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8/15/2019 Komatsu PC200-6 Shop Manual
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Shop
Manual
CEBMOOOI 2
Pc2 2 1c4PC21OLC=liPC22OlLliPC25OlbiHYDRAULIC EXCAVATOR
PC200 6 A82001PC2OOLC 6 A82001PC21OLC 6 A82001
SERIAL NUMBERS PC22OLC 6 A82001 andup
PC25OLC 6 A82001This material is proprietary to Komatsu America lnternational Company and is not to be reproduced, used, ordisclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to makechanges or add improvements at any time without incurring any obligation to install such changes on products soldpreviously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.It is recommended that customers contact their distributor for information on the latest revision.
00 l
October 1996 Copyright 1996 Komatsu America International Company 0
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CONTENTS
01 GENERAL ............................................. 01-I
IO STRUCTURE AND FUNCTION ............................ IO-I
20 TESTING AND ADJUSTMENT ............................. 20-I
30 DISASSEMBLY AND ASSEMBLY .......................... 30-I
40 MAINTENANCE STANDARD .............................. 40-I
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The affected pages are indicated by using the followingmarks. It is requested that necessary actions be takento these pages according to the table below.
Mark Indication Action
New page to be added Add
Page to be replaced Replace
( 1 Page to be deleted Discard
Pages without marks were previous additions or revisedpages.
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repairtechniques recommended and described in this manual are both effective and safe methods of operation.Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols A and *$ are used to mark safety precautions in this manual. Thecautions accompanying these symbols should always be followed carefully. If any dangerous situation arisesor may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on thefloor. Smoke only in the areas provided for smoking.
Mistakes in operation are extremely dangerous. Read the Never smoke while working.
OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine. PREPARATIONS FOR WORK
1.
2.
3.
4.
5.
6.
I
I
i
3efore carrying out any greasing or repairs, read all:he precautions given on the decals which are fixed to:he machine.
7.
When carrying out any operation, always wear safetyshoes and helmet. Do not wear loose work clothes,)r clothes with buttons missing.
Always wear safety glasses when hitting parts witha hammer.
8.
Always wear safety glasses when grinding partswith a grinder, etc. 9.
f welding repairs are needed, always have a trained,experienced welder carry out the work. When carry-ng out welding work, always wear welding gloves, 10,apron, glasses, cap and other clothes suited forMelding work.
JVhen carrying out any operation with two or moreNorkers, always agree on the operating procedureoefore starting. Always inform your fellow workers
Before adding oil or making repairs, park the ma-chine on hard, level ground, and block the wheels ortracks to prevent the machine from moving.
Before starting work, lower blade, ripper, bucket orany otherwork equipment to the ground. If this is notpossible, insert the safety pin or use blocks to preventthe work equipment from falling. In addition, be sureto lock all the control levers and hang warning signson them.
When disassembling or assembling, support themachine with blocks, jacks or stands before startingwork.
Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting on oroff the machine. Never jump on or off the machine.If it is impossible to use the handrails, ladders orsteps, use a stand to provide safe footing.
sefore starting any step of the operation. Before PRECAUTIONS DURING WORKstarting work, hang UNDER REPAIR signs on thezontrols in the operator’ s compartment. 11.
<eep all tools in good condition and learn the correctNay to use them.
Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools and partsn their correct places. Always keep the work area 12.
When removing the oil filler cap, drain plug or hy-draulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,water or air circuits, first remove the pressure com-pletely from the circuit.
The water and oil in the circuits are hot when the
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SAFETY SAFETY NOTICE
13.
14.
15.
16.
17.
18.
engine is stopped, so be careful not to get burned.Wait for the oil and water to cool before carrying outany work on the oil or water circuits.
Before starting work, remove the leads from thebattery. ALWAYS remove the lead from the negative(-) terminal first.
When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equipmentwhich has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane andoperate slowly to prevent the component from hittingany other part. Do not work with any part still raisedby the hoist or crane.
When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts toremove.
When removing components, be careful not to breakor damage the wiring, Damaged wiring may causeelectrical fires.
When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor, wipeit up immediately. Fuel or oil on the floor can causeyou to slip, or can even start fires.
As a general rule, do not use gasoline to wash parts.In particular, use only the minimum of gasoline when
19
20.
21.
22.
23.
24.
washing electrical parts.
Be sure to assemble all parts again in their originalplaces. Replace any damaged part with new parts.
When installing hoses and wires, be sure thatthey will not be damaged by contact with otherparts when the machine is being operated.
When installing high pressure hoses, make sure thatthey are nottwisted. Damaged tubes are dangerous,so be extremely careful when installing tubes for highpressure circuits. Also check that connecting partsare correctly installed.
When assembling or installing parts, always use thespecified tightening torques. When installing protec-tive parts such as guards, or parts which vibrateviolently or rotate at high speed, be particularlycareful to check that they are installed correctly.
When aligning two holes, never insert your fingers orhand. Be careful not to get your fingers caught in ahole.
When measuring hydraulic pressure, check that themeasuring tool is correctly assembled before takingany measurements.
Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyone standat either end of the track.
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FOREWARD GENERAL
FOREWARD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurateunderstanding of the product and by showing him the correct way to perform repairs and make judgements. Make sureyou 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 the following sections. These sections are further divided into eachmain group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel,coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding ofthe 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 madeat completion of the checks and repairs. Troubleshooting charts correlating “ Problems” to “ Causes” are alsoincluded in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling eachcomponent, 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 advancenotice. Contact your distributor for the latest information.
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FOREWARD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying outrepairs. They are divided as follows:Chassis volume: Issued for every machine model
Engine volume: Issued for each engine seriesElectrical volume: Each issued as one to cover all
When a manual is revised, an edition mark (000 . ..) isrecorded on the bottom outside corner of the pages.
REVISIONS
modelsAttachment volume: Each issued as one to cover all
Revised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.
modelsSYMBOLS
These various volumes are designed to avoid duplicationof information. Therefore to deal with all repairs for anymodel, it is necessary that chassis, engine electrical andattachment be available.
So that the shop manual can be of ample practical use,important places for safety and quality are marked withthe following symbols.
