2

Alternator signal *3

CNP13 (2)

CNP14 (1)

CNP13 (1)

-

H

Engine oil pressure CNP13 (2)

- ---

------

Goes out

L

Coolant level CNP14 (3)

Engine oil pressure signal L or starting signal of Goes out starting motor H

Engine water temperatu re CNP13 (3)

Engine oil pressure signal L ---or starting signal of Goes out starting motor H

Battery charge CNP13 (1)

Flashes

Table 1

H

Flashes

----

Engine oil pressure signal L Flashes or starting signal of Goes out starting motor H

-----

-

H H

-----

L H

Flashes

H

----L

L -

H

PPC oil pressure CNP14 (11)

----

Engine oil pressure signal L or starting signal of Goes out starting motor H

H

Overload warn ing CNP13 (7)

Engine oil pressure signal L or starting signal of Goes out starting motor H

H

Flashes

Flashes

----

Sensor signal input for monitor items

1) Engine started 2) Connect T-adapter

H 1-----L

--~--L

62-33 (~

TESTING AND ADJUSTING

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

S ystem

Component

Connector No.

Testing method

Measurement conditions

Judgement table

1) Engine started 2) Connect T-adapter (two T-adapters needed for B and D)

Table 2

A

B

CNP14 (2), (5), (6), (9), (12), (13), (14) CNP13 (4) (Open terminals) CNP14 (4), (7), (8), (10), CNP13 (5), (6), (1) Ground connection)

Open (no wiring connected) Each terminal - CNP14 (16) 20 - 30V Lamp switches I,ll 20 - 30V

C

Voltage between CNP14 (15) and chassis (night lighting input) Lamp switches 0 F F OV

-

Starting switch ON 20 - 30V

Mon itor module

0

CNP14 (16) - CNP14 (8) (+24V input) Starting switch OF F OV

www. k omat s upar t s book . c om .gc 0

E

E

OJ

c

.

Lamp switch OFF

OV

Lamp switch I

20 - 30V

OJ

c::

.;: :J ~

1) Starting

switch ON 2) Connect T-adapter

to

OJ

~

1) Starti ng OJ OJ

:!l CNP12 (9) - (16) (GND) (Emergency output)

(5

OV

Connect short connector to CN5.

3.5 - 6V

Disconnect short connector from CN5

Approx.OV

>

OJ

c

.;:

~

to OJ

~

PC200. 220-3

For 3 sec. after tu rning starting switch ON

switch ON 2) Connect short connector to CN5 (coolant temperature sensor) . 3) Connect T-adapter

62-35 (~

TESTING AND ADJUSTING

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

S ystem

Component

Connector No.

Testing method

Measu rement conditions

Judgement table

1) Turn starting

Q)

OJ

switch ON. 2) Connect T-adapter.

~

Between CNP12 (female) (15) - (16) (GND) (+24V)

0

>

Starting switch OFF

OV

Starting switch ON

20 - 30V

OJ

c

:::J ~

co

Q)

~

Gauge module 1 ) Connect socket. CNP12 (female) pin (16) (GND)

~ :::J

c

C 0

u

Between CNP12 (16) (female) - chassis, and between CNP3 (2) (female) [controller] - chassis

Continuity

1) Connect

Q)

OJ

~

Between CNP1 (female) (1) - (4) (GND) (+24 V output)

0

>

Starting switch ON

-

CNP3. 2) Connect socket.

-~-27V

OJ

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~ co

Starting switch OFF

OV

~----

Q)

~

B c

11 Connect CNP3. 21 Connect socket.

Q)

OJ

0

~

E Between CNP2 (female) (1) ground connection (+24Voutput)

Q)

c .c u co ~

U

0

Starting switch ON

:;

Starting switch OFF

> OJ c

~

co

Q)

~

l

15 - 27V OV

1) Start engine. 2) Connect T -adapter.

Q)

OJ

~

Controller

Between CNP2 pins (1) - (2) (buzzer outputl

0

>

OJ

c

I

Engine oil pressure, coolant level, engine water temperature sensor connectors disconnected

15 - 27V (Buzzer soundsl

Above sensors connected

OV

~ co

-

Q)

~

Q)

OJ

Between CNP3 (female) pins (1) - (2) (+24V)

-~ 0 >

Starting switch ON

20 - 30V

Starting switch OFF

OV

OJ

c

:; ~

11 Disconnect CNP3 21 Connect socket

co

Q)

~

CNP1 (male) 4 pinCNP3 (female) 2 pin (GND)

~ :::J

c

~

c 0

U

Between CNP1 (4) (male) - chassis, and between CNP3 (2) (femalel - chassis

Continu ity

11 Disconnect CNP1, CNP3 2) Connect socket

62-36

PC200, 220-3

-

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Component

System

Connector No.

Testing method

Measurement conditions

Judgement table

1) Turn

Q)

u

c

;;

'v;

~ OJ

c

.;:

Engine speed sensor (3-mode selector OLSSif equ ipped)

iilOJ Q)

Resistance between CNS (male) (1) - (2)

300 - 1000rl

Between CNS (male) (1) chassis, and between CNS (male) (2) chassis

No continu ity

starti ng switch OFF 2) Disconnect CNS

::2:

CNS pins (1),12)

1) Screw in the speed sensor until it contacts OJ

the ring gear, then tu rn back one tu rn. 2) Should work normally after this adjustment.

c

~

:;

-

ii'

«

OJ

Q)

c

u

c

iilOJ ~ Q)

"v;

::2:

~

Resistance between CN9 (male) (1) - (3)

4 - 6 krl

1) Engine started

1) Turn starti ng switch OFF

www. k omat s upar t s book . c om (j) (j)

-I

0

Potentiometer 13-mode selector OLSS if equipped)

CN9 (male) pins (1), (2), 13)

OJ

c

.S! c

'5;

2

ii'

VOltage Vcc between CN9 (male) 11) - (3)

4.S - 5.2V

Adjust voltage between CN9 (male) (1) - (2) to Vcc/2

-

:l

«

u

Q)

a;

""(J

1) Turn starting switch ON 2) Use T-adapter 3) Fuel lever FULL

c

OJ

u u Q)

W

1) Continuity must be as in following table.

-

CN36 pin numbers ~

Prolix switch (3-mode selector OLSS if equipped)

CN36 (male) pins (1), (2), (3), (5), (6), (S)

:l

c

";;

c 0

U

1) Turn

starting switch OFF

Prolix switch OFF

ON

Between pins (1) - (3)

Continuity

No continuity

Between pins (2) - (5)

Continuity

No continu ity

Between pins (3) - (6)

No continuity

Continuity

Between pins (5) - (S)

No continuity

Continuity

2) There must be no continuity between the chassis and any of the following: prolix switch CN36 (male) (1), (2), (3), (5), (6), (S)

.

--

TVC valve solenoid I t is impossible to check the operation of the TVC solenoid valve by itself, so see Troubleshooting.

PC200. 220-3

Q)

u

CN13 (male) pins (1) - (2)

c

.; V> Q)

a:

Resistance between CN 13 (male) (1) - (2)

10 - 25rl

Between each terminal and chassis

No continuity

1) Turn starting switch OFF

62-37 (~

TESTING AND ADJUSTING

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

S ystem

Component

Connector No.

Testing method

Cl

Resistor for prolix circuit (3-mode selector OLSS if equipped)

CN34 (male) pins (1), (2)

Measurement conditions

Judgement table

1) Turn

OJ

.~

u

c:

aco 'u;t1

OJ

Resistance between CN34 (male) pins (1) - (2)

Approx. 10- 30n

starting switch OFF

~

:2

Input signal normal if it satisfies Tables 1 - 3. Table 1 Between CNP4 (1) (male)CNP4 (2) (male) No continuity

(f) (f)

Between CNP4 (3) (male) CNP4 (4) (male)

...J

0

1) Turn

starting switch OFF 2) Turn mode selector switch to H mode

u

c:

g u

OJ OJ

CNP4 (male) (1), (2), (3), (4)

"D

c:

co

.~

Mode selector switch

~ ~

u

OJ

UJ

[eh"klm ] continuity between CNP4 (male) (1)- (2), (4); (3) - (2), (4)

Table 2

~

c: .'"" c: 0

u

Between CNP4 (1) (male)CNP4 (2) (male)

No continuity

Between CNP4 (3) (male) CNP4 (4) (male)

Continu ity

1 ) Turn starting switch OFF 2) Turn mode selector switch to S mode

www. k omat s upar t s book . c om Table 3

Between CNP4 (1) (male) CNP4 (2) (male) Continuity Between CNP4 (3) (male) CNP4 (4) (male)

1) Turn starti ng switch OFF 2) Turn mode selector switch to L mode

1) Turn

Limit switch for travel ing

CN31 (male) pins (1), (2) CN32 (male) pins (1), (2)

.~

When traveling in a straight line

No continuity

When not traveling in a straight line

No continuity in one of CN31 or CN32

"c:

~

c: 0

u

starti ng switch OFF

-

:0 OJ

0. 0.

"

C"

~

OJ

.....

2u

-c:

1) When using the short connector, the following results show that the sensor is defective.

1) Start engine 2) Fuel lever FULL

OJ

c: c:

.Q

0

~

u

~

Short connector connected

Deceleration works normally

CN33 disconnected

Deceleration does not work

~

a

OJ

Qj

u

.J::;

OJ

(f)

V

2

Hydraulic sensor for arm, boom, bucket pick-up

«"

CN33 (male) pins (1), (2) 1) When carrying out a continuity test, the

following resu Its show that the sensor is normal. ~

"c:

~

c:

Each control lever at neutral

Continuity

Any lever in operating position

No continuity

1) Turn starting switch OFF

0

U

62-38 @

PC200, 220-3

-

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

System

~ Q)

n. n.

Component

Auto-deceleration cancel switch

Connector No.

Between both terminals of switch

::J

Testing method

.~

Auto-deceleration switch ON

::J

c::

C

Continuity

Q)

1) Turn starting switch OFF.

-

Auto-deceleration switch OFF -

0

U

0-

Measurement conditions

Judgement table

.

No continuity

.-

~

c:: 0

~

Q)

Q)

u

c::

Q)

u

Q)

u

-

8 ::J



11 Turn

~

CN10 (female) (2) pin (GND)

::J

Between CN10 (2) (female) - chassis

c::

C

starting switch OFF.

Continuity

0

u

-u

Q)

n. n.

CN11 (7) (male)CN11 (S) (male)

::J

0Q)

No continuity

~

-

--

CN10 (3) (female)CN10 (1) (femalel --

I

c::

11 Turn start ing switch OFF. 2) Turn mode selector switch to H.

0

~

Q)

a;

CN10 (1) (female) CN11 (9) (malel (input for mode selector switch I

::J

co

crJcrJ ..J

0

.~

CN11 (7) (male) CN11 (S) (malel

c::

.- -_."--

::J

~

CN 10 (3) (female) CN10 (1) (female)

c::

0

u

~

.

_

.

.

2

_

Control box -

Q)

u

_

u

No continuity

Continuity

11 Turn starting switch OFF. 2) Turn mode selector switch to S.

'--

.S' c::

2 u

11

Q)

w CN11 (7) (male) CN11 (S) (male) Continuity CN10 (3) (female)CN10 (1) (femalel

CN10 (female) (6), (7), (S) (potentiometer input signal)

PC200, 220-3

--

C>Q)

c:: u .- c::

~ co .;;;

~

Q)

:;;

Resistance between CN1 0 (female) (6) - (S)

Turn starting switch OFF. 2) Turn mode selector switch to L.

4 - 6r1.

11 Turn starting switch OFF.

~

62-39 ®

TESTING AND ADJUSTING

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

System

Component

Connector No.

CN10 (female) (11), (12) (input circuit for auto·deceleration, sensor, switch)

Testing method

>-

~

::l

c

C 0

u

:0 OJ

u

a. a.

1 ) Engine started.

All control levers at neutral, and auto-deceleration cancel switch OF F

Continuity

Control levers operated, or auto-deceleration cancel switch ON

No continuity

Resistance between CN11 (male) (1)

OJ

Measurement conditions

Judgement table

~

1) Turn

(2)

starting switch OF F.

c

::l

c-

OJ

--

I c ,2

~

CN 11 (male) (1), (2)

'Vi

(TVC solenoid output)

''::

~

'"c ::l

Prolix switch OFF

15 - 25n

Prolix switch ON

No continuity

-

~

ttl

OJ

~

~

ttl

di

-&

Carry out test of prolix switch.

a;

u OJ -0

Control box

www. k omat s upar t s book . c om 6

CN11 (malel (3), (4)

::l ttl

(auto-decelerati on solenoid (A) output)

vi

(/)

....J

0

"'OJ C U ,- C

~

.~

~

ttl

Resistance between CN11 (male) (3) - (4)

::

CN10 (female) (9), (10)

U OJ

w

(a uto-decelerati on solenoid (6) output)

50 - son

~

OJ

~ ~

U C

~

"'OJ C u ,- C ::l

~

~

ttl

OJ 'Vi

.

~stance b'etween CN10 (female) (9) -

(10)

~ ~

~O- son

Continuity between CN11 (male) (7) CN11 (male) (7), (S)

~

(mode selector S, L signal input)

C

::l C

0

U

(S)

Mode selector switch S

No continuity

Mode selector switch L

Continuity

1) When using the short connector (swing lever at neutral)

2u 0 u

OJ a. a.

~

0

.r::

::l

c-

-

(/)

OJ

-

OJ

""-

Disconnect CN24.

OJ C C

--0

Swing brake hydrau Iic sensor

1) Turn starting switch OFF,

Connect short connector.

I

11 Turn starting switch OFF.

1) Turn starting switch OFF.

11 Engine started.

Five seconds after short connector is connected Swing brake operates (electricity flows to swing brake solenoid) Swing brake released

CN24 (male) (1), (21

ttl

.0

';:'"

1) When carrying out a continuity test

C

(/)

1) Engine started.

.~ ::l

"

Swing lever at neutral

No continuity

Swi ng lever operated

Continuity

~

C

0

U

62-40

PC200, 220-3

TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE

TESTING AND ADJUSTING

Component

S ystem

Connector No.

Testing method

Measu rement conditions

Judgement table

C1l

u

c

Swing mechanical brake solenoid

l'l

CN18 (male) (1), (2)

Between CN18 (male) (1) - (2)

~

~

10

~

30n

C1l

]

1) Engine started.

a:

Continuity

1) Turn starting switch OFF.

20 - 30V

1) Turn stari tng switch ON.

~ :::J

CN19 (female) (1) (GNO)

Between CN19 (1) (female) - chassis

c

C 0

U

-

Ol

c

CN19 (female) (2) (+24V)

'0

C1l

:::J

Voltage between CN 19 (2) (female) - chassis

OJ)

C1l

~

C1l

~

:'ii~

C1l

a. a. :::J

0-

C1l

-

C1l OJ)

C1l

(2)

1) Engine started.

;3

""" C1l

..0

Voltage between CN19 (female) (3) -

0

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

Timer

.":

;:

CN 19 (female) (3) - (2) (sensor input)

(f)

>

OJ)

c

Swing lever at neutral

OV

Swing lever operated

20 - 30V

~

C1l

C1l

~

Voltage between CN19 (2) -

(4), (2) - (5)

C1l OJ)

CN 19 (female) (2) - (4) (2) - (5)

;3 0

(Solenoid, lamp output)

.C:

• OV

Swing lever operated

20 - 30V

>

OJ)

c

~

C1l

C1l

~

-

Swing lever at neutral

1) Engine started. 2) Connect T-adapter.

.

Approx. 5 sec. after swing lever is placed in neutral, voltage becomes OV. (I t is also possible to use the short connector instead of placing the swing lever in neutral)

PC200, 220-3

62-41 (~

TESTING AND ADJUSTING

TROUBLESHOOTING TOOLS

-

TROUBLESHOOTING TOOLS Troubleshooting chart No. H No.

Troubleshooting tools -1

-2

-3

-4

-5

-6

-7

0

0

0

0

0

0

-8

-9

-10 -11 -12 -13 -14 -15 -16

Diagnostic tools 1

Hydraulic tester

0

2

Stop watch

0

3

Thermistor kit

0

4

Measuring cylinder

0

5

Push pull scale

6

Scale

7

Multi-purpose tachometer

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

0 0

-

0

0

Replacement parts

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

Servo valve

9

Jet sensor rei ief valve

0

0

0

0

0

0

0

0

0

0

10

Travel shuttle valve

11

Swing safety valve

0

12

Swing check valve

0

13

Main relief valve

14

Control valve, suction valve

0

0

0

0

0

-

KES parts

0

15

Cap plug (07376-50315) 3 pieces

16

Sleeve nut (07221-20210,20315,20422) 0

0

0

0

0

0

0

0

0

17

Plug (07222-00210,00312,00414)

0

0

0

0

0

0

0

0

0

18

Flange (07379-00500,00600)

0

62-42 (~

pe200.220-3

TESTING AND ADJUSTING

TESTING TRAVEL AND OPERATING FORCE

TESTING TRAVEL AND OPERATING FORCE 1. TESTING TRAVEL OF CONTROL LEVERS Measuring Travel Set the scale on the bottom of knob (1) of the control lever, and measure the travel need to move the lever to each position.

* _

If the result of the measurement shows that the travel is not within the standard value, check as follows. 1) In linkage type (travel control lever), lever travel is the same as valve spool travel. If there is no abnormal ity in the rod, check the travel of control valve spool. 2) In PPC valve type, if the linkage between control lever and PPC valve is normal, disassemble the PPC valve and check.

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

_

Adjusting Travel Levers at Neutral Position • When the each lever position is not in line and lever contacts to cab in operating, check according to the following procedure. 1) See if the rod is bent, twisted, worn, or has other abnormalities. 2) Adjust the lever stopper as follows. i) Loosen locknut (4) of the stopper bolt. ii) With the lever moved to the end of its stroke, adjust stopper bolt (5) so that it lightly touches the lever. iii) Then turn back the stopper bolt by 1/3 to 1/2 turns and secure it with the locknut.

PC200. 220-3

62-43 ®

TESTING AND ADJUSTING

TESTING TRAVEL AND OPERATING FORCE

2. TESTING OPERATING FORCE OF CONTROL LEVERS

*

When measuring, engine is full speed and hydraulic oil temperature is 45 - 55°C.

Measuring Operating Force Hook push-pull scale CD on the bottom of knob (1) of the control lever, and measure the force needed to move the lever to each po~ition.

*

If the result of the test shows that the operating force is not within the standard value, check as follows. 1) The operating force of valves which are pulled directly is decided by the return spring of the valve spool. If there is no abnormality in the rod, yoke or any other part, disassemble the control valve and check. 2) In PPC valve, if the linkage between control lever and PPC valve is normal, disassemble the PPC valve and check.

-

www. k omat s upar t s book . c om 3. TESTING TRAVEL OF CONTROL VALVE SPOOLS Measuring Travel Set the scale to the spool (1) measured, and measure the travel when operating the control lever. When measuring by one person, pull the control lever by a cord or disconnect the linkage (rod) from spool and pull the spool directly. Except linkage type, it is impossible to measure the travel of spool.

*

-

*

*

If the result of the measurement shows that the travel is not within the standard value, check as follows. 1) Remove cover (1). Check the bolts (2) loosened. If there is no abnormality, disassemble control valve and check. 2) In PPC valve type, first check the PPC valve.

2

i

205F2419

62-44

PC200, 220-3

-

MEASURING HYDRAULIC OIL TEMPERATURE

TESTING AND ADJUSTING

MEASURING HYDRAULIC OIL TEMPERATURE Special tool

A

-

Part No.

Part Name

Q'ty

790-500-1300

Thermistor temperature aauae

1

Lower the work equipment completely to the ground and stop the engine. Operate the control lever several times to release the remaining hydraulic pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the remaining oil pressure in the hydraulic tank. • •

Remove cover (1), then measure the oil temperature using thermistor A. When hydraulic oil temperature is lower than 45°C, raise the oil temperature as follows. Start the engine and warm up running. Operate the arm or bucket control lever fully to relieve oil from main relief valve so that oil temperature is raised. Continued operation in above is within 30 seconds.

www. k omat s upar t s book . c om •

*

Note: When relieving oil in boom, arm, bucket or travel circuit, CO valve acts and main pump delivery is minimum. In result, as oil flows only for hydraulic tank - main pump - main relief valve - hydraulic tank, operate boom, arm and bucket cylinders to raise the temperature of components sometimes.

-

PC200, 220-3

62-45 ®

TESTING AND ADJUSTING

AIR BLEEDING

--

AIR BLEEDING 1. AIR BLEEDING IN HYDRAULIC CYLINDER

*

When removing hydraulic cylinder or disconnecting piping, bleed air in hydraulic cylinder as follows. 1) Start the engine and run at low idling for 5 minutes. 2) Raise and lower the boom at 5 times repeatly in engine slow speed. When operating, stop the piston rod before 100 mm of stroke end, and never rei ieve oi I. 3) Operate 2) in engine full speed. 4) Operate boom control lever fully to relieve oil. 5) For arm and bucket cylinders, operate as the same procedure as above 2), 3) and 4).

*

2.

*

AIR BLEEDING IN MAIN PUMP

--

When replacing or dismounting the main pump, bleed air in main pump to prevent pump inner parts seizing as follows. 1) Remove plug (1). 2) Disconnect drain hose (2). 3) Supply oil from drain plug hole fully. 4) Connect hose (2). 5) Attach O-ring and tighten plug (1).

www. k omat s upar t s book . c om 3.

* *

REMAIN-PRESSURE RELIEVING IN PPC CIRCUIT When disconnecting piping between hydraulic cylinder and control valve because of open circuit, relieve remainpressure in circuit as follows. As travel circuit are not remain-pressure, remove cap only to relieve remain-pressure. 1) Loosen the filler cap gradually to relieve pressure. 2) Operate control lever several times to relieve pressure of accumulator. 3) Start engine and run for "5 sec." and stop engine. Then operate control lever. Continue 2 and 3 times repeatedly above opetion to relieve remain-pressure completely.

--

*

4.

*

AIR BLEEDING IN TRAVEL MOTOR When removing travel motor or disconnecting piping, bleed air as follows. 1) Start engine and run for about 5 min. at low idling speed. 2) At low idling, loosen plug (1) until oil without air issues. Never work at the front of plug because oil is spurted out often. 3) When completing the air bleeding, tighten plug (1).

*

-62-46 (5)

PC200. 220-3

TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS)

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS) Special tool

A

Part No.

Part Name

Q'ty

799-101-5000

Hydraulic tester

1

1. MEASURING MAIN RELIEF PRESSURE

*

Oil temperature when measuring: 45 - 55°C Lower the work equipment to the ground anEl stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1.

Remove pressure pick-up plug (1) or (2) (PT1/8) from the circuit to be measured, and install hydraulic tester A (600 kg/cm 2 ). Start the engine, operate the circuit to be measured, and measure the main relief pressure with the engine at full throttle. Condition of actuator when measuring i) When measuring the cylinders, operate each cylinder to the end of its stroke. ii) When measuring the swing, lock with the swing lock pin. iii) When measuring the travel, fit block under the grouser at the front of the track, or fit block (2) between the sprocket and frame to lock the track, then measure one side at a time.

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

3.

-

Pump Front pump

(Rear pump)

205P2500

1

(F ront pump)

Actuator controlled Arm cylinder Boom cylinder Swing motor Right travel motor

Rear pump

Arm cylinder Boom cylinder Bucket cylinder Left travel motor

Note 1: The set pressure of the safety valve at the swing motor and boom cylinder head end is lower than the main relief pressure, so theset pressure of the safety valvei is measured. 2: The set pressure of the safety valves in the other equipment is higher than the main relief pressure, so it is impossible to measure the pressure directly. However, it ispossible to judge if the pressure is correct as follows.

PC200, 220-3

62-47 ~)

TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS)

TESTING AND ADJUSTING

*

Example for rear pump When measuring the relief pressure for the four items of equipment, if the relief pressure for all of the equipment is low, the main relief pressure has dropped; if the pressure of only certain equipment is low, the set pressure ofthe safety valve for that equipment has dropped. Table of set pressure for safety valve for each actuator Set pressure (kg/cm 2

Actuator Boom cylinder

Arm cylinder

Head end

250

Bottom end

340

Head end Bottom end

Bucket cylinder

Travel motor

340

-

Head end Bottom end

Swing motor

)

340 297 +15 -10 360

www. k omat s upar t s book . c om 2. ADJUSTING AMIN RELIEF PRESSURE

2

Adjuste the main relief valve as follows. • Loosen locknut (1) and turn adjustment screw (2) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting, repeat Section 1 above to check the pressure again.

*

-

*

205F2420

62-48 (9)

PC200, 220-3

TESTING AND ADJUSTING

3.

TESTING AND ADJUSTING HYDRAULIC PRESSURE (WORK EQUIPMENT, SWING, TRAVEL CIRCUITS)

ADJUSTING RELIEF PRESSURE OF SWING MOTOR

Adjust the relief pressure of the swing motor safety valve as follows. • Loosen locknut (1) and turn adjustment screw (2) to adjust. * Adjust withthe adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * After adjusting, repeat Section 1 above to check the pressure again.

2

205F2474

* -

Safety valve (3) is for left swing, and safety valve (4) is for right swing.

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

PC200, 220-3

62-49 ®

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT

TESTING AND ADJUSTING

~..

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT Special tool

A

Part No.