DISTRIBUTION AND UPDATINGSymbol Item Remarks
Any additions, amendments or other changes will be sentto your distributors. Get the most up-to-date informationbefore you start any work.
ASafety
Special safety precautions are nec-essary when performing the work.
FILING METHOD * Caution
Special technical precautions orother precautions for preservingstandards are necessary whenperforming the work.
1
2.
3.
See the page number on the bottom of the page. Filethe pages in correct order.Following examples show how to read the pagenumber:Example 1 (Chassis volume):
Y
Item number (10. Structure andFunction)
Consecutive page number foreach item
Example 2 (Engine volume):Refer to the pertinent engine manual.
Additional pages: Additional pages are indicated by ahyphen (-) and numbered after the page number. Fileas in the example.Example:1 o-41 o-4-11 O-4-2 I
Added pages
el Weight
Weight of parts or systems. Cau-tion necessary when selectinghoisting wire or when working pos-ture is important, etc.
Tightening
Places that require special atten-
torque tion for tightening torque duringassembly.
CoatPlaces to be coated with adhesivesand lubricants etc.
Oil, waterPlaces where oil, water or fuelmust be added, and the capacity.
Places where oil or water must be
.t. Drain drained, and quantity to bedrained.
1 o-5
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FOREWARD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
&iHeavy parts (25 kg or more) must be lifted witha hoist etc. In the DISASSEMBLY AND AS-
SEMBLY section, every part weighing 25 kg or moreis indicated clearly with the symbol
6 kg
If a part cannot be smoothly removed from themachine by hoisting, the following checks should bemade:1) Check for removal of all bolts fastening the part
to the relative parts.2) Check for existence of another part causing
interface with the part to be removed.
WIRE ROPES1) Use adequate ropes depending on the weight of
parts to be hoisted, referring to the table below:
Wire ropes(Standard “ Z” or “ S” wist ropes without galvanizing
Rope diameter (mm) Allowable load (tons)
10.0 1.011.2 1.4
12.5 1.614.0 2.216.0 2.818.0 3.620.0 4.422.4 5.630.0 10.040.0 18.050.0 28.060.0 40.0
* The allowable load value is estimated to be 116 or
I/7 of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of thehook. Slinging near the edge of the hook maycause the rope to slip off the hook during hoisting,and a serious accident can result. Hooks havemaximum strength at the middle portion.
100% 88% 79% 71% 41%
FSO 64
3) Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.
Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the rope,
or slipping of the rope from its original winding posi-
tion on the load, which can result in a dangerousaccident.
4) Do not sling a heavy load with ropes forming a widehanging angle from the hook. When hoisting a loadwith two or more ropes, the force subjected to eachrope will increase with the hanging angles. Thetable below shows the variation of allowable load(kg) when hoisting is made with two ropes, each ofwhich is allowed to sling up to 1000 kg vertically, atvarious hanging angles. When two ropes sling aload vertically, up to 2000 kg of total weight can besuspended. This weight becomes 1000 kg whentwo ropes make a 120” hanging angle. On theother hand, two ropes are subject to an excessiveforce as large as 4000 kg if they sling a 2000 kgload at a lifting angle of 150” .
6 ’ 9
Lifting angle : ct
12 ” 15 ”
FSO 65
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FOREWARD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category 1 Code 1 Part No. Main aoolicationsfeatures
LT-IAI
790-I 29-9030
Qty
150g
790 I 9-9050 20 9 ca
50 g
790 I 9 9060
Set of adhesiveand hardening
agent
Adh 1 kgHard agt
500 kg
790-I 29-9040 250 g
50 cc
790 l 9 9010 200 g
790 I 9-9070 1 kg
790 I 9-9020 200 g
790 I 9 9080 1 kg
09940 00011 250 g
09920-00150 1509
09940 00051
09940-00040
60 g
200 g
SYG-35OLISYG-400LI
SYG-400LI-ASYG-160LI
SYGA-1 GOCNLI
SSG2-400CA
SYG2-350CASYG2-400CA-A
SYGZ-I 60CASYGA-1 GCNCA
Various
Various
SYG2-400M400 g
(1 O/case)
Container
TubeUsed to prevent r ubber gaskets, rubber cushions and cork plugs fromcoming out
Plasticcontainer
Plasticcontainer
Used in places requiring an immediately effective, strong adhesive.
Used for plastics (except polyethylene. polypropylene,tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
Features: Resistance to heat, chemicalsUsed for anti-loosenina and sealant ourooses for bolts and oluas.
Can Used as adhesive or sealant for metal, glass or plastic.
Plasticcontainer
Used as sealant for machined holes.
___ Features: Resistance to heat, chemicalsUsed at joint portions subject to high temperature.
TubeUsed as adhesive or sealant for gaskets and packing of power traincase, etc.
Can
Features: Resistance to heatUsed as sealant for flange surfaces and bolts at high temperaturelocations; used to prevent seizure.Used as sealant for heat resistant gasket for at high temperaturelocations such as engine pre-combustion chamber, exhaust pipe.
Tube
Features: Resistance towater, oilUsed as sealant for flange surface, thread.Also possible to use as sealant for flanges wi th lar ge clearance.Used as sealant for mating surfaces of final drive case, transmissioncase.
Plasticcontainer
Used as sealant for various threads, pipe joints, flanges.Used as sealant for tapered plugs, elbows, nipples of hydraulicpiping.
Features: Silicon based, resistant to heat, cold.Tube Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case, etc.
TubeFeatures: Silicon based, quick hardening type.Used as sealant for flywheel housing, intake manifold, oil pan,thermostat housing, etc.
Can Used as lubricant for sliding parts (to prevent squeaking).
TubeUsed to prevent seizure or scuffing of the thread when press fitting orshrink fitting.Used as lubricant for linkage, bearings, etc.
Various General purpose type
VariousUsed for normal temperature, light load bearing at places in contactwith water or steam.
Bellows type Used for places with heavy load.
LT-1 B
Adhesive
LG-1
tLG-3
LG-4
Gasket sealant
LG-7
I
Rust oreven- I
Lithium grease G2-Ll
+
Calcium grease G2-CA
I
Molybdenumdisultide grease ---
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FOREWARD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections ofDISASSEMBLY AND ASSEMBLY.