Part Name

Q'ty

799-101-5000

Hydraulic tester

1

1. TESTING AND ADJUSTING RELIEF PRESSURE OF CHARGING PUMP

*

1.

*

Oil temperature when measuring: 45 - 55°C Measuring relief pressure i) Remove pressure pick-up plug (1) (PT 1/8). and install hydraulic tester A(60 kg/cm 2 ). ii) Start the engine, run at full throttle, and measure the pressure. When testing for internal leakage in any of the equipment in the charging circuit, use the parts given below to block the following parts of the circuit, and measure the relief pressure.

-

www. k omat s upar t s book . c om No.

Portion of hydraulic circuit shut off

Equipment that can be tested

1

Charging pump outlet port

. Charging pump . Relief valve

2

Main pump inlet port

Main pump

3

Auto-deceleration solenoid valve inlet port

Auto-deceleration solenoid valve

4

Right PPC valve inlet port

Right PPC valve

5

Left PPC valve inlet port

Left PPCvalve

6

Swing brake solenoid valve inlet port

Swing brake solenoid valve

-

Use the following parts to shut off the circuit. Sleeve nut: 07221-20210,07221-20422 Plug: 07222-00210,07222-00414 Auto-deceleration solenoid valve

Swing brake solenoid valve

Left PPC valve ~­ L

6

Main pump Charging pump

62-50 ®

205F2475

PC200, 220-3

-

-

E-4

TROUBLESHOOTI NG

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1. Measure voltage between CN13 (male) (1) and (2). 2.

Check for short circuit between CN13 (female) (1), (2) and chassis ground.

3.

Measure resistance between CN13 (female) (1) and (2).

~ 11 m {Jill ~ 1

-

2

4,5. Measure resistance between CN34 (female) (1) and (2).

~n:Jrro] m~ www. k omat s upar t s book . c om 2

6.

1

1

2

Check for continuity between CNP4 (female) (1) and (2).

-

PC200, 220-3

62-49-2 @

TROUBLESHOOTING

E-4

-

Troubleshooting Chart No. E-4 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: No change in output when mode switch is operated.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters. connect to both the male and female ends; for the socket. connect to the connector marked in (

a)

).

YES

2

Self-testing display shows abno rmality

YES Abnormality in power supply OFF

OOFF

O Red

Green

Is voltage between CN10 (female) (1) and (2) 20 - 30 V? 1)

->

Is voltage between fuse 4 and chassis ground 20 - 30 V? • Turn starting switch ON. IDo not start engine)

YES

Is voltage between CN10 (female) (2) and chassis ground V?

Connect T-adapter (socket) to CNl O. Turn starting switch ON. (Do not start engine)

2)

3

NO

1

o 1)

2)

:\0

NO

Connect T-adapter (socket) to CNl O. Turn starting switch ON.

Abnormality in control box

YES

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

YES

Is CN13 Imale) 111, (2) - chassis ground insulated?

1)

Abnormality in TVC solenoid

1 2)

Is resistance between CN 13 (male) (1) and 12110 - 25 Red

4 Is resistance be-

Connect T-adapter (socket) to CN13 (malel. Turn starting switch OFF.

3 Is resistance be-

tween CN36 Ifemale) 131 and (5) 10 - 25 117 Is

l\JO

each pin to chassis

1)

2)

ground insulated? 1)

Connect T -adapter (socket) to CN13 (male!. 2)

;\iO

b)

tween CN36 (female) 11) and 12) 10 - 25 ll? Is each pin to chassis ground insulated?

YES

1P

Green

...YES

Connect T-adapter (socket) to CN36 (female!. Turn starting switch OFF.

Turn starting switch OFF. Turn prolix circuit switch OFF

~(

;,\0

-

If cause is removed when switching to prolix circuit (when self-testing display shows normal!

• In H-mode, display is not 0

~

3 YES Is there continuity between CN20 (femalel (19) and (20)7

YES YES

1 Is mode selector switch normal?

1)

2)

Remove CNP4. Turn starting switch OFF.

Is there continuity between CN 10 (female) (11 and (3)? 1) 2)

Remove CNP4. Connect T-adapter (socket) to CN 10 (female).

::lOV>

000

~~~

Tester T -adapter or socket adapter (for EKONO)

62-50 @

1)

2) 3)

NO

Remove CN 10 (female) Connect T -adapter (socket) to CN20 Ifemale!. Turn starting switch OFF.

NO

NO

, 0>

~c

..c";:;

2

T -adapter or socket adapter (forMIC)

-

T -adapter or socket adapter (for DLD

PC200, 220-3

TESTING AND ADJUSTING

2.

TESTING AND ADJUSTING PRESSURE OF CHARGING CIRCUIT

Adjusting main relief pressure Loosen locknut (2) and turn adjustment screw (3) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting, repeat Section 1 above to check the pressure again.

3

2

* *

205F2476

-

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

* 1.

MEASURING OUTPUT PRESSURE OF PPC VALVE Oil temperature when measuring: 45 - 55°C Remove pressure pick-up plugs (1). (2). and (3) (PT 1/8). and install hydraulic tester A (60 kg/cm 2 ). For hydraulic pressure of boom, bucket (1) For hydraulic pressure of arm (2) For hydraulic pressure of swing (3) Start the engine, run the engine at full throttle, then operate the control lever, and measure the pressure. When measuring the swing equipment, lock the swing with the lock pin. When measuring the work equipment, operate each cylinder to the end of its stroke.

* 2

*

PC200, 220-3

62-51 (9)

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

Serial No. 20001

~

.

Special tool Part No. A

799-101-5000

Q'ty

Part Name Hydraulic tester

1

1. TESTING AND ADJUSTING OUTPUT PRESSURE OF TVC VALVE Note:

The output pressure of the TVC valve changes according to the average pressure (

P + P I

2

2) =

av-

erage pressure) for the discharge pressure of the piston pump, so before measuring, always adjust the main relief pressure to the specified pressure. See Fig. 1. Measuring output pressure of TVC valve Oil temperature when measuring: 45 - 55°C Measure the relief pressure of the charging pump first to check that it is normal. i) Remove pressure measurement plug (1) (Thread dia. = 10 mm, Pitch = 1.25 mm). and install hydraulic tester A (60 kg/cm 2 ). ii) Run the engine at full throttle, and measure the pressure with the control levers at neutral and with the pump relieved. See the STANDARD VALUE TABLE. Reference 1. The average pressure with one pump' relieved is approx. 170 kg/cm 2 . This is the average pressure of the discharge pressure of the relieved pump (320 kg/cm 2 ) and the discharge pressure of the pump not relieved (approx. 20 kg/cm 2 ). 2. For details of the relationship between the change in the output pressure of the TVC valve and the discharge volume of the pump, see Fig. 1 and 2.

-

*

1)

* *

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

up port for valve pressure

205P2503A

Fig. 1 (When i = O.18A)

18

100

-

300

200

PI + P 2 Pump discharge pressure (--2-) = average pressure (kg/cm 2

)

205F2477

Fig. 2

(Engine at full throttle)

90 1 - - - - - " " \ >

CD

-':o::.

Control area of TVC valve

o

c "o E co

Ql

~ co

45 Control area of NC valve

..

.t::

~ -0 C.

E

"

"-

100

200

300

PI + P2 Pump discharge pressure (--2-) = average pressure (kg/cm 2

)

205F2478

62-51-1 ®

PC200, 220-3

-

TESTING AND ADJUSITNG

2)

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

Adjusting output pressure of TVC valve If the results of the measurement show that the hydraulic pressure is not within the standard value, adjust as follows. i) Loosen locknut (2). ii) Turn adjustment screw (3) to adjust. If the adjustment screw is stiff and excessive force is used to turn it, the tip may break. * If the adjustment screw is stiff, remove the TVC valve assembly, then remove the cover assembly and add lubricant to the screw before trying to turn it. iii) Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by approx. 3.5 kg/cm 2 • iv) After adjusting with the adjustment screw, repeat Section 1)-i), ii) to measure the output pressure again.

*

-

*

www. k omat s upar t s book . c om 3

205F2479

PC200, 220-3

62-51-2 ®

TESTING AND ADJUSITNG

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

2. TESTING AND ADJUSTING OUTPUT PRE· SURE OF NC VALVE The output pressure of the NC valve controls the discharge amount from the piston pump flowing to the servo valve. The oil flows from TVC valve -+ CO valve -+ NC valve -+ servo valve. The output pressure changes as follows according to the operation of the control levers or work equipment. Control levers at neutral Because of the differential pressure of the jet sensor, the NC valve is actuated and the output pressure drops to below 7 kg/cm 2 . (The pump discharge amount becomes the minimum.) When hydraulic cylinders and travel circuit are relieved. The CO valve is actuated, and reduces the pressure to below 7 kg/cm 2 until it enters the NC valve. The NC valve continues to supply this pressure to the servo valve. (The pump discharge amount at this point is also the minimum.) When work equipment, swing, travel circuit are actuated. The output pressure of the TVC valve is not influenced by the CO valve or NC valve, and continues to supply pressure to the servo valve. (The pump discharge amount varies between the maximum and the point where the CO valve is actuated.) Oil temperature when measuring: 45 - 55°C

Solenoid

*

From charging pump

*

205F2480

Front end

4

4

Rear end

-

*

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

1)

As seen from bottom of pump

205F2481

Measuring output pressure i) Remove pressure pick-up plug (4) (Thread dia. = 10 mm, Pitch = 1.25 mm). This is on the body side of the servo valve. ii) Install hydraulic tester A (25 kg/cm 2 ).

*

•

Measuring pressure when NC valve is actuated Set all the work equipment levers at neutral, and measure the hydraulic pressure with the engine at full throttle. Set the auto-deceleration switch to OF F. 2 If the output pressure is more than 7 kg/cm , measure the differential pressure of the jet sensor.

-

* *

62-51-3 ®

PC200, 220-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

•

Measuring pressure when CO valve is actuated Relieve anyone of the boom (except LOWER), arm, bucket, or travel circuits, and measure the hydraulic pressure with the engine at full throttle.

•

Measuring pressure when work equipment, swing, and travel are actuated Measure the pressure when the swing circuit (front pump) is relieved, and the track is rotating under no load (front and rear pumps) at the same time as measuring the output pressure of the TVC valve. If there is an excessive difference from the output pressure of the TVC valve, the op~ration of the CO valve or NC valve is probably defective. When measuring the pressure with the work equipment operated, be extremely careful that the surrounding area is safe.

*

-

A

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

Adjusting CO valve and NC valve • Adjusting CO valve If the set pressure of the CO valve is too high, the discharge amount is not reduced when the circuit is relieved. As a result, the relief pressure becomes higher, so always adjust it to the standard pressure. i) Loosen locknut (5) and turn adjustment screw (6) to adjust. Adjust with the adjustment screw as follows. To INCREASE pressure, turn CLOCK• WISE. To DECREASE pressure, turn COUN• TERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by 41.25 kg/cm 2 . If the pressure is not reduced even when the adjustment screw is turned, there is probably some internal defect in the CO valve. ii) After adjusting with the adjustment screw, repeat Section 2.-i) to check the set pressure again.

*

-

*

*

*

Front end

Rear end 205F2482

5

6

205F2483

PC200, 220-3

62-51-4 ®

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

•

Adjusting NC valve The NC valve is actuated by the differential pressure of the jet sensor, so when adjusting, always check that the differential pressure of the jet sensor is normal. • Loosen locknut (7) and turn adjustment screw (8) to adjust. Adjust with the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNT• ERCLOCKWISE. One turn of the adjustment screw adjusts the hydraulic pressure by approx. 4.3 kg/cm 2 •

*

*

*

-

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

-

62-51-5 ®

PC200. 220-3

TESTINT AND ADJUSTING

TESTING AND ADJUSTING CONTROL PRESSURE OF MAIN PUMP

3. TESTING AND ADJUSTING DI FFERENTIAL PRESSURE OF JET SENSOR.

Relationship between control lever stroke and differential pressure of jet sensor

The jet sensor produces high pressure and low pressure (high pressure - low pressure = differential pressure) at the outlet port of the control valve. The NC valve is controlled by this differential pressure. The differential pressure is highest when the control levers are at neutral, and is lowest when the control levers are operated to the end of their stroke. 1.

Measuring differential pressure Travel of control lever (mm)

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

-

Remove pressure pick-up plugs (9) (high pressure side) and (10) (low pressure side) (PT 1/8). In both front and rear, the engine side is the high pressure side. ii) Install hydraulic tester A (high pressure side: 2 60 kg/cm 2 ; low pressure side: 25 kg/cm ) iii) Run the engine at fulll throttle, and measure the differential pressure with the control levers at neutral. High pressure (Pt) - Low pressure (Pd) = Differential pressure iv) Using the work equipment, raise the track assembly from the ground, and measure the differential pressure with the track rotating under no load (operate the control lever to the end of its stroke).

205F2486

i)

*

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

*

-

*

2.

.-i;ff

~

Front control valve (for rear pump)

Any lever can be operated, but it is better to operate the travel circuit under no load, because the measurement time can be selected freely. The differential pressure is the minimum.

Adjusting If the result of the measurement shows that the differential pressure is not within the standard range, adjust as follows. i) Loosen locknut (11) and turn adjustment screw (12) to adjust. Adjust the high pressure side with the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. After adjusting with the adjustment screw, repeat Section 3-i) to check the differential pressu re agai n.

*

*

PC200, 220-3

12

11

205F2487

62-51-6 ®

MEASURING DELIVERY OF MAIN PUMP

TESTING AND ADJUSTING

-

MEASURING DELIVERY OF MAIN PUMP Special tools Part No.

Part Name

a'ty

A

790-303-1001

Flowmeter kit

1

Al

790-303-1010

Flowmeter

1

A2

790-303-1030

Flange

2

A3

790-303-1440

Nipple

4

A4

790-303-1050

Hose

2

As

790-303-1410

Nipple

2

A6

790-303-1091

Adapter (flange)

1

A7

790-303-1081

Adapter (flange)

1

B

790-502-1001

.

Tachometer

207F238A

1

-

www. k omat s upar t s book . c om METHOD OF MEASURING DELIVERY 1.

Preparation 1) Set flowmeter kit A and tachometer in position. 2) When measuring with the flowmeter, do as follows to prevent the jet sensor from working. i) When measuring the L.H. pump, jack up the left track frame and lock the right track. ii) When measuring the R.H. pump, jack up the right track frame and lock the left track. iii) Or remove the hose from jet sensor and block the jet sensor at the hose side and the CO, NC valve side. Part number of blind plug: Jet sensor hose side (07376-50210) NC' CO valve side (07221-20210) (07222-00210) Procedure for measuring 1) Rotate the track on the side being measured (the side where the flowmeter is attached). Move the control lever to the end of its travel. (If this is done, the jet sensor will not function.) Or remove the hose from jet sensor and block the jet sensor at the hose side. 2) Set the engine speed to the rated speed, and measure the delivery at the pressures in the main pump performance of judgement standard value.

Flowmeter

P20503202

*

2.

*

62-52 (j)

Jet sensor hose

PC200,220-3

-

TESTING AND ADJUSTING

METHOD OF LOCATING DEFECTIVE EaUPMENT WHEN THERE IS TRAVEL DEVIATION

METHOD OF LOCATING DEFECTIVE EQUIPMENT WHEN THERE IS TRAVEL DEVIATION The ports of the piston pump, control valve, and swivel joint are connected to the travel motors as shown in Figs. 1 and 2. Therefore, if there is any deviation in travel, the cause is one of the following: 1. If the deviation is as shown in Fig. 3, the packing at the swivel joint is defective. 2. If the deviation is in the same direction when traveling in both forward and reverse, the problem is not in the swivel joint but in one of the following.

Control valve

Front pump

Drain Right A rear

Rear

Left B front Right C front

Front

Left Drear

Rear pump

205F2488

Fig. 1 Piping for travel system To judge which of these three the problem is in, do as follows. 1) Reverse the front and rear hoses between the piston pump and the control valve as shown in

Up

I

F

I

Right

Fig. 1. If the problem is reversed, the hydraulic pump is defective; if it is not reversed, the control valve or travel motor are defective. Reverse the left and right hoses at the swivel joint end between the control valve and swivel joint.

* 2)

R

Up

R

I

www k omat s upar t s book . c om * . (See Fig. 4) (Turn the top of the swivel joint 180°.) If the problem is reversed, the control valve is defectIve; if it is not reversed, the travel motor is defective.

Left

I

F

205F2303

Fig. 2 (Condition when connected normally) Forward

Forward Right reverse only

Drain

Left B front

Right reve and left forward

Right C front

Right for

Right A rear

R'' * f

Does not deviate

Forward

-

Left reverse only

Reverse

Left 0 rear

Bottom

'''\

and left reverse

Re verse

205F2489

Fig. 3 Location of defective swivel joint packing and direction of deviation in travel

Disconnect

-

Fig.4

PC200, 220-3

205F2432B

62-53 ®

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE OF SWING, TRAVEL MOTOR

MEASURING OIL LEAKAGE OF SWING, TRAVEL MOTOR

* *

+ +

-

Oi I temperature when measuring: 45 - 55° C Lower the work equipment completely to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Measuring oil leaking 1)

Disconnect the drain hose of the motor, and fit a blind plug at the tilnk end. i) For the travel motor, disconnect drain hose (1) of the travel motor, and fit a blind plug CO at the hose end. ii) For the swing motor, disconnect hose (2) and fit a blind plug (1) at the tank end. For the travel motor, disconnect drain hose and fit a bling plug (3) at the travel motor end.

-

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

Start the engine, and operate the actuator to be measured. i) For the travel motor, put a block under the track on the side to be measured to lock the track in position. ~ When measuring oil leakage from the travel motor, mistaken operation of the levers can lead to accidents, so always follow agreed signals when measuring. ii) For the swing motor, lock the upper structure with the swing lock pin. iii) Run the engine at full throttle, put a measuring cylinder under the disconnected hose, relieve the circuit for one minute and measure the leakage.

-

Note: When measuring, move the motor slightly (move the position of the valve plate and cylinder, and piston and cylinder). and measure several times. Turn the swing motor 180° when measuring.

62-54 (5)

PC200, 220-3

TESTING AND ADJUSTING

CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE

CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE CHECKING AND ADJUSTING DEVIATION IN TRAVEL CHECKING Carry out the test on a firm level road surface. Hydraulic oil temperature when measuring: 45 - 55°C

* * 1.

-

Adjust the track shoe tension as follows. 1) Using the boom and arm, raise the track frame and measure the clearance between the track link rotating surface and the tread of the 4th (PC200, 220-3) or 5th (PC200LC, PC220LC-3) track roller from the sprocket. Standard dimension: 60 - 100 mm 2) To increase the track tension, pump in grease through lubricator (1); to loosen the tension, loosen lubricator (1) to let some grease out.

20SF2427

*

~

Never loosen lubricator (1) more than one turn. If the grease does not come out properly, move the machine backwards and forwards sIi ghtl y.

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

Check that the stroke of the travel spool is within the standard value. For details, see "Checking stroke of control valve "spool".

3.

Measuring five rotations unloaded 1) Using the boom and arm, raise the track frame on the side to be measured. 2) Run the engine at full throttle, rotate the track one turn unloaded, then measure the time taken for the track to turn five more times unloaded. Measure in forward and reverse. Carry out the measurement several times and take the average.

-

*

4.

Measuring by driving 1) Set the machine in the travel position. For the travel position, extend the bucket and arm cylinder rod fully, and hold the boom at a 45° angle. 2) Drive the machine for 10 m, then measure the deviation over the next 20 m. When measuring, run the engine at full throttle, and measure for each mode.

*

*

_.

20SF2428

PC200, 220-3

62-55 @

TESTING AND ADJUSTING

CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE

ADJUSTMENT If the measurements are not within the standard value, adjust as follows.

*

For machines equipped with 2-stage mode selector switch.

~ Travel deviation Deviation to right

Deviation to left

*S

a: Adjust front pump with shims

b: Adjust rear pump with shims

L

c: Adj ust front pump by turning back screw

d: Adjust rear pump by turning back screw

Measurement mode"

*

If the travel deviation is not within the specified value even after adjusting according to the adjustment procedure, go to Troubleshooting "Excessive travel deviation". For the PC200-3, if the deviation cannot be corrected by shims, adjust by turning back the screw.

-

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

For machines equipped with 3-stage mode selector switch.

~Travel deviation Measurement

H

S,L

mod~

Deviation to right

Deviation to left

Adjust front pump with shims

b: Adjust rear pump with shims

c: Adj ust front pump by turning back screw

d: Adjust rear pump by turning back screw

a:

-

If the travel deviation is not within the specified value even after adjusting according to the adjustment procedure, go to Troubleshooting "Excessive travel deviation".

62-56 (5)

PC200. 220-3

CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE

TESTING AND ADJUSTING

Procedure for adjusting with shims 1) Loosen 4 bolts (1). The shims are a semi-split type, so it is unnecessary to remove them. 2) Insert shim (2) of a thickness to match the contact, then tighten bolt (1 ).

*

*

Additional shims and amount of travel deviation. (mm)

(Q/min)

-f-

;: .;: 10c OJ

'-'

g

5

c

-

+-----",1----1200 c

~

100

~

o o

"""--_~----=-_'_::_-___::_'_:=-------=,-l--::--......J

0.1

02

OA

O~

Additional shim thickness (mm)

*

www. k omat s upar t s book . c om The maximum additional shim thickness should be 0.4 mm. ~

Mounting bolt: 5.5 ± 2 kgm

Adjusting by turning back screw 1) Loosen locknut (4) of servo valve (3). 2) Turn back adjustment screw (5) an amount to match the deviation, then tighten locknut (4).

-

Screw return angle and amount of travel deviation.

*

(mm)

(Q/min)

"0

;:

20

400

15

300

c

10

200

OJ

'-' c ~

~

'"OJ C

0 ~

co

':;

~ 0

eco E

0

;;::

OJ

5

100

o "'-_.L-_.L-_.L-_.L-_.L-_.L------.J 20

40

60

80

100

Adjustment screw return angle (

*

120 0

"0 Q)

> co

~

)

Turn back the screw a maximum of 100°. ~

Locknut: 0.8 ± 0.2 kgm

PC200, 220-3

62-57 (~

TESTING AND ADJUSTING

TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK

TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK

-

1. CHECK OF TVC VALVE SOLENOID 1)

2)

Remove TVC valve solenoid. (Leave the connector still connected) Turn the starting switch ON, and see if solenoid spool (1) moves when the mode selector switchis operated. (Be careful because oil will fly out when the spool moves.)

2. CHECK OF CONTROL VALVE SPOOL

-

Remove left and right cases of the control valve, then remove the left and right springs and see if spool (2) moves easi Iy.

www. k omat s upar t s book . c om 3.

CHECK OF ACTUATING PRESSURE OF SWING MECHANICAL BRAKE (IF EQUIPPED) Run the engine at low idling, and hold inlet hose (3) of the swing mechanical brake by hand. Check that there is vibration from the hose when the selector switch of the swing mechanical brake is operated.

4.

-

CHECK OF INLET PRESSURE OF DECELERATION CYLINDER (IF EQUIPPED) Run the engine at mid-range speed (1500 rpm or above), and hold inlet hose (4) of the deceleration cylinder by hand. Check that there is vibration from the hose when the auto decelerat ion se lecto r sw itch is operated.

62-58

PC200, 220-3

TROUBLESHOOTING Circuit diagram Connection table for connector pins Connector position for troubleshooting Troubleshooting procedure Checks before troubleshooting Abnormality judgement conditions for self-testing display " Troubleshooting Troubleshooting (except troubleshooting for machine monitor) Troubleshooting for electric system (El - E6) Troubleshooting for hydraulic and mechanical system (Hl - H16)

-

6262626262-

60 64 67 68 69

62- 71 62- 72 62- 78 62- 86 -62-140

www. k omat s upar t s book . c om Failure mode and components

62-169

-

PC200, 220-3

62-59 @

CIRCUIT DIAGRAM

TROUBLESHOOTING

CIRCUIT DIAGRAM E. OLSS AND AUTO-DECELERATION SYSTEM (IF EQUIPPED) PC200-3 (Serial No. 20001 21463) PC220-3 (Serial No. 20001 20364) CNJ3 Engine speed sensor

Swing oil pressure sensor

CN]?

Potentiometer

Limit switch (neutral)

CN]1

r---L.L-L.L..l---L.L---l.~=±==fCN

CN2CJ

1

~ON'=.W

1 011- 0LY oH- 02R

Control box

Auto-decelerator

02B

---._----'

O'lVV 0713

solenoid

-

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

:Mode selec-:

~S_~i~

Auto-decelerator switch

05W

Fuse box CN4D

PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up)

-------, 02'(8

02 02LG

Tirner

02LG

CN33 I::nqllle

spf'ed

\1'[1501

POlen ('orn('lf'r

CN38

Resistor 02P 02V

Control box

Resistor

Battery relay

-

MW Fuse box

62-60 @

-

F20503064

PC200.220-3

TROUBLESHOOTI NG

CIRCUIT DIAGRAM

SWING BRAKE SYSTEM (IF EQUIPPED)

Timer

'--1-_ _--'

02Y1::l ()2GY

Swing mechanical brake solenoid

Oil pressure sensor

~~~~~~~ To battery relay terminal

Swing brake caution lamp

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

PC200. 220-3

62-61 @

TROUBLESHOOTING

CIRCUIT DIAGRAM

-

MONITOR SYSTEM Coolant

Water temp. Engine oil pres- Hydraulic oil sensor level sensor sure sensor

Engine oil level sensor

level sensor

,

fWi:\

I

'1

I

028

1

1

rt+t-+t--t-----fto;

111 02B

21 21 20 20 19 19

02G

17 17

-

I1-+1H-+-++-_t--"0"'20::.-(_:tt~~0

Of--f-Q

ON

of-o

W

o-f-O-I-O

PC200, 220-3

CIRCUIT DIAGRAM

TROUBLESHOOTING

MONITOR SYSTEM PC200-3 (Serial No. 20001 - 30309), PC220-3 (Serial No. 20001 - 22627) Water temp. Engine oil pres- Hydraulic oil level sensor sensor sure sensor

Engine oil level sensor

Coolant level sensor

rAAi"A\

1==

1==

~

~

~ ~ 1 2

Hi

==

,~\

"

'

\

~~)i

oJ

F=

F=

~ 1 2

~

It

F===

1

2

01BW

- 0- k)- k>

PC200, 230-3

'" o§"

zJ!l

ON W

0 -

-0

0 - -0 0 -0 0-.0- -0

62-61-2

CIRCUIT DIAGRAM

TROUBLESHOOTING

--

PC200-3 (Serial No. 30310 and up) PC220-3 (Serial No. 22628 and up) C Galant Ie vel sensor

~

~

>---

f) >--1

~

I-CN~2

I

nglne 01 level sensor

2

I

i

w ater temp sensor

2

~

I

'"-

Engine oil pressure sensor

"

([I::)

~

2

I

2

Hydraulic oil level sensor

Fuel level sensor

~""

1-

~

I 2 3 4 0

eN I

~14

eN -15

2

I

-=-

2

-

-

I--

-

Starting

{ 8

t

----'

I

Fuse box ISA

I

SWitch

Ace

~

I

[ ~~p

b

To starting motor C termmal To alternator R terminal 10 0 0 00 I 2 3 4 5 6 7 8 9 10 I I 12 10

0

0

0

-

21J

I

C N-I

www. k omat s u p a r t s b o o k . c o m 1 """p ~ "''1 Electflcallntake air heater

Heater relay

J~l

crr;~~~ o

Wiper,

; -~

'---, CNP6f--------- -

Lamp

,

C~r---~ I

Mode

2 3

selector

~ 21 020 19 018 17 016 015 14 13 12

To control b ox

To control bo x

"

10 09 08 7 6 05 04 03 02

To control bo x

IL

-

I 2

3 0 0 0

CNP1

~:lj~r\~r(~;

3 4

5 6 7 08 9 010

0 0 0 0

(UUldl

~

2

III vpl

H'y'cl(c1UIH oil

III

I

-

g-

Willer temp

0

f-ul'llevel

o~(

Spdf('

6

Sparp

07 \

8

0

SlldlP iGNDI

3

--'--

,

':GNi)"

~

02

~c

;5> SP~HP

12

I

(J)

f- 'HJII"~ oil pr(!S'"Ht'

CNP2

0

I

t levpl

frll) III ()

~

3

1

--

,4V

I 2

I

0 0

0 0 0 0

I:

Service meter

"

08 07 06 05 -04

~

4 05

~

02 I

~/ T1 '77

CNP9

0

I

SW~C~

q

BUllP!

Do

,

--~

Battery relay

Buzzer

205F2457

62-62 (B)

PC200, 220-3

--

-

CIRCUIT DIAGRAM

TROUBLESHOOTING

ELECTRICAL SYSTEM Heater relay

Starting motor

lUI

""

Electrical intake

~~~~g~~~~;;±trr===~_a_ir_he_a-fter I

CN/'O

"l"

~ 1I[l;;;=u:~r""""'-~./

OOB

)

/

Antenna ~

~~

I

I

R~adio

~ID~

02V;

~

01 R

___Washer ::::-JI

cml

-

,

L L::

Room lamp

,...2.!Ol~RSiN~30fF~~ --~

IV

I~====~I 11 12

2

B L LB

(If equipped)

A, ..

(If equipped)

02W

LW

1 2 3 4

v

To cooler compressor

6

01LW alB alL 01LB

1 2 3 4

01R

05W

CN7

Wiper

CN29

CN28 01LW 02B 01 R 01 LB

nl

Alternator

1 ~ Speaker

;:cHI 001 o

To control_ box

20'0+1-"-°1c.R :-"L=-------HI+-Hr---1h

Ie

Cigarette lighte AlA.

17otf-°;;..O;;..5:..;C,--,- - - ,

eN2'J

130

I"

-

r-_~O~1l:,L!:,R--I~~, fF~~_1U-:.1122~5L:..!R~I---l

01WY 01YL 005BY

9 8 7

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

608

~~i~d~ pressu re - - - - - - I l o

~ b

R

E

r

-HI+-H--HI+-HI----':0C!.1=.L~W-1to ,,01LB

01 YB 01BR 01WR 01 R

5 4 3 2

LW l I

125 1.25LB

Heater

C~(

~-.....:Oo.;l~Lc:.R:"---k>°;

Cooler or air conditioner

4+H+-"':~'-~C:~':'~:"--I, monitor Trouble-

shooting Charts No. M-l - M-14.

62-68 ®

6. Troubleshooting (Main troubleshooting) 1) Electronic OLSS, auto-decele-

ration, swing brake 1) Using the Judgement Table, decide if the problem is in the electric system, or in the hydraulic or mechanical system. 2) Go to the troubleshooting chart indicated in the Judgement Table. 2) Monitor on machine 1) Choose the troubleshooti ng chart wh ich matches the problem.

PC200.220-3

-

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

-

E-G

TROUBLESHOOTING

Troubleshooting Chart No. E-6 Failure mode: Upper structure does not swing, or hydraulic drift of swing is excessive.

-

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Hydraulic drift of swing is excessive Carry out all checks with the swing control lever at neutral.

*

3 YFS

Is there continuity between CN18 (female) (2) and chassis ground?

YES 2

YES

Is resistance between CN18 (malel 11) and (2) 10 - 30

!P 2)

11 Connect

2)

NO

11 Connect

T-adapter (socket) to CN 18 Imale!. T urn starting switch OFF.

T -adapter Isocket) to CN 18 (femalel. Turn starting switch OFF.

NO

• When using T6-adapter. -

I Does swing brake lamp light up normally 7

11

5 1)

Tum starting switch ON. Lights up about 5 seconds after stopping swing.

-

I

YES

Is voltage between CN 19 (femalel (3) and 11) 20 - 30V7

NO

Measurement conditions same as in previous

step. Turn starting switch ON.

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

YES

Is voltage between CN19 (21 and (1) 20 - 30V7

21

S

Is voltage between CN24 121 and chassis ground 20 - 30 V7

YES

11

4

NO

Is there continuity between CN 19 Ifemale) (1) and chassis ground?

Connect T -adapter (socket) to CN19. 2) Turn starting switch ON. 3) Place swing lever

7

Is voltage between CN24 (1) and chassis ground 20 - 30 V7

in neutral.

Measurement conditions same

as in previous step. Turn starting switch ON.

2)

11 Connect T- adapter

I

1) Connect T-adapter (socket) to CN1 9 (female). 2) T urn starting switch OFF.

1)

2) 31

to CN24. Turn starting switch ON. Place swing

NO

I

lever at neutral.

NO

• When using socket adapter.

6

6 11

Connect socket to CN 18 Ifemale) and CN19 (female!. Turn starting switch OFF.

21

2)

-

Connect socket adapter to CN19 (male!. Turn starting switch OFF.

NO S

,

YES Is voltage between CN24 111 and chassis ground 20 - 30 V7

11 Connect socket ~.c

~ocn

O~B II=~

T -adapter or socket adapter (forEKONO)

62-68 CD

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DLD

2)

adapter to CN24 (female!. Turn starting switch ON.

I :\0

11 Connect socket 2)

Tester

YES

Is there continuity between CN24 Imale) (11 and (2)7

7

, Cl

-

NO

Is resistance be-

tween CN19 (male) (1) and 121 200 300 !l7

,

YES

Is there continuity between CN 18 Ifemalel (1) and CN 19 Ifemale) (31?

YES

1)

,

I

adapter to CN24 (male!. Turn starting switch OFF.

I I, I

NO

I PC200, 220-3

-

-

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING (,. Checks before starting, 2. Other check items)

~

Judgement standard

Remedy

1. Check fuel level

-

Add fuel

2. Check for dirt or water in fuel

-

Clean, drain

3. Check hydraulic oil level

-

Add oil

u

4. Check hydraulic oil strainer

-

Clean, drain

0

5. Check swing machinery oil level

-

Add oil

6. Check engine oil level (Level of oil in oil pan)

-

Add oil

7. Check cooling water level

-

Add water

8. Check condition of dust indicator

-

Clean or replace

9. Check for loose or corroded battery terminals

-

Tighten or replace

10. Check for loose or corroded alternator terminals

-

Tighten or replace

11. Check for loose or corroded starting motor terminals

-

Tighten or replace

"-

Item

Q)

+-'

'"3::

OJ

e .-

OJ

t

e .-

'"

0

-

-.-

+-' -y - - - - - - - - - IL NO

_

('-.----+-_..----~--+----~_.-+--- +----

(about 6 seconds) is strange

---

1----- - - - - - - - - - - - -

10

Abnormal noise comes from around pump

r- - - -

11

Swing speed is slow

f-----

12

Upper structure does not swing

I---------f---- ---- -----

f-----

----------------1--------_.(

)

13

Excessive hydraulic drift of swing

1----------------------

14

Excessive hydraulic drift or work equipment

15 Parking brake does not work (on slopes)

1--------- - - - - - - - - - - - - - - - 1---- - - - - - - - - - - - - - - - - - - - - - - - -

16 Excessive time lag for work equipment

1------------------------- ----

62-80 ®

PC200, 220-3

JUDGEMENT TABLE

TROUBLESHOOTING

Checking swing brake solenoid voltage

Checking by switching

Check self-testing display

prolix circuit

Troubleshooting chart

2. Does NORMAL display appear? 3. Does problem disappear 4. Is voltage at inlet -,:-)-=-Du-ri:-n-g-d:-e-ce-l-e-ra-t-io-nr-r--'-t-h-e-r-th-a-n-d-e-c-e-Ie--~ when prolix circuit port of swing brake (H, Sand L modes) ration (H and L switch is operated? solenoid normal?

Go to E -(\,0

2I O

for abnormali-

ties in electrical system; go to H - OX for

modes 1

0

Red Green

-

OFF Slow flashing (once every

~

0

Red

! I ~~~~

OFF

Lever at neutral

Fast flashing

Green -()

(Stimes per second)

2 secondsl

switch at OFF

3)

23 - 30V

OV

I I

abnormalities in hydraulic or mechanical

1) Disconnect connector of

,) Engine at half throttle or above

swing brake solenoid 2) Run engine for about

21 Engine at half

throttle

I I

system.

11 Auto-deceleration

All control levers at neutral 2) Engine at full 1)

operating

10 sec.

throttle Operate mode switch H-S-L.

3) Stop engine, and turn

starting switch to ON. 4) Move swing lever

between neutral and swmg.

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

- -

---------'l

H-1

~

H-2

- - - - - -

-- -

- - -

- - - - - - - - 7 H-3

--------~ H-4

--------

--------I---------~H--5 i - - - - - - - - - - ' ! £-2

-- - - - - - -

---- ----

YES

H

~---.-{==

6

(Step 91

E

NO

---------------- ----------------"£ YES r - -

--------i---------

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

-

-

-

-

- -

-

--------- 1----- -

YES

---- ----- ---e--i~

-

£ - 3 (Step 8) H 7

--'

£

-.-0-+1'0 t..:.:

--------1---------

--------

4

H-3 E - 4

--------"

(Step 5)

----------------1----------> E

(Step 4) II

- - - - - - - - I-- - - - - - - -

--------

~

-

-

-

-

-

-

~

-

-

-

-

-

-

-"

10

H - 11

---------------- ------YES-" H -13

- - - - - - - - - - - - - - - -----------~-;;, ~

- -

-

-

- - - - -

- -- -

- - - - -

-

-., £ - 6

-- --

H

6

---------------------------~

-

-

-

-

-

-

-

PC200, 220-3

f- -

-

-

-

-

-

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-?

H -16

62-81 ®

TROUBLESHOOTING

JUDGEMENT TABLE

2) JUDGEMENT TABLE (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up)

Check self-testing display

1. Is location of abnormality displayed?

c:

Power

Control

supply

box

TVC solenoid system

Red

0

OFF

Red.

ON

Red

-(l-

Green

0

OFF

Green.

ON

Green

0

Potentiometer system

sensor system

FlashlmJ

OFF

( -(;- , See 62-78 )

Engine speed

Red

-(} Flashing

Red.

Green"') Flash'nq

Green

0

NORMAL display

Auto..::!eceleratlon solenoid system

ON

Hell.

ON

OFF

Green.;

Flash,nq

Red

0

OFF

Grt'p".

ON

1) Run engine at low idling.

_'2

*

11

If the - marks in the table below indicate some additional abnormality. this means that two or more abnormalities have occurred at the same time

21

than deceleraTion

The s,tuJliOn dunnq normal decplpratlon I';

-

on th"

tprn "'1 ht

dec"l"r,l!lon

Failure mode Machine deviates excessively

r---------------

2

Machine deviates excessively (compound operations)

1--

3

Machine deviates excessively (when starting)

4

Control levers are heavy

5

Work equipment, travel, and swing start suddenly

6

Speeds for work equipment, swing, and travel are all extremely slow, or there is no power

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

--I-----I---~-----

-----~

r

---

~-

--j-~---

---- ----

-

----1-----

----

-------j----

.::tL.:..-:-~-=-=+__-__ Applies H mode to

>-« 'J:::~_ ~ ~:\()

or L

-~.--

_--r-:-=-~~":"-7

Engine stalls or engine speed drops during operations

8

No change in output when mode selector switch is operated

9

Auto-deceleration does not work properly No deceleration Deceleration stays on Time taken for deceleration to work (about 6 seconds) is strange

--

~ ~)-- -------.--,_/', IF S _~__ - __ +.~ yf-'.:.:c_

-.-

-~-

~ ~)---~~-+--~------+----

~--1-~

- - - ---t---

_-t---- >-« J

-

j-' ES

I L~(2...

... _

(

10

Abnormal noise comes from around pump

r----

11

Swing speed is slow

I-----------------!----I----

12

Upper structure does not swing

1---------1----- 1---- 1-----

)

I----I----------------- r ---- - --

-----_.(

13

Excessive hydraulic drift of swing

14 Excessive hydraulic drift or work equipment 15

Parking brake does not work (on slopes)

16 Excessive time lag for work equipment

62-82 ®

-

--

)

f---------i-------------

--------r----- ----

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

- -

-

-

- - - - - - - -

--

- - -

PC200, 220-3

-

JUDGEMENT TABLE

TROUBLESHOOTING

-

Check self-testing

Checking voltage of auto.-deceleration solenoid

display 2. Does NORMAL display appear?

0

Troubleshooting

solenoid voltage

chart

switch is operated?

• Is voltage at inlet of auto-deceleration

Go to E -/',0 for abnormali-

ties in electri-

solenoid normal?

cal system; go to H - OX for

solenoid correct?

OFF

I

Fast flashmg

Green -(}

Checking swing brake

3. Does problem disappear 4. Is voltage at inlet when prolix circuit port of swing brake

Other than decele· ration ( Sand L modes) Red

Checking by switching prolix circuit

Lever at neutral

I ~~~~ operating

(5 tImes

per secondl

I

[20 - 30V

ov

[

1

abnormalities in hydraulic or mechanical

system.

1)

Auto-deceleration switch at OFF 2) Engine at half throttle 3) Operate mode switch

H ...... S-L.

1) Lever NEUTRAL solenoid A (3-pin side) 20 - 30V 21 Lever operation solenoid B (2-pin sidel 20 - 30V 3) Engine at half throttle or more 41 Measure solenoid A after about 5 seconds

1)

1) Disconnect connector of swing brake solenoid 2) Run engine for about 10 sec. 3} Stop engine, and turn starting switch to ON. 41 Move swing lever between neutral and swing.

Engine at half throttle or above

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

-

-

-

-

-

-

- -

-

-- -

-

-

- -'i

H-]

H

H-3

---------'l

-----------------~-------

H

H

5

f--------~ E-2 YES

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

r----.-{==~ NO

---------------- ----------------' YES

r - -

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

-

-

-

-

-

-

-

-...o---tLi:!

tween CN1 0 Ifemale) 14) and 151 500 - 600 117

2)

• OJ

~c

:JO~

Tester

000

~~B

T-adapter or socket adapter (for EKONO)

62-94 @

• See TESTING AND ADJUSTING.

Is resistance be-

11

..c..;:::;

NO

1

3

Turn starting

switch OFF. Connect Tadapter (socketl toCN10.

YES

Is resistance be-

:'\0

T-adapter or socket adapter (forMIC) T-adapter or socket adapter (for DLIl

tween CNS (male) 11) and (2) 500 600 117

NO

Connect T -adapter (socket) to CNS.

PC200, 220-3

-

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

TROUBLESHOOTING

E-2

-

Troubleshooting Chart No. E-2 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: Work equipment, swing, travel speeds extremely slow, or lack of power.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket).

*

For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in

(

a)

l. Self-testing display shows abnormality

YES

2

YES

Is voltage between CN10 (female) (1) and (2) 20 - 30 V?

Is resistance between CNl 0 (female) (2) and chassis ground 00]

1 OFF

O

OOFF

Red

Green

1) Connect T -adapter (socket) toCN10. 2) Turn starting switch ON. (Do not start engine)

Is voltage between fuse 4 and chassis ground 20 - 30 V?

.

Turn starting switch ON. (Do not start engine)

3 YES

NO

NO

1)

Connect T -adapter (socketl to CN-l O. 2) Turn starting switch OFF.

NO

-

Abnormality in control box

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

4

Is there continuity between CN36 Imale) (1) - 13) and 12) - 15P

YES 3 Is resistance be-

tween CN36 (female) (3) and 15) 10 - 25 IPls each pin to chassis ground insulated]

YES 2

Abnormalith in TVC solenoid

f -(lRed

OOFF Green

1)

Is CN13 (male) (1), (2) - chassis ground insulated?

YES

I2)

1

-->

l) Connect T -adapter Isocket) to CN13 (malel. 2) Turn starting switch OFF.

Is resistance be-

tween CN13 (male) (1)and(2)1025lP

Connect T -adapter (socketl to CN13 (malel. 2) Turn starting switch OFF.

Connect T -adapter Isocket) to CN36 Ifemalel. Tum starting switch OFF.

~

o

N Turn starting L;. switch OFF. 2) Turn prolix circuit switch OFF. 31 Connect T -adapter Isocket) to CN36 Imal el. 1)

NO

-

NO

NO 2 YES

YES

Is cause removed if engine speed sensor is adjusted again?

NO

1

Red

Is resistance between CN10 (female) (4) and (5) 300 - 1000 O?

Green

1) T urn starting switch OFF. 2) ConnectTadapter (socket) toCN10. • 0>

~.~ ::10

~~E 1-'",

Tester T -adapter or socket adapter (forEKONOl

62-94 ®

• See TESTING AND ADJUSTING.

3

NO

T -adapter or socket adapter (forMIC)

Is resistance between CNS (male) (1) and (2) 300 10000?

YES

NO

Connect T -adapter (socketl to CNS.

--

T -adapter or socket adapter (for DLI)

PC200,220-3

E-2

TROUBLESHOOTING

Cause

Control box defective. (circuit between CN10 (male) (11, (2) and inside of box)

Disconnection in wiring harness, defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4. Disconnection in wiring harness. defective contact between CN 10 (2) - battery relay - terminal E, or battery relay defective.

-

-

Disconnection in wiring harness or defective contact between CN20 (20) - fuse 4 - CN21 '" (2) - battery.

*

PC200-3 Serial No 25924 and up

Remedy

Replace

Clean (defective contact) or replace.

Clean (defective contact) or replace.

Clean (defective contact) or. replace.

CN21 (2) and (4) PC220-3 Serial No. 21 556 and up CN21 (2) and (4)

Control box defective.

Replace

www. k omat s upar t s book . c om 5

YES

Control box defective.

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN36 (female) (1) and CNll (male) (1), or CN36 (female) (2) and CNll (male) (21.

Clean (defective contactl or replace.

Prolix circuit switch defective.

Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CN 13 (female) (1) and CN36 (female) (3), or CN13 (female) (2) and CN36 (female) (5).

Clean (defective contact) or replace.

TVC solenoid defective.

Replace

TVC solenoid defective.

Replace

Engine speed sensor adjustment defective.

Adjust

Control box defective. (circuit between CNl 0 (male) (4), (5) and inside of box)

Replace

Disconnection in wiring hamess, defective contact or contact between chassis ground and CN8 (1), (2) - CNl (13), (14) CN10 (4), (51.

Clean (defective contact) or replace.

Engine speed sensor defective. (Disconnection in wiring harness or contact with chassis ground)

Replace

Is resistance be-

-

tween CNll (malel 111 and (2) 10 - 25 II ? Is each pin to chassis ground insulated?

1)

:'lO

Connect T -adapter (socket) to CN 11 (malel. 2) Turn starting switch OFF. 3) Turn prolix circuit switch OFF.

PC200.220-3

62-95 ®

E-2

TROUBLESHOOTI NG

• When using T -adapter

I-Y;5

3 YES

IIt

Is voltage between CN10 (6) and (7) Vcc/2?

I

YES Abnormality in potentiometer

ONe Red

I

1

2)

Measurement condi-

1)

tions same as in

OOFF

NO I

I

NO

previous step 2) Take voltage between CN9 (1) and (3) as Vcc. 3) Place governor lever in FULL.

Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

Green

Connect T - adapter toCN10. Turn starting switch OFF. 3) Place governor lever in FULL.

1)

Is voltage between CN9 (1) and (2) Vcc/2?

-

4

I)

Connect T -adapter (socketl to CN9. 21 Turn starting NO switch OFF.

-

YES

Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V?

NO

Connect Tadapter to CN10. Turn starting switch ON

1)

www. k omat s u ar t s book . c om •p 21

3

When using socket adapter

YES 3

YES 2

I

bl

If condition changes when switching to prolix circuit (when self-testing display shows normal) 2

YES 1

Is resistance between CN9 (male) (1) and (3) 5 ± I K n ? Is it insulated from chassis ground? 1)

2) 3)

Disconnect CN9. Do not start engine. Governor lever at FULL.

Is difference in resistance between CN9 (male) (1) and (21. and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

Is difference in res istance between CN 10 (female) (6) and (81. and resistance between (7) and (8) less than 30 Q? 1) Connect socket adapter to CN9. 2) Disconnect CN10. 31 Tum starting switch OFF.

YES r-

INo I

I

NO

NO

I

YES

-

Is mounting of engine speed sensor normal?

NO

Is difference of resista nee between CN9 (male) (1) -

See TESTING AND ADJUSTING.

(2) and (2) - (3) below 30 n? 1)

Connect T -adapter (socketltoCN9. Turn starting switch OFF. Place governor lever in FULL.

2) 3)

NO

, Cl

~c:

Tester

..c".;::;

::>0'" 000

~-S£>

T -adapter or socket adapter (forEKONO)

62-96 ®

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DU)

PC200, 220-3

E-2

TROUBLESHOOTING

Cause

-

Remedy

Control box defective. (circuit between CNl 0 (61, (7) and inside of box)

Replace

Disconnection in wiring harness, defective contact or short circuit between chassis ground and CNS (1), (21 - CNl (15), (16) CN10 (6), (81.

Clean (defective contact) or replace.

Potentiometer defective or mounting defective.

Adjust or replace.

Disconnection in wiring harness, defective contact or contact between chassis ground and CNl 0 (6), (8) - CNl (15), (17) - CNS (1), (31.

Clean (defective contactJ or replace.

Control box defective. (circuit between CN 10 (6), (81 and inside of box)

Replace

Control box defective. (circuit between CNl 0 (6), (71 and inside of box)

Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CNS (2) - CNl (16) - CN10 (7).

Clean (defective contact) or replace.

www. k omat s upar t s book . c om Potentiometer defective or mounting defective.

-

Potentiometer defective.

Replace

Control box defective.

Replace

Engine speed sensor mounting

Adjust

defective.

Potentiometer mounting defective.

pe200.220-3

Adjust or replace.

Adjust

62-97 ®

E-2

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 Troubleshooting of power source 1. Measure voltage between fuse 4 and chassis ground.

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) (2) and chassis ground.

-

2

www. k omat s upar t s book . c om E-2 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1), (2) and chassis ground.

·1

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Check for continuity between CN36 (male) (1) and (3), (2) and (5).

2

[53). 5 2

1 3

3

62-98 ®

-

5

PC200.220-3

E-2

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 5. Measure resistance between CN11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

2

1

[5lJ]G -

E-2 (Troubleshooting of speed sensor) 1. Measure resistance between CN10 (female) (4) and (5).

4

5

(I)[[] www. k omat s upar t s book . c om 2.

Adjust speed sensor (CN8) again.

3.

Measure resistance between CN8 (male) (1) and (2).

2

j0S

PC200, 220-3

1

m[~~

62-99 ®

E-2

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 (Troubleshooting of throttle sensor) 1. Measure voltage between CN9 (female) (1) and (3). 2. (T-adapter) Measure voltage between CN9 (1) and (2).

3. 4.

(T-adapter) Measure voltage between CN10 (6) and (7). Measure voltage between CN10 (male) (7) and (8).

-

8l~

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

7

2.

(Socket) Measure resistance between CN9 (male) (3). Check for continuity between CN9 (male) \ and chassis ground. 3. (Socket) Measure resistance between CN9 (male) (2). Check for continuity between CN9 (male) and chassis ground.

3

(1) and (1), (3) (1) and (1), (2)

-

1

~~ 3'.

(Socket) Measure resistance between CN10 (female) (6) and (7). Check for continuity between CN10 (female) (6), (7) and chassis ground.

7

6

62-100 @

PC200, 220-3

E-2

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-2 (If problem is removed when switching to prolix circuit)

1.

Measure resistance between CN9 (male) (1) and (2).

1

2

~¥ 2.

Check mounting of speed sensor.

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

PC200, 220-3

62-101 @

TROUBLESHOOTING

E-3

Troubleshooting Chart No. E-3 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED)

-

Failure mode: Engine stalls during operations, or engine speed drops.

*

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket!.

* For T -adapters. connect to both the male and female ends; for the socket, connect to the connector marked in ( a)

). Self-testing display shows abnor mality

2

YES

21

Is voltage between CN 10 (female) (1) -and (2) 20 - 30 V?

3 YES

NO

1

Abnonnality in power supply

I~

YES

Is resistance

between CN10 (female) (2) and chassis ground On?

1) Connect T-adapter (socket! to CN1 O. 2) Turn starting switch ON. (Do not start engine)

Is voltage between fuse 4 and chassis ground 20 - 30 V? • Turn starting switch ON. (Do not start engine)

NO

Connect T -adapter (socket) to CN 1O. 2) Turn starting switch OFF.

1)

NO

Abnonnality in control box

ONe eONI l

Red

Green

_

-

.

...YES

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

Is there continuity between CN36 (male) (1) - (3) and (2) - (5)7

YES 3

Is resistance be-

tweenCN36 (female) (3) and (5) 10 - 25 II? Is' each pin to chassis ground insulated?

YES 2

YES Abnormality in TVC solenoid

j -(t Red

OOFF Green

1 l)

Is resistance between CN 13 (male) (1) and (2) 10 - 25 n? 1)

2)

Connect T-adapter (socket) to CN 13 (malel. Tum starting switch OFF.

2)

Connect T-adapter (socket! to CN13 (malel. Turn starting switch OFF.

1)

Connect T-adapter (socket) to CN36 (female). 2) Turn starting switch OFF.

Is CN13 (male) (1), (2) - chassis ground insulated?

CN9 (male) (1) and (2) Vcc/2?

Red

1 Is voltage between CN9 (female) (1) and (3) 5 - 5.2 V?

Green 1)

Connect T-adapter (socket) to CN9. 2) Turn starting switch ON.

tV g> ..e'-

Tester

gg~

T -adapter or socket adapter (for EKONO)

t=~

62-102 ®

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DUl

NO

• When using T-adapter (for socket adapter see page 62-46.1 3 YES,

YES' n,...."',._:

OOFF

No

NO

YES

ONe

Turn starting switch OFF. 2) Turn prolix circuit switch OFF. 3) Connect T -adapter (socket) to CN36 (mal el.

NO

~Abnonnality in potentiometer

1)

1)

Measurement

NO

-

Is voltage between CN 10 (6) and (7) Vcc/]

NO 1)

2) 3)

Connect T- adapter toCN10. Tum starting switch ON. Place governor lever in FULL.

I I

conditions same as in previous step

l NO

2) Take voltage between CN9 (1) and (3) as Vcc. 3) Place governor lever in FULL.

A

YES Is voltage between CN 10 (male) (7) and (8) 5 - 5.2 V?

NO 1)

Connect T-adapter (socket! to CNI O. 2) Turn starting switch ON.

PC200,220-3

E-3

TROUBLESHOOTING

-

Cause

Remedy

Control box defective. Icircuit between CNl 0 (male) (1), (2) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CNl 0 (1) - CN20 (20) - fuse 4.

Clean (defective contactl or replace.

Disconnection in wiring hamess, defective contact between CN 10 (2) - battery relay - terminal E, or battery relay defective.

Clean (defective contact) or replace.

Disconnection in wiring hamess or defective contact between CN20 (20) - fuse 4 - CN21 "-' (2) - battery.

Clean (defective contactl or replace.

*

PC200-3 Serial No. 25924 and up· CN2' (2) and (4)

-

PC220-3 Serial No, 21556 and up CN21 12l and (4)

5 YES

-

Is resistance between CNll (male) 11) and 12)10 - 2511> Is each pin to chassis ground insulated 7

Control box defective.

Replace

Control box defective.

Replace

www. k omat s upar t s book . c om NO

1) Connect T-adapter (socket) to CNll (male). 2) Turn starting switch OFF. 3) Turn prolix switch OFF.

PC200, 220-3

Disconnection in wiring harness. defective contact or contact between chassis ground and CN36 (female) (1) and CNll (male) (1), or CN36 (female) (2) and CNll (male) (2).

Clean (defective contact) or replace.

Prolix circuit switch defective.

Replace

Disconnection in wiring hamess, defective contact or contact between chassis ground and CN 13 (female) (1) and CN36 (female) (3), or CN13 (female) (2) and CN36 (female) (5).

Clean (defective contactl or replace.

TVC solenoid defective.

Replace

TVC solenoid defective.

Replace

Control box defective. (circuit between CNl 0 (6), (7) and inside of box)

Replace

Disconnection in wiring harness, defective contact or contact between chassis ground and CN9 (1), (2) - CNll 116), (17) - CN10 (6), (7).

Clean (defective contactl or replace.

Potentiometer defective or mounting defective.

Adjust or replace.

Disconnection in wiring harness. defective contact or contact between chassis ground and CN10 (6), (8) - CNll (15), (17) - CN9 (1), (3).

Clean (defective contact) or replace.

Control box defective. (circuit between CNl 0 (6), (8) and inside of box)

Replace

62-103 ®

E-3

TROUBLESHOOTING

Cause

adapter • When using socket -

I

-

-

3 YES

YES 3

I

YES 2

J

I

Is resistance between CN9 (male) (1)and(3)5±1 K n ? Is it insulated from chassis ground?

Remedy

Is difference in resistance between CN9 (male) (1) and (2), and resistance between (2) and (3) less than 30 n? Measurement conditions same as in previous step.

Is difference in res istance between CN 10 (female) (6) and (7), and resistance between (7) and (8) less than 30 n? 'l-. 1) Connect CN9. NO 2) Disconnect CN10. 3) Do not start engine.

NO

Control box defective. (circuit between CN 10 (6), (7) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN9 (2) - CN1 (16) - CN10 (7)

Clean (defective contact) or replace.

Potentiometer defective or mounting defective.

Adjust or replace.

Potentiometer defective.

Replace

I

1) Disconnect CN9. 2) Do not start engine. 3) Governor lever at FULL.

NO

I

If condition changes when switching to prolix circuit (when self-testing display shows normal)

-

--

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

2

YES 1

Is difference of resistance between CN9 (male) (1) (2) and (1) - (3) below 30 n? 1) Connect T-adapter (socket) to CN9 (male). 2) T ~rn starting switch OFF. 3) Governor lever at FULL.

Is mounting of engine speed sensor normal?

• See TESTING AND ADJUSTING.

NO

YES

NO

Control box defective.

Replace

Engine speed sensor mounting defective.

Adjust

Potentiometer sensor mounting

Adjust

defective.

-

62-104 ®

PC200. 230-3

E-3

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-3 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

-

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) chassis ground.

(2) and

www. k omat s upar t s book . c om E-3 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1). (2) and chassis ground.

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Measure resistance between CN36 (female) (1) and (2). Check for short circuit between CN36 (female) (1), (2) and chassis ground.

1

2

-.

PC200, 230-3

62-105 ®

TROUBLESHOOTING

E-3

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-3 (Troubleshooting of TVC valve) 5. Measure resistance between CN 11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

2

1

B31G E-3 (Troubleshooting of throttle sensor) 1. Measure voltage between CN9 (female) (1) and (3), 2. (T-adapter) Measure voltage between CN9 (1) and (2).

1

-

3

~tQJ www . k omat s upar t s book . c om 3. 4.

(T-adapter) Measure voltage between CNlO (6) and (7). Measure voltage between CN10 (male) (7) and (8).

2.

3.

(Socket) Measure resistance between CN9 (male) (3). Check for continuity between CN9 (male) and chassis ground. (Socket) Measure resistance between CN9 (male) (2). Check for continuity between CN9 (male) and chassis ground.

(1) and (1), (3) (1) and (1), (2)

1

[05im~ 3

62-106 @

-

2 PC200. 220-3

E-3

T ROUB LESHOOTI NG

E-3 (Troubleshooting of throttle sensor) 3'. (Socket) Measure resistance between CN10 (female) (6) and (7). Check for continuity between CN10 (female) (6), (7) and chassis ground.

_

E-3 (If problem is removed when switching to prolix circuit) 1. Measure resistance between CN9 (male) (1) and (2).

1

2

~m¥ www. k omat s upar t s book . c om 2.

Check mounting of speed sensor.

-

PC200, 220-3

62-107 (5)

TROUBLESHOOTI NG

E-4

-

Troubleshooting Chart No. E-4 (2-STAGE MODE SELECTOR OLSS) Failure mode: No change in output when mode switch is operated.

* *

S-mode performance in L-mode L-mode performance in S-mode Remedy

Cause

4Y~

YES

Is resistance between CN34 (female) (11 and (2) within standard value? 1) Connect T-

adapter (socket) to CN34 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

3 Is resistance between NC13 (female) (1) and (2) 10-25!l?

YES 2

YES

Is CN13 (female) (1), (2) - chassis ground insulated? 11 Connect Tadapter (socked to CN13 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

1 Is voltage between CN13 (male) (1) and (2) within standard value?

1) Connect NO T-adapter (socket) to CN 13 (female!. 2) Leave male disconnected. 3) Turn starting switch OFF.

NO 6

YES

~

NO

For travel deviation, see H-l For lack of power, see H-B

Resistance defective

TVC solenoid defective

Replace

TVC valve defective

Replace

Harness defective 1) Disconnection in wiring harness 21 Short circuit

Replace

Mode selector switch defective

Replace

Resistance defective

Replace

-

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

Turn mode selector switch (Ll. 2) Turn starting switch ON. 3) Connect Tadapter (socked to CN13 (malel.

Is there continuity between CNP4 (female) (1) and (2P

YES 5

NO

Is resistance betweenCN34 (female) (1) - (2) within stanC:ard value?

1)

2)

1)

2) 3) 41

Turn mode selector switch (Ll Turn starting switch OFF.

~

NO

Connect T -adapter (socked to CNP4 (femalel. Leave male disconnected. Turn starting switch OFF. Turn mode selector switch (Ll.

NO !l

PC200

55 ± 5%

PC220

40 ± 5%

-

d>Cl

~.§

Tester

::JO'"

o~f f-", ~..c

T -adapter or socket adapter (for EKONO)

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DLD

62-108 ®

PC200, 220-3

E-4

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 1. Measure voltage between CN13 (male) (1) and (2).

-

2.

Check for short circuit between CN13 (female) (1), (2) and chassis ground.

3.

Measure resistance between CN13 (female) (1) and (2).

4, 5. Measure resistance between CN34 (female) (1) and (2).

www. k omat s upar t s book . c om 6.

Check for continuity between CNP4 (female) (1) and (2).

3

PC200, 220-3

62-109

TROUBLESHOOTING

E-4

-

Troubleshooting Chart No. E-4 (3-STAGE MODE SELECTOR OLSS - IF EQUIPPED) Failure mode: No change in output when mode switch is operated.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). * For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( l.

a)

YES

2

Self-testing display shows abn ormality

YES 1

Abnormality in power supply OFF

l)

OOFF

->

O Red

Is voltage between CN10 (female) (1) and (2) 20 - 30 V?

Green

Is voltage between fuse 4 and chassis ground 20 - 30 V?

Connect T-adapter (socket) to CNl O. Turn starting switch ON. (Do not start engine)

2)

• Turn starting switch ON. (Do not start engine)

NO

3 YES

NO

Is resistance between CN 10 (female) (21 and chassis ground OO}

NO

1)

Connect T-adapter (socket) to CNl O. 2) Turn starting switch OFF.

Abnormality in control box

ION! !ONII---

_

-

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

~

Is there continuity between CN36 (male) (1) and (31. (2) and (5)?

YES

resistance betweenCN36 (female) (31 and (51 10 - 25 ll} Is each pin to chassis ground insulated} IS

YES Is CNl 3 (male) (1). (2)chassis ground insulated?

YES Abnormality in TVC solenoid

f l}

cJFF

LI-

Red

Green

Is resistance between CNl 3 (male) (1) and (2) 10 - 250}

~->

• Connect T-adapter (socket) to CN13 (malel.

b)

1)

Connect T-adapter (socket) to CN 13 (male!. 2) Turn starting switch OFF.

1) Connect T-adapter (socket) to CN36 (female). 2) Turn starting switch OFF.

1)

Turn starting switch OFF. 2) Turn prolix circuit switch OFF.

~

NO

NO

-

NO

If cause is removed when switching to prolix circuit (when self-testing display shows normal)

• In H-mode. display is not 0

:(r

3 YES Is there continuity between CN20 (female) (19) and (20)7

YES YES

1 Is mode selector switch normal}

1)

2)

Remove CNP4. Turn starting switch OFF.

Is there continuity between CN 10 (female) (1) and (3)7 1)

2)

Remove CNP4. Connect T-adapter (socket) to CNl 0 (female).

Tester

..c.~

::lo~

000

~-SP

T -adapter or socket adapter (forEKONO)

62-110 ®

1)

2) 3) 4)

NO

Remove CNl 0 (female) Connect T -adapter (socket) to CN20 (female). Turn starting switch OFF. Remove CNP4.

NO

NO

, C'l

~c

2

T -adapter or socket adapter (forMIC) T -adapter or socket adapter (for DU)

PC200.220-3

E-4

TROUBLESHOOTING

-

Cause

.. YES

Remedy

Control box defective. !circuit between CNl 0 (male) (11. (2) and inside of box)

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4.

Clean (defective contact) or replace.

Disconnection in wiring harness, defective contact between CN 10 (2) - battery relay tenminal E. or battery relay defective.

Clean (defective contact) or replace.

Disconnection in wiring harness Or defective contact between CN20 (20) - fuse 4 - CN21 (2) - battery.

Clean (defective contact) or replace.

Control box defective.

Replace

Control box defective.

Replace

www. k omat s upar t s book . c om Is resistance be-

-

tween CN 11 (male) (1) and (2) 10 - 25 !l 7 Is each pin to