1 kam = 9.806 Nm
Thread diameter of bolt Width across flat 0 0mm mm km Nm
6 10 1.35 *0.15 13.2 *I .4
8 13 3.20 kO.3 31.4 *2.9
10 17 6.70 *0.7 65.7 56.8
12 19 11.5 *I .o 112 kg.8
14 22 18 k2.0 177 *I9
16 24 28.5 &3 279 *29
18 27 39 *4 383 *39
20 30 56 *6 549 i58
22 32 76 *8 745 *78
24 36 94.5 iI0 927 *98
27 41 135 *I5 1320 *I 40
30 46 175 *20 1720 *I 90
33 50 225 *25 2210 &240
36 55 280 *30 2750 i290
39 60 335 i35 3280 *340
k This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are tobe used, or which require tightening to otherwise specified torque.
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FOREWARD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter of bolt
mm
10
12
16
Width across flat
mm
14
17
22
Tightening torque
kgm Nm
6.70 *0.7 65.7 k6.8
11.5 &I .o 112 k9.8
28.5 k3 279 *29
TIGHTENING TORQUE FOR FLAIRED NUTS
Use these torques for flaired part of nut. cm483
Thread diameter of bolt Width across flat I Tightening torque
mm mm kgm Nm
14 19 2.5 k0.5 24.5 k4.918 24 5 *2 49 &I 9.6
22 27 8 *2 78.5 *I 9.6
24 32 14 i3 137.3 Q9.4
30 36 18k3 176.5 i29.4
33 41 20 zt5 196.1 zk49
36 46 25 k5 245.2 k49
42 55 30 *5 294.2 *49
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FOREWARD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire codetable will help you understand WIRING DIAGRAMS.Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Cable Current ratingO.D. (mm) (A)
Nominalnumber
0.85
2
5
Copper wire
Number of Dia. Of strandstrands (mm)
11 0.32
26 0.32
65 0.32
Applicable circuit
Starting, lighting, signal etc.
Lighting, signal etc.
Charging and signal
Starting (Glow plug)5 1 1 0.454 13.36 I 159.0
40 1 1 0.805 42.73 I ’351.4 Starting
60 1 1 0.8027 63.84 I 783.6 Starting
100 1 217 I 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Priority Lighting Instruments Signal 1 Otherlassification Circuits Charging Ground Starting
R Y1
Code W B BPrimary
Color White Black Black Red Yellow
RW YR2
Code
Color
Code
Color
Code
WR ___
White/Red --
WB ___
White/Black ---
WL _-
BW
Black/White
BY
BlXk/Yt?lOW
BR
Yellow/Red Green/White Bluewhite
RB
Red/Black
RY
YB
Yellow/Black
YG
3
GY I LY4
I Color I White/Blue I --- I Black/Red Red/Yellow Yellow/Green reenNellow BlueNellow
YL
Yellow/Blue
YW
RG
Red/Green
RL
6 Red/Blue Green/Blue I --
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FOREWARD CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of the method ofusing the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.1. Convert 55 mm into inches.(1) Locate the number 50 in the vertical column at the left side, take this as 0, then draw a horizontal line from
0.(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from @.(3) Take the point where the two lines cross as 0. This point @ gives the value when converting from millimeters
to inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by IO (move the decimal one place to the left) to
convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by IO, so multiply 2.165 inches by IO (move the decimal one place
to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches1 mm = 0.03937 in
mm 0 1 2 3 4 50 6 7 8 9
0.039 0.079 0.118 0.157 0 197
IO 0.394 0.433 0.472 0.512 0.551 0 591
20 0.787 0.827 0.866 0.906 0.945 0 984
30 1.181 1.220 1.260 1.299 1.339 1.378
40 1.575 1.614 1.654 1.693 1.732 1.772
3 50 1.969 2.008 2.047
60 2.362 2.402 2.441
2.087 2.126
2.480 2.520
2.874 2.913
3.268 3.307
3.661 3.701
2.165
2.559
2.953
3.346
3.740
70 2.756 2.795 2.835
80 3.150 3 189 3.228
90 3.543 3.583 3.622
0.236
0.630
1.024
1.417
1.811
0
2.2052.598
2.992
3.386
3.780
0.276 0.315 0.354
0.669 0.709 0.748
1.063 1.102 1.142
1.457 1.496 1.536
1.850 1.890 1.929
2.244 2.283 2.323
2.638 2.677 2.717
3.032 3.071 3.110
3.425 3.465 3.504
3.819 3.858 3.898
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FOREWARD CONVERSIONTABLES
Millimeterstolnches
1 mm=O O3937in
mm 0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0 118 0 157 0 197 0 236 0 276 0 315 0 354
10 0.394 0 433 0 472 0 512 0 551 0.591 0 630 0 669 0 709 0 748
20 0 787 0 827 0 866 0 906 0 945 0 984 1 024 1 063 1 102 1 142
30 1 181 1 220 1 260 1 299 1 339 1 378 1 417 1 457 1 496 1 536
40 1 575 1 614 1 654 1 693 1 732 1 772 1 811 1 850 1 890 1 929
50 1 969 2 008 2 047 2 087 2 126 2 165 2 205 2 244 2 283 2 323
60 2 362 2 402 2 441 2 480 2 520 2 559 2 598 2 638 2 677 2 717
70 2 756 2 795 2 835 2 874 2 913 2 953 2 992 3 032 3 071 3 110
80 3 150 3 189 3 228 3 268 3 307 3 346 3 386 3 425 3 465 3 504
90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898
Kilogramto Pound1 kg = 2 2046 lb
Tg 0 1 2 3 4 5 6 7 8 9
02 20 4 41
6 61 8 82 11 02 13 23 15 43 17 64 19 8410 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89
20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 53 61 73 63 93
30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98
40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03
50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07
60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12