~~~~~~~9?ound

1)

2) 3)

Disconnection in wiring harness,

defective contact or contact between chassis ground and CN36 (female) (1) - CNll (male) (1). Or CN36 (female) (2) - CNll (male) (21.

NO

Connect T -adapter (socket) to CNll (malel. Turn starting switch OFF. Turn prolix circuit switch OFF.

Prolix circuit defective.

Clean (defective contact) or replace.

Replace

Disconnection in wiring harness.

defective contact or contact between chassis ground and CN 13 (female) (1) - CN36 (female) (3). or CN13 (female) (2) CNll (female) (51.

..

PC200. 220-3

Clean (defective contact) or replace.

TVC solenoid defective.

Replace

TVC solenoid defective.

Replace

Contact between + 24V terminal and wiring harness from CN20 (female) (19) to CNP4 (31.

Repair or replace.

Short circuit between +24V terminal and wiring harness from CN 10 (female) (3) and CN20 (male) (191.

Adjust or replace.

Control box defective.

Replace

Mode selector switch defective.

Replace

62-111 (5)

TROUBLESHOOTING

E-4

• In S-mode. display is not

6 YES

•

OFF

ON

0

5

YES 4 Is there continuity between CN 11 (male) (7) and chassis ground?

YES 3 Is voltage between CN 10 (female) (2) and (3) 20 V to 30 V?

1) Turn starting switch OFF. 2) Connect T-adapter (socket) to CNll (male).

Connect T-adapter (socket) to CN 10 (female). 2) Turn starting switch ON.

Is there continuity between CN20 (female) (19) and CNP4 (female) (3)7

YES

2

YES

Is there continuity between CN20 (female) (6) and chassis ground?

YES

Green

Red

Is there continuity between CN35 (female) (3) and chassis ground] 1) Connect T-adapter (socket) to CN35 (male). 2) Turn starting switch OFF.

[

o

1)

Connect T-adapter (socket) to CN20 (female). 2) Turn starting switch 0 FF.

NO

-

NO 7

1)

YES

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

Is voltage between CNP4 (female) (4) and chassis ground 20V to 30V?

1)

2)

Connect T-adapter (socket) to CNP4 (female). Turn starting switch ON. (Do not start engine,)

Is mode switch selector normal?

NO

1)

1) 2)

Remove CNP4. Turn starting switch OFF.

2)

NO

NO

Turn starting switch OFF. Connect T-adapter (socket) to CN20 (female) and CNP4 (female).

NO

OFF

• In L-mode. display is not

Flash

O-()Red

Green

-

YES 2

YES

Is there continuity between CNll (male) (7) and (8)?

YES NO Is there continuity between CN35 (female) (3) and (4)7

1)

1 Is there continuity between CNP4 (male) (1) and (2)7 1)

2)

Connect T-adapter (socked to CNP4 (female). Turn starting switch ON. (Do not start engine,)

Connect T-adapter (socket) to CNll (male). 2) Turn starting switch OFF.

NO

3

NO Is there continuity between CN20 (female) (6) and (12)7

1)

Turn starting switch OFF. 2) Connect T-adapter (socket) to CN35 (female). 3) Remove CNll.

4

1)

2) 3)

YES

NO

Remove CNll and CN35. Connect T-adapter (socked to CN20 (female). Turn starting switch OFF.

62-112 ®

PC200. 220-3

-

E-4

TROUBLESHOOTING

Cause

.. -

Remedy

Contact between chassis ground and wiring hamess between CN20 (female) (6) and CNP4 (1).

Repair or replace

Contact between chassis ground and wiring hamess between CN35 (female) (3) and CN20 (male) (6).

Repair or replace

Contact between chassis ground and wiring hamess between CN 11 (male) (7) and CN35 (male) (3).

Repair or replace

Control box defective.

Replace

Disconnection in wiring harness or defective contact between CN20 (male) (1 9) and CN 10 (female) (3l.

Clean (defective contact) or replace.

www. k omat s upar t s book . c om Disconnection in wiring harness or defective contact between CN20 (female) (19) and CNP4 (female) (3).

Clean (defective contact) or replace.

Mode selector switch defective.

Replace

Disconnection in wiring harness or defective contact between fuse 4 and CNP4 (female) (4).

Clean (defective contact! or replace.

Control box defective.

Replace

Disconnection in wiring harness

or defective contact between CN11 (male) (7) and CN35 (male) (3) or CN11 (male) (8) and CN35 (male) (4). Disconnection in wiring harness or defective contact between CN35 (female) (3) and CN20 (male) (6) or CN35 (female) (4) and CN20 (male) (12). Disconnection in wiring harness or defective contact between CN20 (female) (6) and CNP4 (female) (1) or CN20 (female) (12) and CNP4 (female) (2l. Mode selector switch defective.

Clean (defective contact) or replace.

Clean (defective contact) or replace.

Clean (defective contact) or replace.

Replace

PC200. 220-3

62-113 ®

TROUBLESHOOTING

E·4

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E·4 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

2. 3.

Measure voltage between CN10 (female) (1) and (2). Measure resistance between CN 10 (female) (2) and chassis ground.

-

www. k omat s upar t s book . c om E-4 (Troubleshooting of TVC valve) 1. Measure resistance between CN13 (male) (1) and (2). 2. Check for short circuit between CN13 (male) (1), (2) and chassis ground.

3.

4.

Measure resistance between CN36 (female) (3) and (5). Check for short circuit between CN36 (female) (3), (5) and chassis ground. Check for continuity between CN36 (male) (1) and (3), (2) and (5).

2

811. 5 2

1 3

3

62-114 (9)

-

5

PC200, 220-3

E-4

TROUBLESHOOTI NG

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Troubleshooting of TVC valve) Measure resistance between CN11 (male) (1) and (2). Check for short circuit between CN11 (male) (1), (2) and chassis ground.

5.

2

1

K~i -

E-4 (Green LED does not flash in H mode) 1. Check mode switch.

www. k omat s upar t s book . c om 3

2.

Check for continuity between CN10 (female) (1) and (3).

3

1

~l[]

3.

Check for continuity between CN20 (female) (19) and (20).

20

19

PC200, 220-3

62-115

TROUBLESHOOTING

E-4

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Green LED does not flash in S mode) 1. Measure voltage between CNP4 (female) (4) and chassis ground. 2. Check mode switch.

3.

Measure voltage between CN10 (female) (2) and (3).

-

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

Check for continuity between CN11 chassis ground.

(male) (7) and

5.

Check for continuity between CN35 (male) (3) and chassis ground.

62-116

PC200. 220-3

E-4

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-4 (Green LED does not flash in S mode) 6. Check for continuity between CN20 (female) (6) and chassis ground. 7. Check for continuity between CN20 (female) (19) and CNP4 (female) (3).

19

6

-

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

pe200, 220-3

62-117

E-4

T ROUBLESHOOTI NG

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E·4 (Green LED does not flash in L mode) 1.

Check for continuity between CNP4 (male) (1) and (2).

3

2.

Check for continuity between CN11 (male) (7) and (8).

[5l[]]'

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

3.

7

Check for continuity between CN35 (male) (3) and (4).

81J]w 4

4.

-

3

Check for continuity between CN20 (female) (6) and (12).

6

12

62-118 @

PC200. 220-3

-

-

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

TROUBLESHOOTING

E-5

--

Troubleshooting Chart No. E-5 (3-STAGE MODE SELECTOR OLSS EQUIPPED)

WITH AUTO-DECELERATION - IF PC200-3 (Serial No. 20001 - 21463) PC220-3 (Serial No. 20001 - 20364)

Failure mode: Auto-deceleration does not work.

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T-adapter (or socket), For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Self-testing display shows abnormality

YFS " 2

YES 1

Abnormality in power supply OFF

l)

OOFF

O Red

Is voltage between fuse 4 and chassis ground 20 - 30 V?

Green

Is voltage between CN10 (female) (1) and (2) 20 - 30 V?

• Turn starting switch ON. (Do not start engine)

Connect T-adapter (socket) to CNl O. 2) Turn starting switch ON. (Do not start engine.)

NO

Is resistance between CN 10 (femalel (2) and chassis ground 0 n? 1)

2)

NO

3

YES

NO

Connect T-adapter Isocket) to CNl O. Turn starting switch OFF.

-

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

-

, Ol

~c

Tester

~.gU)

e~E

~'"

T -adapter or socket adapter (forEKONOl

62-120 ®

T -adapter or socket adapter (forMIC) T-adapte·r or socket adapter (for DLI)

-PC200.220-3

E-5

TROUBLESHOOTING

Cause

...

Remedy

Control box defective. !circuit between CN1 0 (male) (11, (2) and inside of box!

Replace

Disconnection in wiring harness. defective contact or contact between chassis ground and CN 10 (1) - CN20 (20) - fuse 4.

Clean (defective contact) or replace.

Disconnection in wiring harness,

defective contact between CN 10 (2) - battery relay terminal E, or battery relay defective.

Disconnection in wiring harness or defective contact between CN20 (20) - fuse 4 - CN21 (2) - battery.

Clean (defective contact) or replace.

Clean (defective contact) or replace.

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

PC200.220-3

62-121 (9)

TROUBLESHOOTING

E-5

b) Self-testing display shows normality

YES Table

------

1

Resistance

Swing. travel levers at neutral AUTO deceleration switch

Continuity

Swing, travel levers at operation position

No continuity

6 auto-deceleration

switch (1 ) and (2) as shown in table?

5 AreCN31 (male) (1), (2) - chassis ground, and CN32 (1). (2) - chassis ground insulated?

--

Is condition between

YES

Is condition between CN10 (female) (11) and (12) as shown in table?

'!-ES

.

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

1)

Connect T-adapter (socked to CN 10. 2) Turn starting switch ON. 3) Start engine

3

YES

Is CN33 (male) (1), (2) - chassis ground insulated?

2

NO

Is condition between CN33 (male) (1) and (2) as shown in table?

1)

2)

ConnectTadapter (socket) to CN33 (male!. Turn starting switch OFF.

Is condition between CN31 (male) (1) and (2). and CN32 (male) (1) and (2) as shown in table?

1) Connect T-adapter (socket) to CN31 and CN32. 2) Turn starting switch OFF.

1)

2)

Connect T-adapter (socket) to CN31 and CN32. Turn starting switch OFF.

Turn starting switch OFF.

N(

NO

NO

1)

Connect T-adapter (socket) to CN33. 2) Turn starting switch ON. 3) Start engine

L-

-

NO

-62-122 (S)

pe200.220-3

E-5

TROUBLESHOOTING

Cause

-

7 YES

-

Is auto-deceleration switch terminals (1), (2) - chassis ground insulated? • Turn starting switch OFF.

NO

Remedy

Control box defective.

Replace

Auto-deceleration switch defective.