70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17
80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 196 21
90 198 42 200 62 202 83 205 03 207 24 209 44 211 64 213 85 216 05 218 26
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FOREWARD CONVERSIONTABLES
Literto S Gallon
e = 0 26r
8
I U.S. Ga
90 1 2 3 4 5 6 7
0 0 0 264 0 528 0.793 1 057 1 321 1 585 1 849 2 113 2 378
10 2 642 2 906 3 170 3 434 3 698 3 963 4 227 4 491 4 755 5 019
20 5 283 5 548 5 812 6 076 6 340 6 604 6 869 7 133 7 397 7 661
30 7 925 8 189 8 454 8 718 8 982 9 246 9 510 9 774 10 039 10 303
40 10 567 10 831 11 095 11 359 11 624 11 888 12 152 12 416 12 680 12 944
50 13 209 13 473 13 737 14 001 14 265 14 529 14 795 15 058 15 322 15 586
60 15 850 16 115 16 379 16 643 16 907 17 171 17 435 17 700 17 964 18 228
70 18 492 18 756 19 020 19 285 19 549 19 813 20 077 20 341 20 605 20 870
80 21 134 21 398 21 662 21 926 22 190 22 455 22 719 22 983 23 247 23 511
90 23 775 24 040 24 304 24 568 24 832 25 096 25 361 25 625 25 889 26 153
Literto K Gallon
le = 0 21997 U K Gal
Q 1 2 3 4 5 6 7 8 9
0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980
10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179
20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6.379
30 6 599 6 819 7 039 7 259 7 479 7 699 7 919 8 139 8 359 8.579
40 8 799 9 019 9 239 9 459 9 679 9 899 10 119 10 339 10 559 10 778
50 10 998 11 281 11 438 11 658 11 878 12 098 12 318 12 528 12 758 12 978
60 13 198 13 418 13 638 13 858 14 078 14 298 14 518 14 738 14 958 15 178
70 15 398 15 618 15 838 16 058 16 278 16 498 16 718 16 938 17 158 17 378
80 17 598 17 818 18 037 18 257 18 477 18 697 18 917 19 137 19 357 19 577
90 19 797 20 017 20 237 20 457 20 677 20 897 21 117 21 337 21 557 21 777
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FOREWARD CONVERSION TABLES
kgm to ft. lb1 kam = 7 233 t b
km
0
10
20
30
40
0 1 2 3 4 5 6 7 I 8 9
0 7 2 14 5 21 7 28.9 36 2 43 4 50 6 57.9 65 1
72 3 79 6 86 8 94 0 101 3 108 5 115 7 123 0 130 2 137 4
144 7 151 9 159 1 166 4 173 6 180 8 188 1 195 3 202 5 209 8
217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1
289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4
50 361 7 368 9 376 1 383 4 390 6 397 8 405 1 412 3 419 5 426 8
60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1
70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4
80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 3 636 5 643 7
90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1
100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4
110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7
120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1
130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 1005 4
140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077 7
150 1084 9 1092 2 1099 4 1106 6 1113 9 1121 1 1128 3 1135 6 1142 8 1150 0
160 1157 3 1164 5 1171 7 1179 0 1186 2 1193 4 1200 7 1207 9 1215 1 1222 4
170 1129 6 1236 8 1244 1 1251 3 1258 5 1265 8 1273 0 1280 1 1287 5 1294 7
180 1301 9 1309 2 1316 4 1323 6 1330 9 1338 1 1345 3 1352 6 1359 8 1367 0
190 1374 3 1381 5 1388 7 1396 0 1403 2 1410 4 1417 7 1424 9 1432 1 1439 4
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kg/cm2 to lb/in2
kg/cm2
0
10
20
30
40
0 1 2 3 4 5 6
Ik
7 8 9
0 14 2 28 4 42 7 56 9 71 1 85 3 99 6 113 8 128 0
142 2 156 5 170 7 184 9 199 1 213 4 227 6 241 8 256 0 270 2
284 5 298 7 312 9 327 1 341 4 355 6 369 8 384 0 398 3 412 5
426 7 440 9 455 1 469 4 483 6 497 8 512 0 526 3 540 5 554 7
568 9 583 2 597 4 611 6 625 8 640 1 654 3 668 5 682 7 696 9
50 711 2 725 4 739 6 753 8 768 1 782 3 796 5 810 7 825 0 839 2
60 853 4 867 6 881 8 896 1 910 3 924 5 938 7 953 0 967 2 981 4
70 995 6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 126690 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
:m2 14 22331b/in2
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FOREWARD
Temperature
CONVERSION TABLES
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa isto enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigradedegrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and readthe corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider thecenter column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
“ “F C “F “C “F “ “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.226.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
I ( = 33.8”F
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01 GENERAL
General assembly drawing (PC200-6, PC2OOLC-6, PC21OLC-6)General assembly drawing (PC22OLC-6, PC25OLC-6) .......Specifications (PC200-6, PC2OOLC-6) .....................Specifications (PC21 OLC-6) .............................Specifications (PC220LC-6) .............................Specifications (PC25OLC-6) .............................Weight table (PC200-6, PC200LC-6) ......................Weight table (PC21 OLC-6) ..............................Weight table (PC22OLC-6, PC25OLC-6) ...................Fuel, coolants and lubricants ............................
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.Ol- 2
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PC200-6, PC200LC-6, PC21 OLC-6
XOlAD 24
Unit: mm
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GENERAL GENERAL ASSEMBLY DRAWING
XOlAD025
Unit: mmI I I
A
PC200-6, PC2OOLC-6PC21 OLC-6
Maximum digging height
1.84m 2.4 m
8,895 9,050
Arms
* 2.93 m ** 4.06 m
9,305 9,700
B Maximum dumping height 6,065 6,255 6,475 6,970
C Maximum digging depth 5,535 6,095 6,602 7,725
I IMaximum vertical wallI
4,965I
5,315digging depth
5 980 I 7,075
I
E Maximum digging depth of 5,160 5,840 6,435 7,590cut for 8 ’ evel
F Maximum digging reach 8,915 9,395 9,875 10,880
G Maximum digging reach at 8,720 9,205 9,700 10,705ground
H Minimum swing radius 3,640 3,710 3,630 3,630
Bucket digging force *** + 14,900 kg
Arm crowd force *** 13,200 kg
* - PC21 OLC-6 available with only this arm** - 1 .I 3 m Extension + 2.93 m arm
12,700 kg 12,700 kg 12,700 kg
11,700 kg 10,000 kg 8,200 kg
*** - At power max’ - Optional bucket cylinder is required
01 3
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GENERAL
PC22OLC-6, PC25OLC-6
GENERAL ASSEMBLY DRAWING
/F
XOlAD 24
Q Machine cab height 2,020 2,140
R Engine compartment height 2,255 2,375
S Operator’ s cab height 2,905 3,020
01 4
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GENERAL GENERAL ASSEMBLY DRAWING
t
1
A
t
1XOlAD025
PC22OLC 6
2.0 m 2.5 m
Arms
Unit: mm
3.05 m 3.5 m
A Maximum digging height 9,070 9,150 9,380 9,620I I I I I
B 1 Maximum dumping height 1 6,120 I 6,215 I 6,515 6,720
D
Maximum digging depth
Maximum vertical walldigging depth
5,720 6,220 6,770 7,220
4,955 5,455 6,005 6,455
E Maximum digging depth of 5,550 6,170 6,440 7,210cut for 8 ’ evel
F
G
Maximum digging reach 9,285 9,655 10,180 10,625
Maximum digging reach at 9,090 9,470 10,000 10,460ground
H Minimum swing radius 3,950 3,925 3,860 3,890
I I I IBucket digging force * +I 6,700 kg 14,500 kg 14,500 kg 14,500 kg 1
Arm crowd force * 14,700 kg 13,600 kg
’ -At power max ’ - Optional bucket cylinder is required
11,900 kg 10,300 kg
01 5
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GENERAL GENERAL ASSEMBLY DRAWING
XOIAD025
Unit: mm
PC25OLC6 Arms
I 2.0 m I 2.5 m I 3.05 m I 3.5 m I
A Maximum digging height 9,300 9,340 9,660 9,780
B Maximum dumping height 6,505 6,350 6,750 7,125
Maximum digging depth 5,610 6,105 6,650 7,105
Maximum vertical wall 4,930 5,055 5,860 6,165digging depth
Maximum digging depth of 5,380 5,895 6,475 6,950cut for 8 ’ evel
F Maximum digging reach 9,285 9,655 10,180 10,625
G Maximum digging reach at 9,035 9,445 9,980 10,385ground
H Minimum swing radius 3,950 3,925 3,860 3,890
Bucket digging force * +I 6,700 kg 14,500 kg 14,500 kg 14,500 kg
Arm crowd force * 14,700 kg 13,600 kg 11,900 kg 10,300 kg
’ -At power max ’ - Optional bucket cylinder is required
01 6
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GENERAL SPECIFICATIONS
PC200-6, PC2OOLC-6
Machine Model
Serial numbers
Bucket capacity (m3)
Operating weight (kg)
Maximum digging depth
Maximum vertical wall depth
Maximum digging reach
Maximum digging reach at ground level
Maximum digging height
Maximum dumping height
Maximum digging force (when using power max.)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(Wkg))
Swing speed
Swing maximum slope angle
(rpm)
(deg.)
Travel speed
Gradeability
(km/h)
(deg.)
Ground pressure I (standard triple shoe width: mm)
Overall length (for transport)
Overall width
Overall width of track
Overall height (for transport)
Overall height to top of cab
Ground clearance of counterweight
Minimum ground clearance
Tail swing radius
Minimum swing radius of work equipment
Height of work equipment at minimum swing radius
Length of track on ground
Track gauge
Height of machine cab
(MPa(kg/cm*))
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
PC200-6 PC2OOLC-6
A82001 and up A82001 and up
0.8 0.8
19,900 21,300
6,620 6,620
5,980 5,980
9,875 9,875
9,700 9,700
9,305 9,305
6,475 6,475
111.7 (11,400) 111.7 (11,400)(124.5 (12,700)) (124.5 (12,700))
11.5 11.5
20 20
Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
35 35
0.045 (0.46) I(600) 0.037 (0.38) I(700)
9,425 9,425
2,800 2,800
2,780 3,080
2,970 2,970
2,905 2,905
1,085 1,085
440 440
2,750 2,750
3,630 3,630
7,570 7,570
3,270 3,348
2,180 2,380
2,255 2,255
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GENERAL SPECIFICATIONS
Machine model
Serial numbers
Model
Type
No. of cylinders - bore x stroke
Piston displacement
(mm)
(cc)
Flywheel horsepower
Maximum torque
High idle in H/O mode
Low idle in H/O mode
Minimum fuel consumption ratio
(kW(HP)/rpm)
(Nm(kgmYrpm)
(rpm)
(rpm)
(g/kWh(g/HPh)
Cranking motor
Alternator
Battery
Type of radiator core
Carrier roller
Track roller
Track shoe
0i
2
a4$2
Type, number
Delivery (Plmin)
Set pressure (MPa(kg/cm’ ))
Type, number
Control method Hydraulic type
Travel motor
Swing motor
Hydraulic cylinder
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC200-6 PC2OOLC-6
A82001 and up A82001 and up
S6D102-1
Ccycle, water-cooled, in-line, vertical, direct injection,with turbocharger
6-102x120
5,880
108.1 (145) / 2,200
576.6 (58.8) / 1,600
2130?60
1066?60
210 (155)
24 V, 5.5 kW
24V,45A
12V, 150Ahx2
cwx-4
~
Variable displacement piston type x 2,gear type x 1
Piston type: 206 x 2
gear type: 30
Piston type: 34.79 (355)gear type: 3.33 (34)
6-spool type x 1
Piston type (with brake valve, parking brake) x 2
Piston type (with safety valve, parking brake) x 1
Reciprocating piston
Box-shaped, open
Tank return side
Air cooled (SF-3)
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GENERAL SPECIFICATIONS
PC21 OLC-6
Machine Model
Serial numbers
Bucket capacity
Operating weight
(m’ )
(kg)
Maximum digging depth
Maximum vertical wall depth
Maximum digging reach
Maximum digging reach at ground level
Maximum digging height
Maximum dumping height
Maximum digging force (when using power max.)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(Wkg))
Swing speed (rpm)
Swing maximum slope angle (deg.)
Travel speed
Gradeability
(km/h)
(deg.)