Replace

Disconnection in wiring harness. defective contact between CN 10 (female) (11) - CN33 - CN32 - CN31 - CN20 - Autodeceleration switch - CN20 CN10 (female) (12), or abnormal contact with chassis ground.

Clean (defective contact) or replace.

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

PC200, 220-3

Auto-deceleration switch defective.

Replace

Limit switch defective.

Replace

Limit switch defective.

Replace

Oil pressure switch defective.

Replace

Oil pressure switch defective.

Replace

62-123 @

TROUBLESHOOTING

E-5

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 (Troubleshooting of power source) 1. Measure voltage between fuse 4 and chassis ground.

2.

Measure voltage between CN10 (female) (1) and (2).

3.

Measure resistance between CN 10 (female) chassis ground.

-

(2) and

2

www. k omat s upar t s book . c om E-5 (Troubleshooting of auto-deceleration solenoid valve) 1. Measure resistance between CN12 (male) (1) and (2). 2. Check for short circuit between CN12 (male) (1), (2) and chassis ground.

3.

Measure resistance between CN11 (male) (3) and (4). Check for short circuit between CN11 (male) (3), (4) and chassis ground.

4

3

1M. 62-124 @

PC200, 220-3

E-5

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 (Operation of auto-decelerator defective) 1. Measure resistance between CN10 (female) (11) and (12).

11

_

2. 3.

12

Measure resistance between CN33 (male) (1) and (2). Is circuit between CN33 (male) (1), (2) and chassis ground insulated?

2

1

rmDrn ~ www. k omat s upar t s book . c om 4. 5.

-

Measure resistance between CN31 (male) (1) and (2), and between CN32 (male) (1) and (2). Check insulation between CN31 (male) (1), (2) and chassis ground, and between CN32 (male) (1), (2) and chassis ground.

1

2

IL[IIIC~m ~ 6. 7.

Measure resistance between auto-deceleration switch (1) and (2). Check insulation between auto-deceleration switch (1), (2) and chassis ground.

PC200. 220-3

62-125

TROUBLESHOOTING

E-5

Troubleshooting Chart No. E-5

PC200-3 (Serial No. 21464 and up) PC220-3 (Serial No. 20365 and up)

(WITH AUTO-DECELERATION - IF EQUIPPED) a)

-

Failure mode: Auto-deceleration does not work. (engine at full throttle)

YES

1 Is resistance between CN41 (male) (1) and (2) 55 70 n and is there continuity between CN41 and chassis?

-

YES

1)

Travel. work equipment lever at neutral. 2) Turn autodeceleration switch ON.

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

NO

6

Is voltage between CN39 (male) (1) and (2) 20 - 30 V?

YES 5

YES 4 Is there continuity

between CN31 Imale) (1) - (2). CN32 (male) (11 (2) as shown in table]

YES 3

NO

Is there continuity between CN33 (male) (1) and (2) as shown in table]

IsCN31 Imale) 111. (2) to chassis ground. CN32 (male) (11. (2) to

Is there continuity between autodeceleration switch I-(1) and 12) as shown in table]

. Turn starting switch OFF.

chassis ground

insulated? . Turn starting switch OFF.

. Turn starting switch OFF.

-

• Turn starting switch OFF.

NO NO NO Continuity Swing. travel levers at neutral. Turn auto-deceleration switch ON.

Yes

Swing. travel levers at operation position. Turn auto-deceleration switch ON.

,

Ol

., c ::0 "';:::

Tester

::> 0

on

~..c:

0

000

f-on_

62-126 (~

T -adapter or socket adapter (forEKONO)

No

T -adapter or socket adapter (forMIC) T-adapter or socket adapter (for DU)

PC200, 220-3

E-5

TROUBLESHOOTING

-

Cause

8

YES

YES

Remedy

Auto-deceleration solenoid defective

Replace

Solenoid valve defective Poppet operation defective Seizure

Replace

Timer defective

Replace

Is there voltage between CN39 (1) and (2) 20 - 30 V 7

www. k omat s upar t s book . c om 7

Y ES

-

-

Is auto-deceleration switch (1), (2) to chassis ground insulated?

' Turn starting switch OFF.

NO

NO

Power source defective

Disconnection in wiring

NO

harness, defective contact or short circuit between (male) (3) - CN33 - CN32 - CN31 - CN20 - auto-deceleration switch - CN20 - CN39 (malel (4)

Replace

Replace

Auto-deceleration switch defective

Replace

Limit switch defective

Replace

Limit switch defective

Replace

Oil pressure switch defective

Replace

PC200. 220-3

62-127

TROUBLESHOOTING

E-5

b) Failure mode: Deceleration stays on (engine does not return to full throttle)

*

Auto-deceleration switch ON (at AUTO position)

Cause

YES

Remedy

Solenoid A defective

1

YES

Does engine return to full throttle when auto-deceleration switch is turned to OFF? 1)

2)

Turn autodeceleration switch OFF. Pull fuel control lever full position.

Auto-deceleration switch defective

2 Is there continuity between autodeceleration switch (2) and (3)7

NO 1)

2)

Disconnect wiring of autodeceleration switch (1), (21. Turn autodeceleration switch OFF.

3

YES

Is there voltage between CN41 (male) (11 and (2) 20 - 30V 7

NO 11

Connect Tadapter (socket) to CN12 (malel. Turn starting switch ON. Turn aotdeceleration switch ON.

NO

Solenoid valve defective Poppet operation defective Seizure

-

Timer defective

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

3)

-

,

C>

'" c:

::c.~

0 '" 000 ~.c: 0 1-",::l

Tester

T -adapter or socket adapter (for MIC)

T -adapter or socket adapter (forEKONO)

T -adapter or socket adapter (for DU)

62-128 (5)

PC200, 220-3

-

E-5

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 a-1. Measure resistance between CN41 (male) (1) and (2).

P20503053

-

a-2. Measure voltage between CN39 (male) (1) and (2).

www. k omat s upar t s book . c om a-3. Check for continuity between CN33 (male) (1) and (2).

a-4. Check for continuity between CN31 (male) (1) -- (2), CN32 (male) (1) - (2).

1

~fQ] 2

PC200, 220-3

62-129

TROUBLESHOOTING

E-5

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-5 a-5. Check for short circuit between CN31 (male) (1), (2) chassis ground, CN32 (male) (1), (2) - chassis ground.

1

t;j) [[JIU 2

b-3. Measure voltage between CN41 (male) (1) and (2).

www. k omat s upar t s book . c om P20503053

-

62-130

PC200, 220-3

-

--

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

--

E-G

TROUBLESHOOTING

Troubleshooting Chart No. E-6 Failure mode: Upper structure does not swing, or hydraulic drift of swing is excessive.

-

* *

Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). For T -adapters, connect to both the male and female ends; for the socket, connect to the connector marked in ( ). a) Hydraulic drift of swing is excessive Carry out all checks with the swing control lever at neutral.

*

3 YES,

Is there continuity between CN18 (female) (2) and chassis ground?

YES 2

YES

Is resistance between CN18 (male) (1) and (2) 10 - 30 Il?

11

2)

NO

1)

Connect T-adapter (socket) to CN18 (female!. 2) Turn starting switch OFF.

Connect T-adapter (socket) to CN18 (male!. Turn starting switch OFF.

NO

• When using T-adapter . 6

i

1 Does swing brake lamp light up normally?

1)

5 1)

Turn starting switch ON. Lights up about 5 seconds after stopping swing.

-

YES

Is voltage between CN 19 (female) (3) and (1) 20 - 30V?

NO

Measurement conditions same as in previous

step. Turn starting switch ON.

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

YES

Is voltage between CN19 (2) and (1) 20 - 30V?

2)

8

Is voltage between CN24 (2) and chassis ground 20 - 30 V?

YES

11

4

Is there continuity between CN19 (female) (1) and chassis ground?

NO 11

2)

Connect T-adapter (socket) to CN1 9 (female). Turn starting switch OFF.

Connect T-adapter (socket) to CN19. 2) Turn starting switch ON. 3) Place swing lever in neutral.

7

Is voltage between CN24 (1) and chassis ground 20 - 30 V?

.,

1) 2)

Connect T - adapter to CN24. Turn starting

1)

Measurement conditions same as in previous step.

2)

T urn starting switch ON.

NO

switch ON. 3)

NO

I

Place swing lever at neutral.

• When using socket adapter.

6

between CN 18 (female) (1) and CN 19 (female) (3)7

6 11

Connect socket to CN 18 (female) and CN19 (female). Turn starting switch OFF

2) 1)

Connect socket adapterto CN19 (male).

2)

Turn starting

NO

switch OFF.

-

8

,

YES Is voltage between CN24 (1) and chassis ground 20 - 30 V? 1)

~.~ =>0

e~E 11-"",

Tester T -adapter or socket adapter (forEKONO)

62-132

T -adapter or socket adapter (for DU)

2)

Connect socket adapter to CN24 (female). Turn starting switch ON.

YES

I

Is there continuity between CN24 (male) (1) and (2)?

7

T -adapter or socket adapter (forMIC)

-

:\0

Is resistance be-

tween CN19 (male) (1) and (2) 200 300 ll?

,

YES

Is there continuity

YES

• Ol

,

I

:\0 11 2)

Connect socket adapter to CN24 (male). Turn starting switch OFF.

I I,

I

NO

I PC200, 220-3

-

E-6

TROUBLESHOOTING

Cause

..

Remedy

Disconnection in wiring harness. defective contact between CN 1 8 (female) (1) and CN19 (female! (3) or CN18 (female) (1) and CN20 (male) (181.

Clean (defective contact) or replace.

Disconnection in wiring harness or defective contact between CN 18 (female) (2) and chassis ground.

Clean (defective contact) or replace.

Swing solenoid defective.

Replace

Disconnection in wiring harness or defective contact between CN 1 9 (female! (3) and CN 18 (female) (11.

Clean (defective contact) or replace.

Swing brake relay defective.

Replace

www. k omat s upar t s book . c om Disconnection in wiring harness or defective contact between CN24 (female) (2) and CN19 (female) (21.

Clean (defective contact) or replace.

Oil pressure sensor defective.

Replace

Disconnection in wiring harness or defective contact between fuse 3 - CN20 (5) - CN24 (female) (1).

Clean (defective contact) or replace.

Disconnection in wiring harness or defective contact between

-

PC200. 220-3

CN19 (female) (1) - CN18 (female) (2) and chassis ground, or between swing brake lamp CN21 (1) and chassis ground.

Clean (defective contact) or replace.

Swing brake relay defective.

Replace

Disconnection in wiring harness or defective contact between CN18 (female) (1) and CN19 (female) (31.

Clean (defective contact) or replace.

Swing brake relay defective.

Replace

Disconnection in wiring harness or defective contact between CN24 (female) (2) and CN19 (female) (21.

Clean (defective contact) or replace.

Oil pressure sensor defective.

Replace

Disconnection in wiring harness or defective contact between fuse 3 - CN20 (5! and CN24 (female! (11.

contact) or replace.

Clean (defective

62-133 (5)

TROUBLESHOOTI NG

E-6

b)

*

Upper structure does not swing. Check items marked * after running engine for at least 10 seconds.

• When using T -adapter

4 YES

-

* YES 3

* 2

* 1 When CN18 is disconnected. does ma-

21

chine swing?

Do not start engine. Tum starting switch ON. Operate swing lever.

1)

Connect Tadapter to CN19. Turn starting switch ON. (Do not start engine.! Operate swing lever.

2)

Connect Tadapter to CN24. Turn starting switch ON. (Do not start engine.1 Operate swing lever.

I

I

-

NO

31 11

1) 2)

3)

Is voltage between CN24 (2) and chassis ground as in Table 17

YES'

:\0

Is voltage between CN 19 (2) and chassis ground as in Table 1 7

YES

I

Is voltage between CN19 13) and (2) as in Table 2?

NO

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

,

NO

• When using socket adapter

,

YFS

YES

Is there continuity between CN24 (male) (1 ) and 1217

YES

adapter to CN24lmalel. Turn starting switch OFF.

,:!i

3

Is voltage between CN 1 9 Ifemale) 12)

I

as in Table 27 11

21 31

~

Voltage

Neutral

Swing

NO

Is resistance be-

tween CN19 Imale) (2) and (1) 200 300 117

1)

21 11

and chassis ground

NO

Table 1

Is there continuity between CN 1 9 (malel (3) and (217

4

II Connect socket 21

YES

5

2

21

Connect socket adapter to CN19 (male). Turn starting switch OFF.

Connect socket adapter to CN19 Imalel. Turn starting switch OFF.

I

-

NO

Connect socket :\0 adapter to CN19 (female) Turn starting switch ON. (Do not start engine) Operate swing lever.

~

Voltage

20 - 30V

Neutral

Approx OV

Approx.OV

Swing

20 - 30V

Table 2

62-134

PC200, 220-3

-

TROUBLESHOOTING

E-6

Cause

-

Remedy

Mistaken connection of wiring harness between CN 19 (female) (3) - CN8 (female) (1) - CN20 and swing brake lamp, or fuse 3 and CN20 (5), or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with +24V)

Swing brake relay defective.

Replace

Mistaken connection of wiring harness between CN19 (female) (2) and CN24 (female) (2), (1), or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with + 24 V)

Oil pressure switch defective.

Replace

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

Swing brake solenoid defective.

Replace

Oil pressure switch defective.

Replace

Swing brake relay defective.

Replace

Mistaken connection of wiring harness between CN 19 (female) (3) - CN18 (female) (1) - CN20 and swing brake lamp, or fuse 3 and CN20 (5),or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with + 24 V)

Swing brake relay defective.

Replace

Mistaken connection of wiring harness between CN24 (female) (1), (2) and CN19 (female) (2), or abnormal contact with + 24 V caused by contact with water or dirt.

Repair or replace (wrongly connected wiring) Dry, clean or replace (abnormal contact with + 24 V)

PC200, 220-3

62-135 @

E-G

TROU BlESHOOTI NG

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-G (Hydraulic drift of swing excessive) a-1 Check lighting of swing brake pilot lamp.

a-2 Measure resistance between CN18 (male) (1) and (2). a-3 Check for continuity between CN 18 (female) (2) and chassis ground.

2

1

[a{!] m~

-

2

@ tQE www. k omat s upar t s book . c om a-4 Check for continuity between CN 19 (female) (1) and chassis ground. a-5 Measure voltage between CN19 (female) (1) and (2). a-6 (T-adapter) Measure voltage between CN19 (3) and (1).

a-7 (T-adapter) Measure voltage between CN24 (1 ) and chassis ground. a-8 (T-adapter) Measure voltage between CN24 (2) and chassis ground.

62-136 ($)

pe200. 220-3

E-6

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-6 (Hydraulic drift of swing excessive) a-6 (Socket) Measure resistance between CN19 (male) (1) and (2l. a-6' (Socket) Check for continuity between CN18 (female) (1) and CN19 (female) (3).

-

www. k omat s upar t s book . c om a-7 (Socket) Check voltage between CN24 (male) (1) and chassis ground. a-8 (Socket) Check for continuity between CN24 (male) (1) and (2).

-

pe200, 220-3

62-137 @

E-G

TROUBLESHOOTING

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING E-G (Upper structure does not swing) b-1 Can upper structure be swung if CN18 is disconnected?

b-2 (T-adapter) Measure voltage between CN24 (3) and chassis ground.

-

www. k omat s upar t s book . c om b-3 (T-adapter) Measure voltage between CN19 (2) and chassis ground. b-4 (T-adapter) Measure voltage between CN19 (3) and (2).

b-2 (Socket) Check for continuity between CN24 (male) (1) and (2).

1

~~

"[ill

2

~ -

62-138

pe200. 220-3

E-6

TROUBLESHOOTING

POSITION OF CONNECTORS FOR TROUBLESHOOTING b-7 Measure voltage between CN 19 (female) (3) and (1).

3

b-8 Measure voltage between CNP16 (male) (2) and chassis ground.

www. k omat s upar t s book . c om b-9 Measure voltage between CN19 (female) (5) and (1).

PC200,220-3

62-139-6 (j)

TROUBLESHOOTING

H-1

-

Troubleshooting Chart No. H-1 Failure mode: Machine deviates excessively (during travel, travel lever at full stroke)

* * * *

For details of measuring deviation, see TESTING AND ADJUSTING. The judgment values given in the troubleshooting chart are the values for H mode. If there is any abnormality in the speed of the work equipment, go to H-6. Check the stroke of the travel control valve and the tension of the track before starting troubleshooting.

-

YES

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

2

YES r-

Deviates in same direction in both forward and reverse

Does condition 'become normal after adjusting according to procedure for adjusting travel deviation?

4

YES

Is output pressure of NC valve on side to which machine deviates normal? • It must be the same

3

NO 1

Is problem reversed if front and rear outlet hoses of pump are interchanged?

pressure as the TVC output pressure when the track is rotated freely or when carrying out normal travel operations.

NO

-

Table 1 How does machine deviate?

.a. See Fig. 1.

Front pump (rear control valve)

YES

Actuator controlled

Pump • • • •

8

Arm cylinder Boom cylinder Swing motor Right travel motor

NO Rear pump (front control valve)

• • • •

Arm cylinder Boom cylinder Bucket cylinder Left travel motor

Is main relief pressure normal for more than two systems in Table 1 ?

.320 +2g kg/em'

NO

'" Except BOOM (RAISE) and SWING

NO ~::~~~ ;;:~~~~~~~ ~~~:;:e ----------------------------------

62-140 ®

PC200,220-3

H-1

TROUBLESHOOTING

-

,,± f

\

Forward

Forward Right reverse only

Drain

Right A rear Does not deviate

Forward

Left B front Right C front

Left reverse only

'.""'~~."'

left forward

Reverse

Right forward and left reverse

Forward

f

Left Drear

Reverse

Reverse

Bottom

Swivel joint Fig 1

Location of defective swivel joint packing and direction of deviation in travel

-

Cause

Remedy

Defective adjustment of pump

See TESTING AND ADJUSTING

Internal leakage in pump

Replace

Pump servo valve defective

Replace

Relief valve of jet sensor defective

Adjust or replace

Orifice defective

Replace

Operation of NC.CO valve defective

Adjust or replace

Final drive defective

Replace

Travel motor defective

Replace

-All are low

Main relief valve defective

Adjust or replace

-

Drop in set pressure of travel motor safety valve

Replace

Swivel joint seal defective

Replace seal

5 YES

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

Does servo piston

move smoothly?

NO

*' If both left and right caps of the servo piston are removed, it can be moved by hand. *' Judgement can also be made by replacing the servo valve. 7

YES 6

-

Is problem reversed if left and right jet sensor hoses are interchanged?

*' It is also possible to judge by interchanging the relief valves.

*' It is also possible to measure the differential pressure. (However, YES and NO are reversed.!

9 YES

-

YES

Does condition become normal if relief valves of jet sensor are adjusted?

Are metal particles found in oil drained from final drive on side to which machine deviates?

NO

NO

Only travel is low

PC200.220-3

62-141 @

TROUBLESHOOTING

H-2

-

Troubleshooting Chart No. H-2 Failure mode: Machine deviates excessively during compound operations

*

The judgement values given in the troubleshooting chart are the values for H mode.

a)

There is deviation in travel when any of the arm, swing, bucket, or boom circuits are used when the machine is traveling.

1 YES

r------~

Cause

Remedy

Straight-travel valve defective

Replace or repair

Travel shuttle valve defective

Replace or repair

Is outlet pressure of travel shuttle valve normal? .30±3kg/cm' • Engine at full throttle

NO

b)

There is deviation in travel when one of the arm, swing, bucket, or boom circuits is used when the machine is traveling.

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

r---------,

YES 1 Operate PPC valve lever on side to which machine

Spool of travel shuttle valve stuck

Replace or repair

Shuttle valve between PPC valve and travel shuttle valve stuck

Replace or repair

T ravel shuttle valve defective

Replace or repair

PPC valve defective

Replace

Is inlet pressure of travel shuttle valve normal?

NO

.30 ± 3 kg/em"

deviates. Is control

pressure at inlet port of travel shuttle valve normal?

.30 ± 3 kg/em' • Engine at full throttle

3

NO

Operate PPC valve lever on side to which machine deviates. Is control pressure at inlet port of travel shuttle valve normal for both directions in which PPC lever is operated?

YES

NO .30 ± 3 kg/em'

-

62-142 (9)

PC200, 220-3

H-l

TROUBLESHOOTING

Cause

18

YES

Remedy

Chargmg pump defective

Replace

Control relief valve defective

Replace

Leakage inside PPC valve

Replace

Leakage inside servo valve

Replace

Block circuit between charging pump and PPC valve. Is pressure in control circuit 30

-

± 3 kg/em"

--

17

NO

-

YES

-

Oil leakage from auto-deceleration solenoid valve

-

Block circuit between control pump and autodeceleration. Is pressure in control circuit 30 ± 3 kg/em"

18

YES

Leakage Inside PPC valve

Replace

Replace

www. k omat s upar t s book . c om Block circuit between charging pump and PPC valve. Is

NO

pressure in control circuit

19

YES

30 ± 3 kg/em"

NO

-

Replace

valve- Is pressure in control circuit

30 ± 3 kg/em'>

NO

---

Leakage inside swing solenoid valve

Block circuit between charging pump and swing solenoid

Leakage inside servo valve

Replace

-

Relief valve of jet sensor defective

Replace

Jet sensor orifice defective

Replace

Excessive leakage from control

valve spool

valve ass'y on side to which machine deviates

Lever link defective

Adjust or replace

Replace control

Operation of spool of travel con-

trol valve on side to which machine deviates defective or component inside spring case

Replace control valve

damaged Replace Link twisted

Adjust or replace

PC200, 220-3

62-143 @

I

H-2

TROUBLESHOOTING

-

Troubleshooting Chart No. H-2 Failure mode: Machine deviates excessively during compound operations.

Cause

YES

2

YES

Is cause removed

Travel shuttle valve defective

Straight-travel valve defective

Replace control valve ass'y

Machine deviates with certain combinations.

Does machine devi-

4

ate which combina-

YES

tion of arm, swing,

bucket, boom and travel is used?

YES 3

Replace travel shuttie valve

Shuttle valve between PPC and travel shuttle valve stuck

Replace shuttle valve

when travel shuttle valve is replaced?

NO

lever on side to

which machine deviates. Is control pressure at inlet port of travel shuttle valve 30 ± 3 kg/em'.

Shuttle spool of travel shuttle valve stuck

Is cause removed

Operate PPC valve

NO

Replace

-

when travel shuttle valve is replaced?

NO 1

Remedy

-

5

www. k omat s upar t s book . c om Machine deviates with every combination

:"i0

Operate PPC valve

lever on side to which machine devi-

ates. Is control pressure at inlet port of travel shuttle valve 30 ± 3 kg/em' for both directions in

which PPC lever is operated?

YES

:\0

Travel shuttle valve defective

Replace

PPC valve defective

Replace

-

'0>

~c

.c".;:;

Oil pressure gauge (60 kg/em')

Travel shuttle valve

~o~

000

~..co

f- "'..,

62-144

Thermistor kit

-

-

PC200, 220-3

-

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

TROUBLESHOOTING

H-3

-

Troubleshooting Chart No. H-3 Failure mode: Machine deviates excessively when starting

*

*

* * a)

If the machine also deviates during normal travel. go to H-1 "Machine deviates excessively." If the machine deviates when the work equipment is operated, go to H-2 "Machine deviates excessively during compound operations". Air must be bled from the circuits. The judgment values given in the troubleshooting chart are the values for H mode.

3 YES

There is deviation only when operating from N to the full stroke.

YES

Does servo piston move smoothly?

2 r---------,

YES

Is problem reversed if front and rear outlet hoses of pump are interchanged?

~ ~

NO

See TESTING AND ADJUSTING. Judgment can also be made by replacing the servo valve.

1

NO Is relief pressure in control circuit normal?

YES 4

.30 ± 3 kg/em' • Engine at full throttle

NO

Is any foreign material found in filter at outlet port of charging pump?

YES 5

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

NO

Auto-deceleration solenoid valve

Is problem removed if relief valve in charging pump is adjusted (replaced)?

Swing brake solenoid valve

NO

b)

-

Machine starts to deviate immediately, regardless of whether the control lever is moved from N with fine control or to the end of its stroke.

*

3 YES

If the pump discharge amo unt is not the minimum when the control levers are at neutral.

YES

Does servo piston move smoothly?

2

YES

Is output pressure of NC valve on fast side normal?

~

1 Control lever at neutral: Max.5 kg/em' With track raised from ground and rotated: Min. 18 kg/em'

Is differential pressure of jet sensor on fast side

(outside) normal?

4 Control lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max.2 kg/em'

NO

NO

If both left and right caps of the servo piston are removed. it can be moved by hand. ~ Judgement can also be made by replacing the servo valve.

NO YES

Is problem reversed if relief valves of jet sensor are

interchanged (adjusted) ?

-

NO

62-144 @

PC200, 220-3

-

H-3

TROUBLESHOOTING

Cause

Remedy

Operation of servo valve defective

Replace

Servo piston stuck

Replace pump

T ravel motor shaft brake defective

Replace motor

Charging pump defective

Replace charging pump

Charging pump relief valve defective

Replace

www. k omat s upar t s book . c om 6 YES

-

Block each circuit between (11 and (6) in Fig. 1. Is pressure in control circuit normal?

.•

30 ± 3 kg/em' Engine at full throttle

PC200. 220-3

NO

Excessive internal

leakage in equipment at location concerned.