Ground pressure I (standard triple shoe width: mm)
Overall length (for transport)
Overall width
Overall width of track
Overall height (for transport)
Overall height to top of cab
Ground clearance of countenveight
Minimum ground clearance
Tail swing radius
Minimum swing radius of work equipment
Height of work equipment at minimum swing radius
Length of track on ground
Track gauge
Height of machine cab
(MPa(kg/cm’ ))
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
PC21 OLC-6
A82001 and up
0.8
23,210
6,620
5,355
9,875
9,700
9,180
6,475
111.7 (11,400)(124.5 (12,700))
11.5
20
Lo: 3.0 Mi: 4.1 Hi: 5.5
35
0.053 (0.54) I(600)
9,515
2,800
3,080
2,970
2,905
1,085
440
2,750
3,630
7,570
3,646
2,380
2,255
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Machine model
Jlodel
fype
\lo. of cylinders - bore x stroke
‘ iston displacement
(mm)
(cc)
Flywheel horsepower
Maximum torque
High idle in H/O mode
Low idle in HI0 mode
Minimum fuel consumption ratio
(kW(HP)lrpm)
(Nm(kgmYrpm)
(rpm)
(rpm)
(g/kWh(glHPh)
Zranking motor
Uternator
3attery
Type of radiator core
Carrier roller
PC21 OLC-6
A82001 and up
S60102-1
Qcycle, water-cooled, in-line, vertical, direct injection,with turbocharger
6-102x120
5,880
108.1 (145) / 2,200
576.6 (58.8) I 1,600
2130?60
1066?60
210 (155)
24 V, 5.5 kW
24V,45A
12V, 150Ahx2
cwx-4
2 on each side
Track roller 9 on each side
Track shoe Assembly-type triple grouser
Variable displacement piston type x 2,gear type x 1
Type, number
Delivery (Plmin)
Set pressure (MPa(kg/cm’ ))
Type, number
Travel motor
Swing motor
iydraulic cylinder
-hydraulic tank
tiydraulic filter
Hydraulic cooler
Piston type: 206 x 2gear type: 30
Piston type: 34.79 (355)gear type: 3.33 (34)
7-spool type x 1
Hydraulic type
Piston type (with brake valve, parking brake) x 2
Piston type (with safety valve, parking brake) x 1
Reciprocating piston
Box-shaped, open
Tank return side
Air cooled (SF-3)
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GENERAL SPECIFICATIONS
PC220LC-6
Machine Model
Serial numbers
Bucket capacity (m3)
Operating weight (kg)
Maximum digging depth
Maximum vertical wall depth
Maximum digging reach
Maximum digging reach at ground level
Maximum digging height
Maximum dumping height
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
Maximum digging force (when using power max.) (Wkg))
Swing speed
Swing maximum slope angle
Travel speed
Gradeability
Ground oressure I (standard triple shoe width: mm)
(rpm)
(deg.)
(km/h)
(deg.)
(MPa(kg/cm’ ))
Overall length (for transport)
Overall width
Overall width of track
Overall height (for transport)
Overall height to top of cab
Ground clearance of counterweight
Minimum ground clearance
Tail swing radius
Minimum swing radius of work equipment
Height of work equipment at minimum swing radius
Length of track on ground
Track gauge
Heiaht of machine cab
(mm)
0-W
(mm)
G-4
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
PC22OLC6
A82001 and up
1 o
23,550
6,920
6,010
10,180
10,000
9,380
6,515
130.3 (13,300)(142.1 (14,500))
11.5
17.5
Lo: 3.0 Mi: 4.1 Hi: 5.5
35
0.040 (0.41) / (700)
9,780
3,280
3,280
3,160
2,905
1,085
440
2,860
3,860
7,760
3,830
2,580
2,255
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GENERAL SPECIFICATIONS
Machine model
Serial numbers
Model
Type
No. of cylinders - bore x stroke
Piston displacement
(mm)
(cc)
Flywheel horsepower
Maximum torque
High idle in H/O mode
Low idle in H/O/ mode
Minimum fuel consumption ratio
(kW(HP)/rpm)
(Nm(kgm)/rpm)
(rpm)
(rpm)
(g/kWh(g/HPh)
Cranking motor
Alternator
Battery
Type of radiator core
Carrier roller
PC22OLC-6
A82001 and up
SAGDI 02-I
Ccycle, water-cooled, in-line, vertical, direct injection,with turbocharger
6-102x120
5,880
129.8 (174) I 2,300
624.7 (63.7) I 1,500
2300 f 60
1066*60
212 (156)
24 V, 5.5 kW
24V,45A
12V, 150Ahx2
cwx-4
2 on each side
Track roller 10 on each side
Track shoe Assembly-type triple grouser
Variable displacement piston type x 2,gear type x 1
Type, number
Delivery (Plmin)
Set pressure (MPa(kg/cm*))
Type, number
Travel motor
Swing motor
Hydraulic cylinder
Hydraulic tank
Hydraulic filter
Hvdraulic cooler
Piston type: 215 x 2gear type: 31
Piston type: 34.79 (355)gear type: 3.33 (34)
6-spool type x 1
Hydraulic type
Piston type (with brake valve, parking brake) x 2
Piston type (with safety valve, parking brake) x 1
Reciprocating piston
Box-shaped, open
Tank return side
Air cooled (SF-3)
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GENERAL SPECIFICATIONS
PC25OLC-6
Machine Model
Serial numbers
Bucket capacity (m3)
Operating weight (kg)
Maximum digging depth
Maximum vertical wall depth
Maximum digging reach
Maximum digging reach at ground level
Maximum digging height
Maximum dumping height
Maximum digging force (when using power max.)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(Wkg))
Swing speed
Swing maximum slope angle
Travel speed
Gradeability
Ground pressure I (standard triple shoe width: mm)
Overall length (for transport)
Overall width
Overall width of track
Overall height (for transport)
Overall height to top of cab
Ground clearance of counterweight
Minimum ground clearance
Tail swing radius
Minimum swing radius of work equipment
Height of work equipment at minimum swing radius
Length of track on ground
Track gauge
Height of machine cab
(rpm)
(deg.)
(km/h)
(deg.)
(MPa(kg/cm*))
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
PC25OLC-6
A82001 and up
1.0
27,500
6,650
6,580
10,180
9,980
9,660
6,750
130.3 (13,300)(142.1 (14,500))
11.5
17.5
Lo: 2.2 Mi: 4.1 Hi: 5.1
35
0.045 (0.46) I(700)
9,780
3,290
3,290
3,250
3,050
1,205
500
2,860
3,860
7,880
3,945
2,580
2,375
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GENERAL SPECIFICATIONS
Machine model
Serial numbers
Vlodel
Type
Vo. of cylinders - bore x stroke
‘ iston displacement
(mm)
(cc)
Flywheel horsepower
Maximum torque
High idle in H/O/ mode
Low idle in H/O mode
Minimum fuel consumption ratio
(kW(HP)/rpm)
(Nm(kgmYrpm)
(rpm)
(rpm)
(glkWh(glHPh)
Cranking motor
Alternator
3attery
Type of radiator core
Carrier roller
cwx-4
2 on each side
Track roller 10 on each side
Track shoe Assembly-type triple grouser
Type, number
Delivery (Plmin)
Set pressure (MPa(kg/cm’ ))
Type, number
Travel motor
Swing motor
Hydraulic cylinder
Hydraulic tank
Hydraulic filter
Hydraulic cooler
f
PC25OLC-6
A82001 and up
SAGDI 02-I
Ccycle, water-cooled, in-line, vertical, direct injection,with turbocharger
6-102x120
5,880
129.8 (174) I 2,300
624.7 (63.7) / 1,500
2300 f 60
1066?60
212 (156)
24 V, 5.5 kW
24V,45A
12V, 150Ahx2
Variable displacement piston type x 2,gear type x 1
Piston type: 215 x 2gear type: 31
Piston type: 34.79 (355)gear type: 3.33 (34)
6-spool type x 1
Hydraulic type
Piston type (with brake valve, parking brake) x 2
Piston type (with safety valve, parking brake) x 1
Reciprocating piston
Box-shaped, open
Tank return side
Air cooled (SF-3)
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GENERAL WEIGHT TABLE
PC200-6, PC2OOLC-6
Machine model
Serial number
Engine assembly
Engine
Damper
Hydraulic pump
Radiator oil cooler assembly
Hydraulic tank ilter assembly (excl. oil)
Fuel tank assembly (excl. fuel)
Revolving frame
Operator’ s cab
Operator’ s seat
Counterweight
Swing machinery
Control valve
Swing motor
Travel motor
Center swivel joint
Track frame assembly
Track frame
0 Swing circle
Idler
Idler cushion
Carrier roller
Track roller
Travel motor inal drive
Track shoe assembly
Standard triple grouser shoe (600 mm)
Standard triple grouser shoe (700 mm)
Wide triple grouser shoe (800 mm)
Wide triple grouser shoe (900 mm)
PC200-6
A82001 and up
684
480
6
142
144
133
114
1,637
287
29
3,280
205
230
9
123x2
42
4,666
2,374
276
140x2
135x2
21 x4
38x14
425x2
Unit: kg
PC2OOLC-6
A82001 and up
684
48
6
142
144
133
114
1,637
287
29
3,280
205
230
9
123x2
42
5,308
2,864
276
140x2
135x2
21 x4
38x18
425x2
1,310x2 1,425 x 2
1,435x2 1,565 x 2
1,565 x 2 1,705x2
1,690 x 2 1.840x2
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GENERAL WEIGHT TABLE
Boom assembly
Arm assembly
Bucket assembly
Boom cylinder assembly
Arm cylinder assembly
Bucket cylinder assembly
Link (large) assembly
Link (small) assembly
Boom pin
Arm pin
Bucket pin
Link pin
Machine model
Serial number
Unit: kg
PC200-6 PC2OOLC-6
A82001 and up A82001 and up
1,334 1,334
620 620
623 623
187x2 187x2
251 251
155 155
78 78
22x2 22x2
43+10x2+25+10+20 43+10x2+25+10+20
10x2 10x2
20x2 20x2
13x2 13x2
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GENERAL WEIGHT TABLE
PC21 OLC-6
Machine model PC21 OLC-6
Unit: kc
Serial number I A82001 and up
Engine assembly I 685
Engine 480
Damper 6
Hydraulic pump 142
Radiator oil cooler assembly I 144
Hydraulic tank ilter assembly (excl. oil) I 133
Fuel tank assembly (excl. fuel) 114
Revolving frame 1,982
Operator’ s cab
Operator’ s seat
Counterweight
290
29
4,730
Swing machinery 205
Control valve
Swing motor
Travel motor
230
I 9
123x2
Track frame assembly
Track frame
0 Swing circle
Idler
Idler cushion
0 Carrier roller
Track roller
Travel motor inal drive
Track shoe assembly
Standard triple grouser shoe (600 mm)
Standard triple grouser shoe (700 mm)
Wide triple grouser shoe (800 mm)
Wide triple grouser shoe (900 mm)
Center swivel joint 42
5,318
2,870
280
140x2
135x2
21 x4
38x18
425x2
1,425 x 2
1,565 x 2
_
-
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GENERAL WEIGHT TABLE
Machine model I PC21 OLC-6 I
Serial number A82001 and up
Boom assembly
Arm assembly
Bucket assembly
Boom cylinder assembly
753
187x2
Arm cylinder assembly
Bucket cylinder assembly
251
155
Link (large) assembly 78
Link (small) assembly 22x2
Boom pin 43+10x2+32+10+26
Arm pin 10x2
Bucket pin
Link pin 13x2
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GENERAL WEIGHT TABLE
PC22OLC-6, PC250LC-6
Machine model
Serial number
Engine assembly
Engine
Damper
Hydraulic pump
Radiator oil cooler assembly
Hydraulic tank ilter assembly (excl. oil)
Fuel tank assembly (excl. fuel)
Revolving frame
Operator’ s cab
Operator’ s seat
Counterweight
Swing machinery
Control valve
Swing motor
Travel motor
Center swivel joint
Track frame assembly
Track rame
0 Swing circle
Idler
Idler cushion
0 Carrier roller
Track roller
Travel motor inal drive
Track shoe assembly
Standard triple grouser shoe (600 mm)
Standard triple grouser shoe (700 mm)
Wide triple grouser shoe (800 mm)
Wide triple grouser shoe (900 mm)
PC220LC-6
A82001 and up
699
495
6
142
163
133
114
1,965
287
29
4,300
205
230
9
123x2
42
5,809
3,286
280
140x2
135x2
21 x4
38x20
425x2
Unit: kg
PC25OLC-6
A82001 and up
699
495
6
142
163
133
114
1,910
287
29
4,730
205
230
9
123x2
42
7,682
4,312
716
166x2
257x2
31 x4
52x16
426x2
1480x2 3,730 x 2
1,625 x 2 4,090 x 2
1,770 x 2 4,455 x 2
_ _
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GENERAL WEIGHT TABLE
Machine model PC22OLC-6
Unit: kg
PC25OLC-6
Boom assembly
Serial number A82001 and up
1,627
A82001 and up
1,627
Arm assemblv I 710 I 710
Bucket assembly
Boom cvlinder assemblv
747 747
215x2 215x2
Arm cylinder assembly 296 296
Bucket cylinder assembly 183 183
Link (large) assembly
Link (small) assembly
80 80
22x2 22x2
Boom pin
Arm pin
51 +10x2+31 +10+26 51 +10x2+31 +10+26
10x2 10x2
Bucket pin
Link pin
20x2 20x2
17x2 17x2
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GENERAL FUEL, COOLANTS AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY @‘ )RESERVOIR KIND OF
FLUID Specified Refill22 -4 14 32 50 68 86 104°F-30 -20 -10 0 10 20 30 40°C
Engine oil pan 23.5 22.5
Damper case
Swing machinery case 6.8 6.8