Replace

Internal leakage in swing solenoid valve

Replace

Operation of servo valve defective

Replace

Servo piston stuck

Replace pump assembly

Operation of CO + NC valve defective

Replace

Relief valve of jet sensor defective

Replace

Jet sensor orifice defective

Replace

62-145 ®

TROUBLESHOOTING

H-4

-

Troubleshooting Chart No. H-4 Failure mode: Control levers are extremely heavy

*

The judgment values given in the troubleshooting chart are the values for H mode.

Cause

a)

Remedy

If travel lever is heavy

4 YES ,-------.,..YES

2

Servo piston stuck

Replace pump assembly

Operation of NC valve defective

Adjust or replace

-

Relief valve of jet sensor defective

Replace

-

Jet sensor orifice

L.-

~

Is output pressure of NC valve normal?

If both left and right caps of the servo piston are removed. it can be moved by hand.

Control lever at neutral: Max. 5 kg/em' With track raised from ground and rotated: Min. 18 kg/em' ~ The pressure is the same as the TVC pressure except when the levers are at neutral and during relief.

NO

NO

Is differential pressure of jet sensor for heavy lever normal?

YES

Replace

Does servo piston move smoothly?

3

YES

Opertion of servo valve defective

Control lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max. 2 kg/em' ~ Judgment can also be made by interchanging the jet sensor hoses for the front and rear pump.

5 YES

-

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

NO

Is lever light when engine is stopped?

6 YES

,--------.,

NO

Is problem reversed if relief valves of jet sensor are interchanged?

NO

defective

Replace

Operation of control valve spool defective

Replace

Linkage and cable twisted

Adjust or replace

Is cable or link twisted?

NO

b)

If work equipment or swing control lever is heavy

1 YES

...-----.....:..,

Interference with boot

Replace boot

Internal part of PPC valve defective

Replace

Does lever become lighter if boot is removed?

NO

62-146 @

PC200.220-3

H-5

TROUBLESHOOTING

Troubleshooting Chart No. H-5 Failure mode: Work equipment, travel, and swing start suddenly during fine control operations

*

The judgment values give in the troubleshooting chart are the values for H mode.

a)

Work equipment and travel both start suddenly Cause

2 YES

YES 1

Travel lever at neutral: 15 ± 1 kg/em' When control lever is operated to end of travel: Max. 2 kg/em'

NO

3 YES

NO

Replace

Is output pressure of NC valve normal?

Control lever at neutral: Max.5 kg/em' With track raised from ground and rotated: 18 kg/em'

Is differential pressure of jet sensor normal?

Servo valve defective

Remedy

CO

+ NC valves defective

Relief valve of jet sensor defective

Replace

Replace

Is problem reversed if relief valves of jet sensor are interchanged?

www. k omat s upar t s book . c om NO

b)

Jet sensor orifice defective

Replace

PPC valve defective

Replace

PPC shuttle valve defective

Replace

Control valve defective

Replace

If only work equipment starts suddenly

YES 1 Is problem removed when hoses between PPC valve and PPC shuttle block are interchanged? Left side Swing -Arm Right side Boom - Bucket

NO

2 YES Is problem removed when hoses between PPC shuttle valve and control valve are interchanged? Left side Swing -Arm Right side Boom - Bucket

PC200.220-3

NO

62-147 @

TROUBLESHOOTING

H-6

-

Troubleshooting Chart No. H-6 Failure mode: Speeds for work equipment, swing, and travel are all slow, or there is no power (no abnormality in auto-deceleration)

* * * a)

Check that there is no abnormality in the auto-deceleration system. If there is any abnormality, go to H-9 "Autodeceleration does not work". If there is any symptom (black exhaust smoke, etc.! that indicates that there is lack of engine output, go to troubleshootYES ing for engine. The judgment values given in the troubleshooting chart are 4 the values for H mode. ...------; YES Is NC output pressure normal on side that Machine hardly moves does not move?

YES .-5 Is there any pin of servo sub assembly on side that does not move?

NO ..:,7 YES

Is there any abnormality in spool or piston of NC valve?

NO

3

YES

NO

abnormality in cotter

.....-

NO

. .;,6 !.ES

Is foretgn material found inoil drained from pump?

Is it the system on one side that does not work?

...--

YES 9

1.,0 ~S

Is foreign material found in oil drained from pump?

Is there any abnormality in cotter pin of servo sub assembly on both sides?

www. k omat s upar t s book . c om YES 8

2

YES

NO

Is NC output pressure normal NOon both sides?

Is output pressure of TVC valve normal?

NO

11 ...-------,

NO

YES

Is there any abnormality in spool or piston of NC valve 7

NO 12 Note 1

Remove solenoid valve of TVC valve. but leavE

YES

connector connected.

Is pressure in control circuit 30 ± 3 kg/cm 27

NO

When mode selector switch is moved. does spool of solenoid valve move?

[Engine at full throttle]

-

NO

1) Starting switch ON

YES

YES

13 Is any foreign material found in filter at outlet

N0 ~~~~ charging

17 YES r------...,-

14 Is problem removed if relief valve in control NO circuit is replaced 7

YES 16

YES 15

Note 1: If there is any abnormal noise heard from the pump, first check for any metal particles in the return element or oil drained from the pump to check if there is any damage to internal parts of the pump.

62-148 ®

NO

Is there any abnormality in drive system of charging pump?

Block circuit between charging pump and PPC valve. Is pressure in control circuit 30 ± 3 kg/cm 2 ?

Block circuit between charging pump and auto·deceleration.ls pressure in control circuit 30 ± 3 kg/cm 2 ?

-NO NO

-

NO

PC200, 220-3

TROUBLESHOOTING

H-6

Cause

Remedy

Cotter pin missing

Assemble

Pump sub-assembly defective

Replace

Servo valve stuck

Replace

NC valve spool, piston stuck

Repair or replace

NC + CO valve defective on side that does not move

AssembJe

Cotter pin missing

Replace

Front rear pump defective

Replace

Servo valves of front and rear pumps stuck

Replace

NC valve spool, piston stuck

Repair or replace

CO + NC valves on both sides defective

Replace

TVC valve stuck

Replace

TVC valve srnenoid valve seized

Replace

Charging pump defective

Replace

Relief valve of charging pump defective

Replace

Shaft broken

Replace

www. k omat s upar t s book . c om 18 Block circuit between charging pump and swing s~enoid valve. Is pressure in control circuit

30 ± 3 kg/cmt?

PC200. 220-3

YES

Oil leakage from

NO

8uto-deceleratton

Replace

solenoid valve

Leakage inside PPC valve

Reptace

Leakage inside swing solenoid valve

Replace

Leakage inside servo valve

Replace

62-149 ®

TROUBLESHOOTING

H-6

b)

Abnormality in some part (abnormality on one side) Swing, travel, and bucket are slow; boom, arm move at half speed

5 YES Is problem removed if servo sub-assembly is replaced]

YES 4

YES

I

Is there any abnormality in the co valve seat (top, bottom)?

NO

3

YES

NO

Is output pressure of NC valve on problem side normal?

-

6 YES

2

YES

NO

Is differential pressure of jet sensor on problem side normal7

Is there any abnormality in the spool or piston of the NC valve]

NO

www. k omat s upar t s book . c om 7

NO

1

YES

Is problem removed if relief valve of jet sensor is replaced?

NO

Is pressure of main relief valve on problem side normal?

YES

YES 8

NO

10

Is problem reversed if left and right relief valves are interchanged]

YES

Is problem reversed if hoses between pump and control valve are interchanged?

12 YES

-

YES 11

9 Is output pressure of PPC valve

NO

30

NO

-

Is problem removed when travel shuttle valve is replaced]

-

Does spool of control valve move smoothly?

No

~~ kg/em'?

NO

NO

Troubleshootingtools

62-150 ®

Oil pressure gauge (450 kg/em 2 ). (60 kg/em 2 ) Travel shuttle valve

Sleeve nut, plug

-

Servo valve

PC200, 220-3

H-6

TROUBLESHOOTING

Cause

Remedy

Deterioration of CO valve seat

Replace

Servo sub-assembly defective

Replace

Pump sub-assembly defective

Replace

NC valve spool, piston stuck

Repair or replace

NC

+ CO valve defective

Replace

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

PC200.220-3

Relief valve of jet sensor defective

Replace

Jet sensor defective

Replace

Relief valve defective

Replace

Pump defective

Replace

Travel shuttle valve defective

Replace

Travel-straight valve defective

Replace

Spool of control valve stuck

Replace

PPC valve defective

Replace

62-151 ®

TROUBLESHOOTING

H-6

c)

Individual symptoms • If only swing speed is slow, go to H-11 "Swing speed is slow." • If only travel speed is slow, check if machine deviates. If machine does not deviate, check swivel joint. • If any work equipment speed is slow, go to next item.

d)

If any work equipment speed is slow

Cause

Remedy

-

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

YES

~~ kg/em'?

NO

Except for long lever

Is hydraulic drift of slow cylinder inside standard range?

YES 3

NO

Control valve defective

Replace

Operation of right PPC valve defective

Replace

Cylinder piston packing defective

Replace

Safety valve defective

Replace

Safety valve defective

Replace

Is output pressure of PPC valve 30

1

YES

Is internal leakage of slow cylinder more than 20 cc/min?

4

NO

YES

Is problem removed if safety valve on HOLD side of slow cylinder is replaced?

NO

Troubleshooting tools

62-152 ®

Scale

Measuring cylinder

Stop watch

Oil pressure gauge (60 kg/em')

Sleeve nut. plug

-

-

PC200, 220-3

H-6

TROUBLESHOOTING

-

Remedy

Cause

-

Engine defective

Adjust

Servo valves on both sides stuck

Replace F, R pump aSs'y

Charging pump defective

Replace

Control relief valve defective

Replace

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

Leakage inside PPC valve

1 NO

:

Leakage inside servo valve

-

-

-

•

-

YES

N0

Replace

7 YES Block circuit between charging pump and swing solenoid valve. Is pressure in control circuit 30 ± 3 kg/em'?

Replace

-

Oil leakage from autodeceleration solenoid valve

Replace

Leakage inside PPC valve

Replace

Leakage inside swing solenoid valve

Replace

I

Leakage inside servo valve

NO

----

-

-

Replace

-

TVC valve stuck

Replace

Solenoid valve burned

Replace

pe200, 220-3

62-153 (6)

H-6

TROUBLESHOOTING

-

b) Abnormality in some part (abnormality on one side) • Swing speed and right travel are slow, boom, arm move at half speed.

YES,

4

YES 3

YES

Is output pressure of NC valve normal 7

Is cause relieved if servo valve is replaced 7

t-

Also possible to replace servo + pump ass'y

NO

2 Control lever at neutral

PC200

YES

Max, 55 kg/em" (H model Max, 4,2 kg/em· (5 model pe22Q Max, 5,5 kg/em· (H model

Is differential pressure of jet sensor on cause side normal?

Max. 6.5 kg/em· (5 model With track raised from ground

Control lever at neutral: 14 - 15 kg/cm' Control lever at stroke Max. 2 kg/cm' end:

5 YES

and rotated Min. 18 kg/em· (All models)

Is cause reversed if relief valves of jet sensor are interchanged 7

NO

1

NO Is pressure of main relip.f valve normal?

-

YES Relief pressure: 320 +25 kg/cm' 0

YES

6 Is cause reversed if left and right relief valves are interchanged 7

8

www. k omat s upar t s book . c om NO

YES

Is cause reversed if hoses between pump and control valve are interchanged 7

y ES

9

7

:\0

Is output pressure of PPC valve 30 ± 3 kg/cm'.

:\0

r-

Does spool of control valve move smoothly7

:.i(

Oil pressure gauge

'Cl

~ 0 I-" !:! ~ ~ " .~ 0 c

Travel

0 0

I!'

Iii

Swing motor

.l?

IJ "

PPC' / valve

.:;;

~

I

~ ~

ff c"{ c .g

~

~

f!

f!

.l? c

~

Control system

lng pump

/

Auto-deceleration

OLSS

Pump control

Swing brake/

Electronic OLSS. auto-deceleration

Component causing failure

/

Hydraulic system

Electrical system

0

0

0

0

0

0 0

0

0

0

0 *: Auto-deceleration

)

62-170 ®

PC200, 220-3

HYDRAULIC SYSTEM 63 DISASSEMBLY AND ASSEMBLY CHARGING PUMP ASSEMBLY Removal Installation MAIN PUMP ASSEMBLY

.

63- 2 63- 3

.

Removal . . Installation . Disassembly . Assembly . Installation . CONTROL VALVE ASSEMBLY Removal . Installation . Disassembly . Assembly . TVC VALVE ASSEMBLY Removal and installation . CO, NC VALVE ASSEMBLY Removal and installation . SERVO VALVE ASSEMBLY Removal and installation . BOOM CYLINDER ASSEMBLY Removal and installation . ARM CYLINDER ASSEMBLY Removal and installation . BUCKET CYLINDER ASSEMBLY Removal and installation . HYDRAULIC CYLINDER ASSEMBLY Disassembly . Assembly . WORK EQUIPMENT ASSEMBLY Removal . Installation . Disassembly . Assembly . . . . . . . . . • . . . . . . . . . . . . .

63- 4 63- 7 63-9-1 63-9-5 63- 7 63-10 63-13 63-16 63-18

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

*

-

63-20 63-21 63-22 63-23 63-24 63-25 63-26 63-29 63-34 63-35 63-36 63-40

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows: 1. Start engine and run at low idling. 2. 3. 4.

Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke end. Next, operate cylinder 3 to 4 times to stroke end. After doing this, run engine at normal speed.

*

After repair or long storage, follow the same procedure.

PC200, 220-3

63-1 Q;)

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

REMOVAL OF MAIN PUMP ASSEMBLY Special tool

A

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulit tank. 1.

Oil stopper 1) Remove strainer cover (1), then take out strainer

(2). 2) 3)

Remove strainer and install tool A on rod (3). Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (4) and drain the oil from the hydraulic tank .

ww• w. k omat s upar t s book . c om *

...:..

Hydraulic tank: Approx. 150 Q

2.

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

3.

Air cleaner assembly Sling air cleaner assembly, remove air cleaner band and hose clamp, then remove air cleaner assembly (5).

4.

Main pump outlet hoses Disconnect hoses (6) and (7) between pump and control valve, and branch hoses (8) and (9) together with block.

5.

Main pump drain hose Disconnect hose (10) between main pump and hydraulic tank.

6.

Charging pump hose Disconnect hose (11) accumulator.

63-4 CD

between charging pump and

PC200, 220-3

DISASSEMBLY AND ASSEMBLY

7.

8. _

MAIN PUMP

Jet sensor hose Mark the pilot hoses with tags to show their mounting position. Disconnect hoses (12) and (13) at rear, and hoses (14) and (15) at front between CO, NC valve and control valve.

*

Suction tubes Disconnect charging pump inlet tube (16), and main pump inlet tube (17).

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

Main pump assembly Sling main pump assembly, remove 12 mounting bolts, then lift off main pump assembly (18).

~

Main pump assembly: 200 kg

PC200, 220-3

63-5 CD

DISASSEMBLY AND ASSEMBL Y

MAIN PUMP

REMOVAL OF MAIN PUMP ASSEMBLY (OPTION) Special tool

A

Part No.

Part Name

a'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1.

Oil stopper 1) Remove strainer cover (1), then take out strainer (2).

2) 3)

Remove strainer and install tool A on rod (3) . Assemble rod and tool A inside tank, then fit spring and install strainer cover. When not using tool A, remove drain plug (4) and drain the oil from the hydraulic tank.

ww•w. k omat s upar t s book . c om *

...:..

2.

Hydraulic tank: Approx. 150 Q

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

3.

Air cleaner assembly Sling air cleaner assembly, remove air cleaner band and hose clamp, then remove air cleaner assembly (5).

4.

Main pump outlet hoses Disconnect hoses (6) and (7) between pump and control valve, and branch hoses (8) and (9) together with block.

5.

Main pump drain hose 'Disconnect hose (10) between main pump and hydraulic tank.

6.

Charging pump hose Disconnect hose (11) accumulator.

63-8 CD

r

between charging pump and

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

8. Wiring connector Connect wiring connector (8) of TVC solenoid valve. Fix the connector securely with the clip.

*

9. Air cleaner assembly -

Raise air cleaner assembly (7) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

www. k omat s upar t s book . c om 10. Covers, hood 1) 2)

3)

Install bottom cover (6) and top cover (5). Close hood and lock with catch. Close side cover.

11. Oil stopper 1) 2) 3)

4)

*

-

Remove cover (1), then take out tool A. Remove tool A and install strainer (2) on rod (3). Assemble strainer inside tank, then install spring and cover again. Bleed air from main pump. For details, see section 62, TESTING AND ADJUSTING, BLEEDING AIR FROM MAIN PUMP. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug and add engine oil through oil filler (23) to the specified level.

W pe200, 220-3

Hydraulic tank: Approx. 150 Q

63-9 CD

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

-

DISASSEMBLY OF MAIN PUMP ASSEMBLY (HPV090 + 090) Special tools No.

Part No.

Part Name

Q'ty

A

790-501-5000

Unit repair stand

1

Al

790-901-2110

Bracket

1

A2

790-901-2150

1

A3

796-720-3530

Plate (For front pump) Plate (For rear pump)

1

Preparatory work Set pump assembly (1) in tool A.

-

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

2.

TVC and CO, NC valve assembly 1) Remove hose (2). 2) Remove tube (3). 3) Disconnect wiring (4), then remove TVC and CO, NC valve assembly (5). (Rear pump) 4) Remove CO, NC valve assembly (6). (Front pump)

-

Rear pump assembly 1) 51 ing rear pump assembly (7). 2) Remove 4 nuts at front pump assembly end, then remove rear pump assembly (7). Disconnect at the middle of the end caps.

*

'P20503079

63-9-1

PC200, 220-3

-

MAIN PUMP

DISASSEMBLY AND ASSEMBLY

*

The front pump can be further disassembled from this point, but for rear pump assembly (7), remove plate A3 before disassembling.

7 P20503080

3. _

Impeller Remove impeller (8) and spacer (9) from front pump. Check the number and thickness of the spacers, and keep in a safe place.

*

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

4.

5.

Servo valve assembly Remove servo valve assembly (12). End cap

1)

Remove bolts (13), then remove plate (14).

P20503083

2)

3) 4)

Remove shim (15), boss (16), and spacer (18). Check the number and thickness of the shims, and keep in a safe place. Remove outer race (20) and bearing (21). Remove end cap (23). Be careful not to drop the valve plate.

*

*

-

P20503084

PC200, 220-3

P20503085

63-9-2 ($)

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

6.

Valve plate Remove valve plate (45).

7.

Pump shaft assembly Support cylinder block and shaft, then remove pump sub-assembly.

8.

Servo piston 1) Using forcing screws (Dia. = 10 mm, Pitch = 1.5 mm) and nut , remove cap (27) and shim (28). 2) Remove spring (31).

-

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

Repeat Step 1) and remove cap (29) and shim (30). Remove servo piston (32). The servo pistons used for the front and rear are not the same part, so mark them to distinguish them.

*

9. Cylinder, shaft 1) Set pump sub-assembly (49) in a vice. Be carefu I not to damage the flange surface of the cradle. 2) Remove slider (38) and cylinder block (35).

*

63-9-3

PC200. 220-3

-

DISASSEMBLY AND ASSEMBLY

3)

Screw in forcing screws, and remove housing (40) and shim.

* *

MAIN PUMP

Check the number and thickness of the shims, and keep in a safe place.

40

10

The charging pump is installed to the rear pump, so collar (10) assembled in the pilot pump must be removed.

P20503095

-

4)

Remove shaft (14).

www. k omat s upar t s book . c om 5)

Remove inner race from pump drive shaft. i)

Remove snap ring (55), then remove washer (54).

ii)

Using puller (3), remove inner race (53).

*

-

For the rear pump shaft, using gear puller, remove inner race.

/55

s9===a;..::.--- 54 53

F20503065

10. Piston

F20503066

Remove 4 screws (56), then remove retainer bearing (57), shoe retainer (58), spacer (56), and piston (60).

58

56 1~--59

-

P20503097

F20703017A

PC200. 220-3

63-9-4

OISASSEMBl Y AND ASSEMBl Y

MAIN PUMP

-

ASSEMBLV OF MAIN PUMP ASSEMBLV (HPV090 + 090) Special tools No.

Part No.

Part Name

Q'ty

A

790·501·5000

Unit repair stand

1

Al

790·901·2110

Bracket

1

A2

790·901·1330

Plate

1

A3

796·720·3530

Plate

1

B

796·720·3810

Gau~e

1

B

796· 720·3840

(for min. swas plate anllle) Gau~e (for max. swas plate angle)

Cl

795·630·1803

Torque wrench set

1

C2

796·720·2220

Socket

1

C3

796·730·2120

Screwdriver

1

01

795·630·1803

Torque wrench set

1

02

796·720·2220

Socket

1

1

-

www. k omat s upar t s book . c om Precautions when assembling. Always use all parts supplied in the kit. In addition, always use the following parts as an assembly. 1) Cradle and rocker arm. 2) Cylinder block and valve plate.

-

Preparatory work Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil (E010·CO, new oil) before installing.

1.

Cradle and piston assem bly 1) Press fit bearing (68) (outside diameter: 85 mm) to cradle (65).

68

63-9-5

PC200, 220·3

MAIN PUMP

DISASSEMBLY AND ASSEMBLY

2)

Select shims to hold bearing as follows. i) Measure distance ® between bearing (68) and end face of cradle. ii) Measure distance (5) of housing (40). iii) Select shim thickness as follows. Shim thickness = ® - (5) - (0 to 0.1 mm)

@

P20503099

*

-

Forthe rear pump, install collar (66) to charging pump (67), and measure distance (5) of the

67

collar.

www. k omat s upar t s book . c om P20503100

3)

Fit dowel pin, and install rocker cam stopper (64) to cradle (65). ~". ,

Stopper bolt:

Thread tightener (LT-2)

~

Stopper bolt:

1.35 ± 0.15 kgm

65

4)

Fit dowel pin to cradle, set rocker cam (62) in position, then install plate (63). The side of the rocker cam with the groove faces the oil hole side of the cradle.

*

*

~,

Plate bolt: Thread tightener (LT-2)

~

Plate bolt: 3.15 ± 0.35 kgm

63

After tightening the bolts, check that the rocker cam moves smoothly.

-

F20503052

PC200,220-3

63-9-6 (5)

..

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

5)

Select the spacer thickness as follows. i) Assemble shoe retainer (58) to piston (60), put on the level block, then measure distance ® to top surface of shoe retainer. ii) Select spacer thickness as follows. Spacer thickness = distance ® + (0.03 to 0.07 mm) There are three types of spacer.

*

F20503053

6)

Install spacer (59) selected in Step 5)-i) and ii). then install piston (60), shoe retainer (58) and retainer bearing (57). ~c,

Bearing retainer bolt: Thread tightener

~

Bearing retainer bolt: 1.35 ± 0.15 kgm

-

www. k omat s upar t s book . c om 7)

Hold rocker cam in position, pull piston (60) with a force of 2 - 3 kg, and measure clearance ® between piston shoe and rocker cam. Measure the clearance with the rocker cam at position a or b, and measure for all nine piston.

*

* *

60

-

Clearance: 0.03 - 0.07 mm If clearance ® is not within the standard range, adjust the spacer again.

P20503105

Rocker cam

Pull

Piston

t

Retainer bearing Screw

I

Spacer

F20703021 Rocker cam

F20703022

63-9-7

PC200, 220-3

-

MAIN PUMP

DISASSEMBLY AND ASSEMBLY

-2.

Cylinder Align piston and install cylinder (35). Always install the valve plate (which forms a set with the cylinder) together with the cylinder, or make a mark and be careful not to make any mistake. Install the spring and washer inside the cylinder after adjusting the preload of the bearing.

*

*

-

3.

Shaft 1) Press fit inner race (53) (inside diameter: 45 mm) to shaft (41). 2) Fit washer (54), then install snap ring (55). 3) Select washer as follows. i) Install inner race (53) to shaft. ii) Install snap ring. Check that the snap ring is not deformed or damaged, and correct any burrs before installing. Install with the cut inside part facing the opposite direction from the inner race. iii) Using a feeler gauge, measure clearance @ between snap ring (52) and inner race. Push the snap ring securely into the groove on the opposite side from the inner race. iv) Install selected washer. Washer thickness = c1earance@+(Oto 0.1 mm) Check that there is no play between the snap ring and the washer. There are four types of washer.

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

*

@

----l~----l-ooI.-I---

......

*

-

r-ll...--_ _

Shaft

F20503054

PC200, 220-3

63-9-8 (5)

....

MAIN PUMP

DISASSEMBLY AND ASSEMBLY

4)

Set cradle and piston assembly (51) in vice 0). Put a block under the cylinder. Align shaft (41) with cylinder, and install.

*

5)

6)

Install housing as follows. i) Install oil seal (50) (outside diameter: 68 mm) to housing. ~.

ii)

*

Lip of oil seal: Grease (G2-L1)

Fit shim selected in Step 1-2), and install housing (40) to pump.

40

For the rear pump, do not install the charging pump at this point. If the charging pump is installed, it is impossible to stop the shaft from turning when adjusting the end play of the bearing. Be careful not to damage the lip of oil seal.

-

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

4.

Servo piston 1) Install pump case (33) in tool A. 2) Install servo piston (32). The servo pistons used for the front and rear are not the same part, so be careful not to make any mistake when assembling them.

*

P20503110

.-

End pump

Rear pump

L2

*

< Ll

The length (L2 < Ll ) from the center is different on the side with the spring and on the side with no spring.

F20503055

3)

Adjust stroke of servo piston as follows. i) Align tool B with dowel pin and groove 9 for servo valve arm of servo piston, and set tool B in position. As seen from the rear of the pump, the right side (the top when mounted on the machine; the side with the spring) is the maximum swash plate angle side. (maximum flow side) Note: For the rear pump, use the same tool turned over.

*

63-9-9 u))

PC200, 220-3

MAIN PUMP

DISASSEMBLY AND ASSEMBLY

Measure distance ® between servo piston and case. iii) Measure distance CW of cap (29). iv) Select shim thickness as follows. CW - ® = © ± 0.05 mm After adjusting the shim, put it in a set with the cap.

ii)

*

P20503116

-

Dowel pin

Dowel pin

Gauge

Gauge Servo valve mounting surface

Servo valve mounting surface CapB

Pump case

www+ . k omat s upar t s book . c om Cap A

Clearance

©

Servo piston -+Clearance

©

Clearance

a)---.+-~~

Servo piston

F20703026 F20703027

*

-

To adjust the minimum swash plate angle, replace tool B with the tool for the minimum angle, and repeat the same procedure as in Steps i) - iv). Note that the case faces in the opposite direction from the maximum swash plate angle side.

F20503056

5.

Pump SUb-assembly

1)

2)

3)

-

Install slider (38) and D-ring. Fit the D-ring in the pilot portion and the joint portion. Install 2 joints on case. Install with the small hole facing the cradle side. Align the slider with the servo piston, and install pump sub-assembly (49). ,,, Be careful that the D-ring is not caught. Also, be careful not to drop the cylinder.

*

*

I~

PC200, 220-3

Mounting bolt:

11.5 ± 1 kgm

63-9-10 (5)

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

6.

Adjusting axial play of bearing 1) Install the following parts in the end cap. i) Install bearing (48) (outside diameter: 42 mm). ~"J

ii)

Bearing mount surface: Grease (G2-L1)

Install outer race (46) to end cap (42). Be careful not to damage the rolling surface of the roller. iii) Coat with engine oil, align with pin and bearing, and install valve plate (45). iv) Install joint (44). Install with the small hole facing the case side. Insta II the part with only one joint to the

*

*

suction port side.

45

-

44

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

44

Install end cap (42) to case (43).

~

Mounting bolt:

7 ± 0.5 kgm (front)

~

3)

Mounting nut: 28.5 ± 3 kgm (rear) (Tighten the nut of the stud bolt.) Install bearing (21), inner race (20), spacer (18) and

P20503121

boss (16). The outer race is slightly stiff, so support the shaft from the other end and tap the boss

* 4) 5) 6)

lightly. Measure distance

®

between end face of boss (16)

and shaft (41). Select shim as follows. Shim thickness = ® + (0.2 ± 0.1 mm) Assemble selected shim (15), fit plate (14), and

-

tighten bolts (13). Hold the shaft down from the other end (to stop it from turning) when tightening.

*

~

Bolt:

7 ± 0.5 kgm

16

0.1 - 0.3 mm

@-++-F20503057

F20503058

63-9-11 (5)

P20503 I :;~,1

PC200.220-3

-

-

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

10. Adjusting impeller shim 1) Install impeller (8) to coupling (26)

P20503137

-

2)

Adjust impeller lock spacer as follows. i) Measure distance ® between spacer (18) and stepped part (25) of end cap of rear pump.

8

www. k omat s upar t s book . c om P2050~138.

F20503059

Measure distance @ between end face of vane and end face of coupling of impeller (8). Measure for all the vanes, and use the largest value. iii) Selece spacer as follows. ® - @ = © + (0.5 ± 0.1 mm) ii)

*

-

P20503139

F20503060

iv)

Measure distance @ between spacer (18) and stepped part (24) of end cap of front pump.

18

-

F20503061

PC200. 220-3

63-9-14 ®

DISASSEMBl Y AND ASSEMBLY

MAIN PUMP

Measure distance ® between stepped pat and coupling end face of impeller (8). vi) Select spacer as follows.

v)

@ -

® = CD + (0.5 ± 0.1

mm)

P20503140

F20503062

vii) Install selected shims at both ends of impeller, them measure overall distance @.

-

www. k omat s upar t s book . c om F20503063

ix) Measure distance (6) between spacer (18) and end face of end cap of rear pump. x) Measure distance CD between spacer (18) and end face of end cap of front pump. xi) If impeller distance @ is greater than ((6) +CDl. a gap will from between front and rear end caps, so select spacer at both ends of impeller again.

-

F20503064

63-9-15 @

PC200, 220-3

-

-

DISASSEMBLY AND ASSEMBLY

3) 4) 5)

-

MAIN PUMP

Install selected spacer (10) to rear pump. Fit selected spacer (9) to front pump, then install impeller (8). Measure rotating torque of pump. i) Rotate pump shaft at 1 revolution every 3 5 sec then measure rotating torque. ii) Rotating torque: Max. 1.4 kgm (at minimum rocker cam angle)

11. Rear pump assembly 1) Install a-rings to front and rear end caps. 2) Raise rear pump assembly (7), align spline, and install. ~

7

28.5 ± 3 kgm

Mounting nut:

www. k omat s upar t s book . c om 12. TVC and CO, NC valve assembly 1)

Fit O·ring and install CO, NC valve assembly (6). (Front pump) ~

2)

3)

3.2 ± 0.3 kgm

Fit a-ring, install TVC and CO, NC valve assembly (5), then clamp wiring (4). (Rear pump) ~

Mounting bolt:

~

Clamp mounting bolt: 7 ± 0.5 kgm

3.2 ± 0.3 kgm

Fit a-ring and install tube (3). ~

4)

Mounting bolt:

Joint bolt:

1.8 ± 0.2 kgm

Install hose (2). ~

*

Sleeve nut:

8 ± 2 kgm

After completion of quality of the parts.

assembly,

check

the

After completing the assembly of the pump assembly, use a test stand (A type or C type) to check the quality.

*

For details of the procedure for checking quality, see TESTING METHODS.

PC200, 220-3

63-9-16 ®

DISASSEMBL Y AND ASSEMBLY

MAIN PUMP

CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1. Checking contact between cylinder block and valve plate 1) Make a centering tool for the cylinder block and valve plate. The tool can be made of a soft material such as plastic or bakelite. 2) Remove grease from the parts to be checked. Do not wipe with a cloth. 3) Set the tool in position, and coat the cylinder block side with inspection paint. Apply the paint thinly. 4) Put the valve plate on top, push with a force of 4 5 kg, and rotate 2 - 3 times. 5) Remove the valve plate, transfer the contact surface to tape, and check the contact surface.

Cylinder block

Centering tool

* *

*

*

,I / (--~

I

I I

I

r--~ I I I I

I

II

I

I I

I I

I I

\..

\

I I

I

I I I

I I I

I

-

The standards for the contact surface are as follows.

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

a. Seal

Min.80%

Cylinder block

a. Seal

Min. 80%

F20703037

Valve plate

Cylinder block F20703038

63-9-17 @

PC200, 220-3

DISASSEMBLY AND ASSEMBLY

MAIN PUMP

2.

Checking contact between rocker cam and cradle 1) Remove grease from the parts to be checked. Do not wipe with a cloth. 2) Set the tool in position, and coat the cradle side with inspection paint. Apply the paint thinly. 3) Put the rocker cam on top, push with a force of 4 - 5 kg, and move 2 - 3 time from the stopper contact position to the maximum angle. 4) Remove the rocker cam, transfer the contact surface to tape, and check the contact surface.

* *

*

*

The standards for the contact surface are as follows. Pump Model

Dimension a (mm)

Contact surface

Contact b from a to outside

HPV 090

72

Min. 80%

Min. 50%

If there is no contact at the center but only at the outside, the contact is no good.

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

-

F20703039

-

Reference: If the contact is not within the contact standard value, when carrying, always lap both parts together. Parts with scratches cannot be reused.

*

PC200. 220-3

63-9-18 (5)

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

-

REMOVAL OF CONTROL VALVE ASSEMBLY Special tool Part No. 796-750-1410

A

Part Name Oil stopper

Q'ty 1

Lower the work equipment completely to the ground and stop the engine. Release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

* 1.

-

Mark the pilot hoses with tags to show their mounting position. 1) 2) 3)

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

ww•w. k omat s upar t s book . c om *

~

2.

Hydraulic tank: Approx. 150 Q

Remove cover above control valve, then· open side cover.

3.

Disconnect travel control cables (3) and (4).

4.

Disconnect hose (5) between PPC check valve and control valve (boom spool).

5.

Disconnect hose (6) between PPC check valve and control valve (bucket spool).

6.

Disconnect hose (7) between PPC check valve and control valve (swing spool).

7.

Disconnect hose (8) between PPC check valve and control valve (arm spooll.

63-10

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

4.

Charging pump hose Connect hose (11) between charging pump and accumulator.

5.

Main pump drain hose Connect hose (10) between main pump and hydraulic tank.

6.

Main pump outlet hoses 1) Fit a-rings and set branch hoses (9) and (8) on main pump. 2) Fit a-rings and connect hoses (7) and (6) between main pump and control valve.

7.

Air cleaner assembly Raise air cleaner assembly (5) and set in position on bracket. Tighten removed air cleaner band and hose clamp.

-.

8.

MAIN PUMP

r

Cover, hood 1) Install top cover of main pump, then close hood and lock with catch. 2) Close side cover.

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

-.

Refilling with oil 1) Remove cover (1), then take out tool A. 2) Remove tool A and install strainer (2) on rod (3). 3) Assemble strainer inside tank, then install spring and cover again. 4) Bleed air from main pump. For details, see 62 BLEEDING AIR FROM MAIN PUMP. If tool A was not used and the oil was drained from the hydraulic tank, tighten the drain plug (4) and add engine oil through oil filler (19) to the specified level.

*

W

Hydraulic tank: Approx. 150 Q

-.

PC200, 220-3

63-11 CD

DISASSEMBLY AND ASSEMBL Y

CONTROL VALVE

-

REMOVAL OF CONTROL VALVE ASSEMBLY Special tool

A

Part No.

Part Name

Q'ty

796-750-1410

Oil stopper

1

Lower the work equipment completely to the ground and stop the engine. Release the hydraulic pressure in the hydraulic piping. For details, see 62 TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

* 1.

-

Mark the pilot hoses with tags to show their mounting position. 1) 2)

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

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

*

•

~

Hydraulic tank: Approx. 150 Q

2.

Remove cover above control valve, then open side cover.

3.

Disconnect travel control cables (3) and (4).

4.

Disconnect hose (5) between PPC check valve and control valve (boom spool).

5.

Disconnect hose (6) between PPC check valve and control valve (bucket spool).

6.

Disconnect hose (7) between PPC check valve and control valve (swing spool).

7.

Disconnect hose (8) between PPC check valve and control valve (arm spool).

63-12 CD

PC200,220-3

-

-

DISASSEMBLY AND ASSEMBLY

8.

Disconnect hoses (9) and (10) between PPC check valve and control valve.

9.

Disconnect hoses (11), (12), (13) and (14) between control valve and CO, NC valve.

CONTROL VALVE

10. Disconnect hoses (15) and (16) between PPC check valve and travel shuttle valve. 11. Disconnect hoses (17) and (18) between pump and control valve.

www. k omat s upar t s book . c om 12. Disconnect hose (19) between PPC check valve and control valve (boom spool). 13. Disconnect hose (20) between PPC check valve and control valve (bucket spool).

-

14. Disconnect hose (21 ) between PPC check valve and control valve (swing spool). 15. Disconnect hose (22) between PPC check valve and control valve (arm spool). 16. Disconnect hose (23) between control valve and inlet tube of pump. 17. Loosen intermediate clamp, then disconnect tubes (24) and (25) between control valve and swing motor. 18. Loosen intermediate clamp, then disconnect tubes (26) and (27) between control valve and arm cylinder. 19. Loosen intermediate clamp, then disconnect tubes (28) and (29) between control valve and swivel joint (L.H. travel ).

-

20. Loosen intermediate clamp, then disconnect tube (30) between control valve and hydraulic tank.

PC200, 220-3

63-13 CD

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

21. Loosen intermediate clamp, then disconnect tubes (31) and (32) between control valve and swivel joint (R.H. travel ). 22. Loosen intermediate clamp, then disconnect tubes (33) and (34) between control valve and boom cylinder. 23. Loosen intermediate clamp, then disconnect tubes (35) and (36) between control valve and bucket cylinder.

24. Using eyebolts CD (Dia. = 10 mm, Pitch = 1.5 mm), sling control valve assembly (37), then remove 8 mounting bolts and lift off control valve assembly.

&J

-

Control valve assembly: 170 kg

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

-

63-14 CD

PC200, 220-3

-

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF CONTROL VALVE ASSEMBLY

* *

Tighten the hose joints (at taper seal) to the following torques. Install hose without twisting or interference. ~

Sleeve nut of hose

Width across flats of nut

-

1.

19 mm

2.5 ± 0.5 kgm

24mm

5 ± 2 kgm

27 mm

8 ± 2 kgm

32mm

18 ± 3 kgm

Using eyebolts CD (Dia. = 10 mm, Pitch = 1.5 mm), raise control valve assembly (37), and set in mounting position. Tighten 8 mounting bolts.

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

Fit a-rings and connect tubes (36) and (35) between control valve and bucket cylinder, then tighten intermediate clamp.

3.

Fit a-rings and connect tubes (34) and (33) between control valve and boom cylinder, then tighten intermediate clamp.

4.

Fit a-rings and connect tubes (32) and (31) between control valve and swivel joint (R.H. travel), tben tighten intermediate clamp.

5.

Fit a-rings and connect tube (30) between control valve and hydraulic tank, then tighten intermediate clamp.

6.

Fit a-rings and connect tubes (29) and (28) between control valve and swivel joint (L.H. travel), then tighten intermediate clamp.

7.

Fit a-rings and connect tubes (27) and (26) between control valve and arm cylinder, then tighten intermediate clamp.

8.

Fit a-rings and connect tubes (25) and (24) between control valves and swing motor, then tighten intermediate

-

-

clamp.

PC200, 220-3

63-15 CD

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

9. Connect hose (23) between control valve and inlet tube of pump. 10. Connect hose (22) between PPC check valve and control valve (arm spool). 11. Connect hose (21) between PPC check valve and control valve (swing spool). 12. Connect hose (20) between PPC check valve and control valve (bucket spool). 13. Connect hose (19) between PPC check valve and control valve (boom spool).

-

14. Fit a-rings and connect hoses (18) and (17) between pump and control valve. 15. Connect hoses (16) and (15) between PPC check valve and travel shuttle valve.

www. k omat s upar t s book . c om 16. Connect hoses (14), (13). (12) and (11) between control valve and CO, NC valve. 17. Connect hoses (10) and (9) between PPC check valve and control valve.

18. Connect hose (8) between PPC check valve and control valve (arm spool). 19. Connect hose (7) between PPC check valve and control valve (swing spool). 20. Connect hose (6) between PPC check valve and control valve (bucket spool). 21. Connect hose (5) between PPC check valve and control valve (boom spool).

63-16 CD

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

22. Connect travel control cables (4) and (3). 23. Install cover above control valve, then close L.H. side cover.

-

24. Remove cover and take out tool A. Remove tool A from rod and install strainer (1). Then assemble inside tank and install cover. If tool A was not used, tighten drain plug (2) and add engine oil through the oil filler to the specified level.

*

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

*

Hydraulic tank: Approx. 150 Q

Run the engine to circulate the oil through the system. Then check the oil level again.

25. Bleed air from hydraulic cylinders and travel motor. For details, see section 62 AIR BLEEDING IN TRAVEL MOTOR.

*

*

After bleeding the air, check the oil level.

-

PC200. 220-3

63-17 CD

DISASSEMBLY AND ASSEMBl Y

CONTROL VALVE

-

DISASSEMBLY OF CONTROL VALVE ASSEMBLY

www. k omat s upar t s book . c om 205F2333

-

205F2334

63-18 CD

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

* 1. 2. 3.

*

-

* 4.

CONTROL VALVE

The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. Remove main relief valve (1) and jet sensor relief valve (2). Remove safety valve (3). and safety and suction valves (4) and (5). Disassemble PPC valve spool as follows. 1) Remove case (6). then remove spring (7) and retainer (8). 2) Remove spool (9). For the control valve on machines with wrist control, this applies to the boom, arm, bucket, swing, and arm Hi spools. With this type, there are shims (10) fitted at the spring of the boom, arm and swing spools, so be careful when removing. For the control valve on machines with long lever control, this applies to the arm, bucket, and swing spools. Disassemble mechanically linked spool as follows. 1) Remove case (11) and bolt (12), then remove retainer (13). spring (14) and retainer (15). Remove bolt (12) with the spool inside the body. 2) Remove spool (16) from body, then remove oil seal

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

(17).

*

Be careful not to damage the oil seal when removing the spool. 3) Remove plate (18), then remove oil seal (19). For the control valve on machines with wrist control, this applies to the travel spool. For the control valve on machines with long lever control, this applies to the travel and boom spools. Remove plate (20), then remove spring (21) and straighttravel spool (22). Remove plug (23), then remove washer (24), spring (25), washer (26), and arm throttle spool (27). This also applies to the swing priority valve. Remove plug (28). then remove spring (29) and check valve (30).

* *

-

5. 6.

* 7.

PC200, 220-3

63-19 CD

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

-

ASSEMBLY OF CONTROL VALVE ASSEMBLY

www. k omat s upar t s book . c om 205F2333

-

205F2334

63-20 CD

PC200. 220-3

CONTROL VALVE

DISASSEMBL Y AND ASSEMBLY

* 1.

Clean all parts, and check for dirt or damage. coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage packing, dust seals or a-rings when installing. Assemble spring (29) and check valve (30) to plug (28), then install plug (28). ~"C,

2.

Plug:

Thread tightener (LT-2) (one drop only)

~ Plug: 15.5 ± 2.5 kgm Assemble arm throttle spool (27). then fit washer (26), spring (25) and washer (24). Fit a-ring and tighten plug (23). ~

-

Plug: 14 ± 2 kgm This also applies to the swing priority valve. Assemble straight-travel spool (22), then fit spring (21). Fit a-ring and install plate (20). Assemble mechanically linked spool as follows. 1) Install oil seal (17) in body, then assemble spool (16). Coat oil seal lip with grease (G2-L1) 2) Assemble retainer (15), spring (14) and retainer (13), then tighten bolt (12).

* 3. 4.

*

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

Bolt: 2.5 ± 1 kgm Tighten bolt (12) with the spool inside the body. Install case (11). then fit oil seal (19) and install plate (18).

*

3)

*

* 5.

-

*

* 6.

For the control valve on machines with wrist control, this applies to the travel spool. For the control valve on machines with long lever control, this applies to the travel and boom spools. Assemble ppe valve spool as follows. Assemble spool (9) in body, then install retainer (8) and spring (7). Fit a-ring and install case (6). For the control valve on machines with wrist control, this applies to the boom, arm, bucket, swing, and arm Hi spools. With this type, there are shims (10) fitted at the spring of the boom, arm and swing spools, so be careful when installing. For the control valve on machines with long lever control, this applies to the arm, bucket, and swing spools. Fit a-rings and install safety and suction valves (4) and (5). and safety valve (3). ~

7.

Safety valve, safety and suction valve: 14±2kgm Fit a-rings and install jet sensor relief valve (2) and main relief valve (1). Main relief valve:

10 ± 1 kgm

Jet sensor relief valve: 5.5 ± 0.5 kgm

PC200, 220-3

63-21 CD

DISASSEMBl Y AND ASSEMBLY

TVCVAlVE

-

REMOVAL OF TVC VALVE ASSEMBLY Open l.H. side cover. 2.

Remove 4 mounting bolts with hexagonal wrench, then remove TVC valve assembly (1).

2

-

www. k omat s upar t s book . c om INSTALLATION OF TVC VALVE ASSEMBLY

1.

Fit O-ring on CO, NC valve assembly (2).

2.

Set TVC valve assembly (1) on CO, NC valve assembly (2), then tighten 4 mounting bolts.

3.

Close l.H. side cover.

F205C3071

-

63-22 CD

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

CO, NCVALVE

REMOVAL OF CO, NC VALVE ASSEMBLY 1.

Open L.H. side cover.

2.

Disconnect hoses (1) and (2) between CO, NC valve and control valve. Mark the hoses with tags to show their mounting position.

* 3.

Remove tube (3) between left and right CO, NC valve.

4.

Remove 4 mounting bolts with a hexagonal wrench, then remove CO, NC valve assembly (4).

-

www. k omat s upar t s book . c om INSTALLATION OF CO, NC VALVE ASSEMBLY

1.

Install filter (6) and a-ring on servo valve assembly (5).

2.

Set CO, NC valve assembly (4) on servo valve assembly (5), then tighten 4 mountings bolts. ~

-

Mounting bolt: 3.15 ± 0.35 kgm

3.

Fit a-ring and install tube (3).

4.

Connect hoses (2) and (1) between CO, NC valve and control valve.

5.

Close L.H. side cover

*

Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

PC200, 220-3

63-23 CD

DISASSEMBLY AND ASSEMBLY

SERVO VALVE

-

REMOVAL OF SERVO VALVE ASSEMBLY 1.

Remove CO and NC valve assembly. For details, see 63 REMOVAL OF CO, NC VALVE ASSEMBLY.

2.

Remove 4 mounting bolts with a hexagonal wrench, then remove servo valve assembly (1).

INSTALLATION OF SERVO VALVE ASSEMBLY 1,

-

Install orifice (2) and filter (3) to servo valve assembly (1).

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

Fit O-ring, align arm with notch in servo piston, then set servo valve assembly (1) in case and tighten 4 mounting bolts. Install the servo valve assembly smoothly, and do not apply force to the protruding part of the arm.

*

~

3.

*

205F2330

Mounting bolt: 3.15 ± 0.35 kgm

Install CO and NC valve assembly. For details, see 63 INSTALLATION OF CO, NC VALVE ASSEMBLY. Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

-

63-24 CD

PC200. 220-3

-

-

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

-

DISASSEMBLY AND ASSEMBLY

PPC VALVE

-

REMOVAL OF PPC VALVE ASSEMBLY Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

*

Before disconnecting PPC valve hoses, mark with tags to show their mounting position.

1.

Disconnect PPC valve hoses (1), (2), (3), (4), (5) and (6).

2.

Remove cover (7) of control box.

3.

Disconnect control rod (8) and (9).

-

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

Remove 3 mounting bolts of control box, then remove control box (10).

5.

Remove PPC valve bracket assem bly (11).

6.

7.

Loosen nut of yoke assembly fastening bolt (12), remove bolt, then remove 4 mounting bolts of PPC valve, and remove bracket (13).

13

Pull out pins (14) of yoke at 4 place, then remove spring (15), spacer (16) and yoke assembly (17).

15 16

14

17

12

P205C3170

63-26 CD

PC200, 220-3

-

-

PPC VALVE

DISASSEMBLY AND ASSEMBLY

INSTALLATION OF PPC VALVE ASSEMBLY 13 1.

Set spacer (16) on top and bottom of spring (15), install yoke assembly (17) then install pins (14) of yoke at 4 place.

2.

Install bracket (13), tighten 4 mounting bolts, install yoke assembly fastening bolts (12), then tighten nut.

15 16

14

17

12

P205C3170

-

3.

Install PPC valve bracket assembly (11).

4.

Set control box (10) in position, then tighten 3 mounting bolts.

www. k omat s upar t s book . c om 5.

6.

Connect control rod (9) and (8). Bend the cotter pin securely.

*

Install cover (7) of control box.

7.

Install PPC valve hoses (6), (5), (4), (3), (2) and (1). When connect the hoses, check the tags marked before disconnected.

*

PC200.220-3

63-27 CD

DISASSEMBLY AND ASSEMBLY

PPC VALVE

-

DISASSEMBLY OF PPC VALVE ASSEMBLY 1.

Remove bolt (1).

2.

Remove plate (2).

3.

Remove seal (3), then remove collar (4).

4.

Remove spool (5).

5.

Remove valve assembly and center spring (7) from valve body (10).

6.

11 12

Remove collar (11), then remove retainer (6), shim (12) and spring (8) from valve (9).

9

10

-

F205C3072

1~ www. k omat s upar t s book . c om ASSEMBLY OF PPC VALVE ASSEMBLY 1.

Install shim (12), spring (8). and retainer (6) on valve (9), then install collar (11).

2.

Install center spring (7) and valve assembly on valve body (10).

3.

Install valve (5).

4.

Fit O-ring and install collar (4).

5.

Install seal (3).

6.

Set plate (2) in position, then tighten bolt (1). ~

-

Bolt: 4.5 ± 0.5 kgm

10

F205C3073

63-28 CD

PC200, 220-3

-

DISASSEBMLY AND ASSEMBLY

BOOM CYLINDER

REMOVAL OF BOOM CYLINDER ASSEMBLY

it 1. 2. 3.

4.

Extend the arm and bucket fully, lower the work

equipment completely to the ground and stop the engine. Disconnect greasing tu be (1).

Remove lock bolt (2), then remove plates (3). Sling boom cylinder assembly (4), push connecting pin (5) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fUlly. Tie the rod with wire to prevent it from coming out.

-

Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

\

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

5. 6.

Raise boom cylinder assembly (4), then set on stand Disconnect hoses (6) and (7).

7.

Sling boom cylinder assembly (4) and remove lock plate (8). Using forcing screw ® (Dia. = 12 mm, Pitch = 1.75 mm), remove pin (9), then lift off boom cylinder assembly (4).

205P2269

~-

6tJ

Boom cylinder assembly:

185 kg (PC200) 200 kg (PC220)

-

INSTALLATION OF BOOM CYLINDER ASSEMBLY 1.

Raise boom cylinder assembly (4), and position bottom connecting pin hole on frame. Assem ble spacer, knock in pin (9), and install lock plate (8).

*

Adjust with spacers so that the clearance between the revolving frame and the cylinder bottom is less than 1 mm.

2.

Fit O-rings and connect hoses (7) and (6).

3.

Raise boom cylinder assembly (4). Start engine, extend piston rod and align with pin hole, then knock in pin (5).

4. 5.

Fit plate (3), then secure with lock bolt (2). Connect greasing tube (1).

*

Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

PC200, 220-3

63-29 CD

DISASSEMBLY AND ASSEMBLY

ARM CYLINDER

-

REMOVAL OF ARM CYLINDER ASSEMBLY ~ 1. 2.

Set stand CD under the arm, lower the work equipment completely to the ground and stop the engine.

Sling arm cylinder assembly, remove lock plate (1), then pull out pin (2). Start engine and retract piston rod fully.

~

Tie the rod with wire to prevent it from coming out. Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

3. 4. 5.

-

Disconnect arm cylinder hoses (3) and (4) at cylinder end. Disconnect greasing tube (5). Remove lock plate (6), pull out pin (7), then lift off arm cylinder assembly (8).

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

Arm cylinder assembly:

245 kg (PC200) 280 kg (PC220)

INSTALLATION OF ARM CYLINDER ASSEMBLY 1.

2. 3. 4.

* *

7

Raise arm cylinder assembly (8) and position bottom connecting pin hole. Knock in pin (7), then secure with lock plate (6). Connect greasing tube (5). Fit O-rings and connect arm cylinder hoses (4) and (3). Start engine, extend piston rod, knock in pin (2), then secure wth lock plate (1).

6

I

-

Adjust with spacers so that the clearance between the boom and arm cylinder bottom is less than 1 mm. Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

63-30 CD

PC200, 220-3

DISASSEMBLY AND ASSEMBLY

BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER ASSEMBLY Lower the work equipment completely to the ground and stop the engine. 1.

2.

Remove lock bolt (1), then pull out pin (2). Insert block between the cylinder and the arm. Pull out pin (2) until the piston rod comes out. Start engine and retract piston rod fully.

* *

CD

~

Tie the bucket cylinder rod with wire to prevent it from coming out. Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve.

3.

Disconnect bucket cylinder hoses (3) and (4) at cylinder end. Sling bucket cylinder assembly (5), remove lock plate (6). then pull out pin (7). Lift off bucket cylinder assembly (5).

www. k omat s upar t s book . c om 4. 5.

/~--

Lk91

Bucket cylinder assembly: 140 kg (PC200) 185 kg (PCnO)

INSTALLATION OF BUCKET CYLINDER ASSEMBLY -

1.

Raise bucket cylinder assembly (5) and position bottom connecting pin hole. Knock in pin (7), then secure with lock plate (6).

2.

Fit O-rings and connect bucket cylinder hoses (4) and (3).

* 3.

* *

Install hose without twisting or interference. Start engine, extend piston rod and align link and hole. Knock in pin (2), then install lock bolt (1).

Adjust with spacers so that the clearance between the arm and bucket cylinder bottom is less than 1 mm. Run the engine to circulate the oil through the system. Then add oil to hydraulic tank to the specified level.

PC200, 220-3

63-31 CD

HYDRAULIC CYLINDER

DISASSEMBL Y AND ASSEMBLY

-

DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Special tool Part No.

Part Name

Q'ty

A

790-502-2000 or 790-502-1001

Cylinder repair stand

1

Al

790-302-1430

Socket (Width across flats: 85mm)

1

A2

790-302-1450

Socket (Width across flats: 95mm)

1

A3

790-101-1102

Pump

1

1.

-

Set cylinder assembly (1) on tool A.

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

2.

205P2279

Remove head bolts (2).

2

3.

Pu II out piston rod assembly (3) about 1 m, then lift off. Prepare a container to catch the oil which comes out when the piston rod assembly is removed. Remove the cylinder from tool A.

* *

i 205P228I

63-32 CD

PC200, 220-3

-

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

4.

Disassemble piston rod assembly as follows. •

Bucket cylinder 1) Set piston rod assembly in tool A. 2) Using tool A, remove nut (4). Width across flats of nut: 85 mm (PC200) 95 mm (PC220)

*

3)

Remove piston assembly (5) and cylinder head assembly (6) from piston rod (7).

205P2282

-

•

Arm cylinder 1) Set piston rod assembly in tool A. 2)

3)

Using tool A, remove nut (8).

*

Width across flats of nut: 95 mm Remove piston assembly (9), plunger (10) and cylinder head assembly (11) from piston rod ( 12).

www. k omat s upar t s book . c om 205P2283

4)

Remove screw (13), take out 12 balls (14), then remove plunger (15).

15

/

205F2335

•

205P2284

Boom cylinder 1) Set piston rod assembly in tool A. 2) Using tool A, remove nut (16). Width across flats of nut: 85 mm (PC200) 95 mm (PC220)

*

3)

Remove

piston

assembly (17), plunger (18)

and cylinder head assembly from piston rod

(19).

PC200, 220-3

63-33 CD

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

5.

Disassemble piston assembly as follows. Remove wear ring (20) and slipper seal (21) from piston.

6.

Disassemble cylinder head assembly as follows. 1) Remove snap ring (22), then remove dust seal (23) from cylinder head. 2) Remove packing (24), bushing (25), a-ring (26) and backup ring (27) from cylinder head.

20

205P2286

26 27

26

24

24 25

-

26

25

27

23

www. k omat s upar t s book . c om 22

205F2336

205P2287

-

63-34 CD

PC200, 220-3

--

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Special tool

*

Part No.

Part Name

Q'ty

A

790-502-2000 or 790-502-1001

Cylinder repair stand

1

Al

790-302-1430

Socket (Width across flats: 85mm)

1

A2

790-302-1450

Socket (Width across flats: 95mm)

1

A3

790-101-1102

Pump

1

B

790-702-1000

Expander

1

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be carefu I not to damage packing, dust seals or O-ring when installing.

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

Assemble cylinder head assembly as follows. 1) Using push tool, install bushing (25) on cylinder head. Outside diameter of bushing: 80 mm (PC200 bucket) 90 mm (PC200 boom) 95 mm (pC220 boom, bucket) 100 mm (PC200, 220 arm) Be careful not to deform the bushing when press fitti ng. 2) Install packing (24). Be careful to install the packing facing in the correct direction. 3) Install backup rings (27) and O-rings (26) in turn on cylinder head. Do not try to force the slipper seal into position. Warm it in warm water (50 - 60°C) before fitting it. 4) Using push tool, install dust seal (23) and secure with snap ring (22).

*

*

-

*

26 27

24

26

25

27

1rn--.....-r-23

*

22 205F2336

24 25

26

27

--

205P2287

PC200, 220-3

63-35 CD

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

2.

Assemble piston assembly as follows. 1) Using tool B, expand slipper seal (21). Set the slipper seal on the expander and turn the handle 8 - 10 times to expand the ring. 2) Remove slipper seal (21) from tool, and install on piston.

*

21 205P2289

3)

Set ring CD in positIOn, then using clamp ®, compress slipper seal (21). Part number of ring 796-720-1660 (PC200 bucket cylinder) 796-720-1670 (PC200 boom, arm cylinder) (PC220 bucket, boom cylinder) 796-720-1680 (PC220 arm cylinder)

-

*

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

Part number of clamp 07281-01279 (PC200 bucket cylinder) 07281-01589 (PC200 boom, arm cylinder) (PC220 bucket, boom cylinder) 07281-01919 (PC220 arm cylinder)

2

205F2338

205F2337

4)

Install wear ring (20) on piston.

20

63-36 CD

Z05P2292

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

3.

Assemble piston rod assembly as follows. • Boom cylinder 1) Set piston rod (19) in tool A. 2) Install cylinder head assembly, plunger (18) and piston assembly (17) on piston rod (19l. 3) Using tool A, tighten nut (16). ~

-

•

Nut:

720 ± 72 kgm (PC200) (Width across flats: 85 mm) 1040 ± 104 kgm (PCnO) (Width across flats: 95 mm)

Arm cylinder 1) Set piston rod (12) in tool A. 2) Position plunger (15) on piston rod, then assemble 12 balls (14). 3) Tighten screw (13) fully, then turn back about 1/2 turn. Check play at tip of plunger, then caulk. Play at tip of plunger: Approx. 6 mm

13

\

15 I

\

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

205P2284

Caulk

205F2339

4)

5)

Install cylinder head assembly (11), plunger (10) and piston assembly (9) on piston rod (12). Using tool A, tighten nut (8). ~

-

Nut:

1040 ± 104 kgm (Width across flats: 95 mm)

205P2283

PC200. 220-3

63-37 CD

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

•

Bucket cylinder 1) Set piston rod (7) in tool A. 2) Install cylinder head assembly (6) and piston assembly (5) on piston rod. 3) Using tool A, tighten nut (4). ~

Nut:

720 ± 72 kgm (PC200) (Width across flats: 85 mm) 1040 ± 104 kgm (PC220) (Width across flats: 95 mm)

205P2282

4.

Set cylinder in tool A.

5.

Raise cylinder head and piston rod assembly (3). and assemble in cylinder. Coat the inside face of the cylinder and the outside face of the piston with engine oil when installing.

-

3

*

www. k omat s upar t s book . c om 6.

Assemble cylinder head assembly in cylinder, then tighten head bolts (2). Align the punch marks and ports when assembling. (There is no punch mark on the bucket cylinder.)

*

2

7.

Remove cylinder assembly (1) from tool A.

A 205P2279

63-38 OJ

PC200. 220-3

-

-

-

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

-

WORK EQUIPMENT

DISASSEMBLY AND ASSEMBLY

-

REMOVAL OF WORK EQUIPMENT ASSEMBLY Special tool Part No.

Part Name

Q'ty

A

796-900-1200

Remover

1

Al

790-101·3800

Cylinder (50 ton)

1

A2

790-101-1102

Pump

1

~

1. 2. 3. 4.

Extend the arm and bucket fully, lower the work equipment completely to the ground and stop the engine.

Disconnect greasing tube (1). Remove lock bolt (2). then remove plates (3). Sling boom cylinder assembly (4), push connecting pin (5) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fully.

\

5

-

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

Tie the rod with wire to prevent it from coming out.

'!'!'Y

Stop the engine and release the hydraulic pressure in the hydraulic piping. For details, see section 62, TESTING AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Raise boom cylinder assembly (4) and lower on to stand

Y

5.

205P2294

CD.

* 6. 7. 8. 9.

Remove the other boom cylinder assembly in the same way, and lower on to the stand. Disconnect head lamp wiring (6) at connector. Disconnect bucket cylinder hoses (7) and (8), and arm cylinder hoses (9) and (10). Sling work equipment assembly, and remove lock plate (11). Using tool A, remove pin (12). Lift off work equipment assembly (13).

~

-

Work equipment assembly: 3400 kg (PC200) 3700 kg (PC220)

63-40 CD

PC200, 220·3

-

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1.

Raise work equipment assembly (13), and positIOn boom foot connecting pin hole on revolving frame. Knock in pin (12), then secure with lock plate (11).

2.

Fit O-rings and connect arm cylinder hoses (9) and (10) and bucket cylinder hoses (7) and (8). Install hose without twisting or interference.

*

-

3.

Connect head lamp wiring (6) at connector.

4.

Raise boom cylinder assembly (4). Start engine, extend piston rod and align with pin hole, then push in pin (5).

5.

Fit plate (3), then secure with lock bolt (2).

6.

Connect greasing tube (1).

*

Install the other boom cylinder in the same way.

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

*

Adjust with spacers so that the clearance between the revolving frame and the boom foot is less than 1 mm.

Run the engine to circulate the oil through the system. Then add oil to the hydraulic tank to the specified level.

*

After installing the work equipment assembly, grease all the pins with grease (G2-L1).

-.

PC200, 220-3

63-41 CD

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

-

DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY Special tools Part No.

Part Name

Q'ty

A

796-900-1200

Remover

1

Ai

790-101-3800

Cylinder (50 ton)

1

A2

790-101-1102

Pump

1

1.

Bucket 1) Lower work equipment to ground so that bottom of bucket (1) is on ground. 2) Remove lock bolt (2). then remove cylinder connecting pin (3). 3) Start engi ne and retract bucket cy I inder rod fu Ily. 4) Remove lock bolt (4).

~

E:~ 4

-

www. k omat s upar t s book . c om 5) 6)

Loosen 4 mounting bolts of cover (5). and remove shims (6). Pullout arm connecting pin (7). then remove bucket (1). ~~

Ck~J

Bucket: 560 kg (PC200) 720 kg (PC220)

P205C3173

2.

Link 1) Lower tip of arm to ground. 2) Set link (8) on block then remove lock bolt (9). Pullout pin (10), and remove link (11). 3) Start engine and retract bucket cylinder rod fully. Tie the bucket cyl inder rod with wire" to prevent it from coming out.

CD.

8 P205C3174

63-42 Q)

PC200, 220-3

-

WORK EQUIPMENT

DISASSEMBLY AND ASSEMBLY

4)

Remove lock bolt (12). pullout link pin (13). and remove link (14).

P205C3175

-

3.

Bucket cylinder assembly

¢ 1)

Release the hydraulic pressure in the hydraulic piping. For detai Is, see section 62, TESTI NG AND ADJUSTING, Bleeding pressure from hydraulic circuit in machine with PPC valve. Disconnect 2 bucket cylinder hoses (15). After disconnecting the hoses, fit blind plug @ in the tube flange to prevent oil from coming

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

out.

2)

Sling bucket cylinder assembly (16). then remove lock plate (17). Pullout pin (18) and lift off bucket cylinder assembly (16).

L£

4.

Bucket cylinder assembly: 140 kg (PC200) 160 kg (PC220)

1\ j

17

Arm 1) Pull in arm fully, and lower on to block (height: approx. 500 mm). 2) Remove lock plate (20), then remove pin (21). 3) Start engine and retract arm cylinder rod fully.

~

4)

Tie the arm cylinder rod with wire to prevent it from coming out.

Remove lock plate (22). then remove pin (23).

PC200, 220-3

63-43 CD

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

5)

Start engine and operate work equipment control lever to raise boom (24). lift off arm (19).

~

Arm: 600 kg (PC200) 700 kg (PC220)

205P2308

5.

Boom cylinder assembly 1) 2) 3)

-

lower tip of boom completely to ground. Disconnect greasing tube (25). Remove lock bolt (26), then remove plates (27).

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

Sling boom cylinder assembly (28), push connecting pin (29) to opposite side, then remove piston rod from boom. Start engine and retract piston rod fully.

5)

Tie the boom cylinder rod with wire to prevent it from coming out.

6)

-

lower boom cylinder assembly (28) on to stand (3).

*

lower the other boom cylinder assembly on to the stand in the same way.

63-44 CD

PC200, 220-3

-

DISASSEMBLY AND ASSEMBLY

6.

WORK EQUIPMENT

Bucket hoses, arm hose Release the hydraulic pressure in the hydraulic piping. For details,see section 62, TESTI NG AND ADJUSTING, Bleeding pressure from hydraulic circuit in machines with PPC valve. Disconnect bucket cylinder hoses (30) and (31), and arm cylinder hoses (32) and (33).

-

7.

Head lamp wiring Disconnect head lamp wiring (34) at connector.

8.

Arm cylinder, boom assembly 1) Remove lock plate (35).

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

Sling boom, then pullout pin (36) with tool A.

3)

Raise arm cylinder and boom assembly (37), and pullout to front to remove.

-

Arm cylinder, boom assembly: 1700 kg (PC200) 2000 kg (PC220)

-

zu,,pz;, 14

pe200, 220-3

63-45 CD

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

-

ASSEMBLY OF WORK EQUIPMENT ASSEMBLY 1.

Arm cylinder, boom assembly 1) Raise arm cylinder and boom assembly (37), and position boom foot connecting pin hole on revolving frame.

-

205P2314 ~.,;

2)

*

Knock in pin (36), then secure with lock plate (35). Adjust with spacers so that the clearance between the revolving frame and the boom foot is less than 1 mm.

-

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

Head lamp wiring Connect head lamp wiring (34) at connector.

3.

Bucket hoses, arm hoses Fit O-rings and connect arm cylinder hoses (33) and (32), and bucket cylinder hoses (31) and (30).

4.

Boom cylinder assembly 1) Sling boom cylinder assembly (28). Start engine, extend piston rod and align with pin hole, then push in pin (29).

63-46 CD

pe200, 220-3

-

DISASSEMBLY AND ASSEMBLY

2) 3)

*

5. -

WORK EQUIPMENT

Fit plate (27), then secure with lock bolt (26). Connect greasing tu be (25). Install the other boom cyli'nder in the same way.

Arm 1) Raise arm (19), and lower on to block approx. 500 mm).

®

(height:

•

www. k omat s upar t s book . c om 205P2315

2)

3)

*

6.

Operate control lever and align pin holes of boom and arm (19). Knock in connecting pin (23), then secure with lock plate (22). Start engine, extend piston rod. Knock in connecting pin (21), then secure with lock plate (20). Adjust with spacers so that the clearance at the joint of the arm and boom is less than 1 mm.

Bucket cylinder assembly 1) Raise bucket cylinder assembly (16), and align connecting hole at bottom. Knock in pin (18), then secure with lock plate (17).

17

1\ I

PC200. 220-3

63-47 CD

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

2)

Fit O-rings and connect 2 bucket cylinder hoses (15).

*

7.

Adjust with spacers so that the clearance between the arm and bucket cylinder bottom is less than 1 mm.

Link 1) Align pin hole of link (14), knock in pin (13), then secure with lock bolt (12). Adjust with spacers so that the clearance between link (14) and the arm is less than 1 mm.

-

*

www. k omat s upar t s book . c om Set link (8) on block CO, raise link (11) and align connecting pin hole of bucket cylinder rod. Knock in pin (10), then secure with lock bolt (9).

2)

8.

P205C3175

Bucket 1) 2)

3)

Set bottom of bucket (1) on ground. Fit O-ring on both side of bucket. Operate control levers, and align bucket (1) with arm pin hole. Knock in arm connecting pin (7). Install shims (6), then tighten 4 mounting molts of cover (5). Adjust with shims (6) so that the clearance between arm and bucket retainer is 0.25 to

-

* 4)

0.5mm. Tighten lock bolt (4).

B P205C3174

P205C3173

63-48 CD

PC200, 220-3

-

-

DISASSEMBLY AND ASSEMBLY

5)

WORK EQUIPMENT

Extend bucket cyl inder rod and al ign pin hole. Knock in link connecting pin (3), then secure with lock bolt (2).

-

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

-

PC200, 220-3

63-49 CD

-

-

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

-

HYDRAULIC SYSTEM 64 MAINTENANCE STANDARD

-

PPC valve

64- 2

PPC shuttle valve Control valve Hydraulic cylinder Charging pump Work equipment

64- 4 64- 6 64-14 64-16 64-18

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

PC200, 220-3

64-1

MAINTENANCE STANDARD

PPC VALVE

PPC VALVE

-

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

205F2223

Unit: mm

No.

Check Item

Criteria

Remedy

Standard size Free length 1

Center spring

2

Spring

3

Tightening torque for bolt

Repair limit

x 0.0.

Installed length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

31.4 x 7.4

29.4

1.7 kg

-

1.4 kg

Free length

Installed load

Replace spring if any damages or deformation are found

4.5 ± 0.5 kgm Tighten

4

Tightening torque for plug

64-2

-

1.8 ± 0.4 kgm

PC200, 220-3

WRIST CONTROL

MAINTENANCE STANDARD

-

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

Unit: mm No.

Check Item

Criteria

Remedy

Standard size

1

Centering spring (for swing and bucked

Repair limit

Free length x 0.0.

Installed length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

41.8 x 12.6

36.0

2.6 kg

-

2.1 kg

31.4x7.4

29.4

1.7 kg

-

1.4 kg

2

Center spring (for arm and boom)

3

Spring

4

Tightening torque for nut

3.5 ± 0.5 kgm

5

Tightening torque for joint

3.5 ± 0.5 kgm

6

Tightening torque for plug

1.8 ± 0.4 kgm

PC200, 220-3

Free length

Installed load Replace spri ng if any damages or deformations are found

Tighten

64-3 ®

MAINTENANCE STANDARD

LONG LEVER CONTROL

-

LONG LEVER CONTROL 1. PPC VALVE FOR ARM, SWING AND BUCKET LEVER

-

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

205F2223

Unit: mm No.

Check Item

Criteria

Remedy

Standard size Free length 1

Center spring

2

Spring

3

Tightening torque for bolt

Repair limit

x 0.0.

Installed length

Installed load

Free length

Installed load

44.8 x 12.2

36.0

0.9 kg

-

0.7 kg

31.4 x 7.4

29.4

1.7 kg

-

1.4 kg

Replace spring if any damages or deformation are found

4.5 ± 0.5 kgm Tighten

4

Tightening torque for plug

64-4 ®

-

1.8 ± 0.4 kgm

PC200, 220-3

LONG LEVER CONTROL

MAINTENANCE STANDARD

2.

PC200-3 (Serial No. 20001 - 24683) PC220-3 (Serial No. 20001 - 21034)

IN-LINE SERVO VALVE FOR BOOM LEVER

4

3

2

5

7

6

-

www. k omat s upar t s book . c om 205F2222

Unit: mm

-

No.

Standard size

1

-

Remedy

Criteria

Check Item

Spool return spring

2

Input spool and holder

3

Pi lot spool and spacer

Repair limit

Free length x 0.0.

Installed length

Installed load

88.4 x 26.0

37.0

8.0 kg

Free length

-

Installed load 6.4 kg

Confirm the following points. • No scratches on sliding surface • Smooth movement of spool when putting it into valve body

4

Pilot spool

~c

Tester

..c..;:::;

::JO~

000

~..co

I-

~+-'

T-adapter or socket adapter (for DU)

82-22

Short circuit between chassis

Connect

socket adapters to CNP2 (female) Turn starting switch ON.

-

"J()

ground and CNP2 Irnalel to buzzerl-L

Adjust or replace

Short connector

-

T-adapter or socket adapter (forEKONO)

PC200, 220-3

M-10

TROUBLESHOOTING

-

Cause

bl

Remedy

Service meter does not stop moving. T -adapter • When using -

-

Y

E~

2

YES , 1

I

Is voltage between CNPS (3) and (4) OV - 1V?

Do..

3

"N;"~'"

I YES

Short circuit between CNPS (female) (4) - CN20 (14) CN 1 (female) (S) and chassis ground

Repair or replace

move?

1) RemoveCN1. 2) Turn starting switch ON.

I

NO

I

Short circuit between CN 1 (male) (S) - CN3 (female) (1) and chassis ground

Repair or replace

I a www. k omat s up r t s book . c om Does service meter move?

1)

2)

Remove CN6 (engine oil pressure) Turn starting switch ON (do not start engine)

1)

2)

NO

Connect Tadapter to CNS. Turn starting switch ON.

Service meter monitor lamp defective

NO

I,

-

Engine oil pressure sensor

defective

• When using socket

r[0"

-

I

2 ,YES

,

m_..,,,

I

Replace

Replace

Engine oil pressure sensor defective

Short circuit between CN6 (female) (1) - CN1 (male) (S) and chassis ground

Repair or replace

Short circuit between CN1 (female) (S) - CN20 (14) - CNPS (female) (4) and chassis ground

Repair or replace

moving?

I 1)

2)

Remove CNS. Turn starting switch ON.

NO

PC200, 220-3

82-27 (5)

TROUBLESHOOTING

M-10

-

POSITION OF CONNECTORS FOR TROUBLESHOOTING M-10 a-1 Movement of service meter defective

a-2 Check for continuity between CNP9 (female) (3) and (4).

-

www. k omat s upar t s book . c om b-3 Check voltage between CNP9 (3) and (4).

-

82-28 Q)

PC200, 220-3

-

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

-

TROUBLESHOOTING

M-11, M-12

-

Troubleshooting Chart No. M-11 Failure mode: Engine coolant temperature is high, but lowest level displayed.

* Turn the starting switch OFF before disconnecting the connectors or connecting the T -adapter (or socket). * For T -adapters, connect to both the male and female ends; for the socket. connect to the connector marked in (

).

Cause

1

YES

Has display of engine coolant tem-

Remedy

Engine coolant temperature sensor defective

Replace

Disconnection in wiring harness. or defective contact between CN5 Ifemalel (1) 121 - CNl (6) (71 - CN22 (3) (4) - CNP12 (female) (8) (10)

Clean Idefective contactlor replace

peratureJauge dis-

appeare when conneet short socket adapter to CN5'

11 Connect short

NO

connector to CN5 Ifemalel. Turn starting switch ON

21

-

, OJ

~c

Tester

Short connector

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

:>o~

000 ~.