6.3 5.5PC25OLC-6 PC25OLC-6
8.0 7.4Final drive case (each) Engine oil
0.07 - 0.08 0.07 - 0.08
0.19 - 0.21 0.19 - 0.21
Idler (each)
Track roller (each)
0.23 - 0.25 0.23 - .025arrier roller (each)
Pc200,Pc210239
Hydraulic system PC22O,PC250246
166
Fuel tank Diesel fuel 310_
Pc200,Pc21022.6
Coolant See “ Coolant” on page 01-23_
Cooling systemPC22O,PC250
22.8
SPECIFIED CAPACITY: Total amount of oil including oil for components and oil in piping.REFILL CAPACITY: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM:SAE:API:
American Society of Testing and MaterialSociety of Automotive EngineersAmerican Petroleum Institute
REMARK
0 When fuel sulphur content is less than OS%, change the engine oil at the normal periodic maintenanceinterval described in the Operation and Maintenance Manual.Change engine oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur content Change interval of oil inengine oil pan
0.5 to 1 .O%
Above 1 .O%
% of regular interval
1/4of regular interval
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GENERAL FUEL, COOLANTS AND LUBRICANTS
OIL
0 When starting the engine in an atmospheric temperature of lower than 0°C (32°F) be sure to use anengine oil grade of SAE 1 OW, SAE 1 OW-30, or SAE 15W-40, even though the atmospheric temperaturegoes up to 10°C (50°F) more or less in the day time.
0 We recommend genuine Komatsu oil which has been specifically formulated and approved for use inengine and hydraulic work equipment application.
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals arecritical factors in maintaining engine performance and durability.SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classificationof CE or CF-4 is recommended.NOTE: CD or CD/SF oils may be used with the interval given in the maintenance schedule in areas whereCE or CF-4 is not yet available.A sulfated ash limit of 1 .O mass percent is suggested for optimum valve and piston deposit and oil con-sumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higherash oils can cause valve and/or piston damage and lead to excessive oil consumption.The API service symbol displays the appropriate oil categories; the lower half may contain words to describeoil energy conserving features. The center section identifies the SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of multi-graded lubricating oil has been found to improve oil consumption control and improveengine cranking in cold temperatures while maintaining lubrication a high operating temperatures.While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previouschart for oil viscosity recommendations for extreme climates.NOTE: Single graded oils may be used if multi-graded oil is not available, but be sure to use oil that
matches the temperature in the table.Special “ break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same typeof oil during the “ break-in” as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “ E.M.A.Lubricating Oils Data Book For Heavy Duty Automotive and Industrial Engines.” The data book may beordered from the Engine Manufacturers Association, 401 North Michigan Avenue, Chicago, IL U.S.A. 60611.The telephone number is (312) 644-6610.
ARCTIC OPERATIONIf an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there is no provisionsto keep the engine warm when it is not in operation, use a synthetic API performance oil classification CE orCF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.The oil supplier must be responsible for meeting the performance service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oilchange intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
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River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to theengine and radiator, and this will decrease heat exchange and cause overheating.Water should meet the following guidelines.
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scaledeposits. Water containing dissolved magnesium and calcium (the usual reason for waterhardness) above the specified amount will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimizesludge deposits, scale deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. Todetermine if local water supplies meet these standards, water samples can be tested by water treatmentlaboratories. “ Softened” water that is prepared using common salt (sodium chloride) contains excessiveamounts of chlorides and should not be used.
When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.
Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine isshipped.This anti-freeze is effective in preventing corrosion of the cooling system.The anti-freeze can be used continuously for two years or 2000 hours. Therefore, it can be used as is evenin hot areas.
Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.
The proportion of anti-freeze to water differs according to the ambient temperature.For details of the mixing proportions, see the Operation and Maintenance Manual.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air inthe coolant.
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10 STRUCTURE AND FUNCTION
Enginerelatedparts ....................................................................... IO -2Radiator, oil cooler, aftercooler .............................................................. 10 -3Powertrain ............................................................................... 10 -4Finaldrive ................................................................................ 10 -5Swingcircle .............................................................................. 10 -7Swingmachinery .......................................................................... IO -8Track frame, recoil spring ................................................................... IO -9Trackshoe ............................................................................... IO -10 Hydraulic piping drawing .................................................................... IO -13 Hydraulic circuit diagram .................................................................... 10 -14 Hydraulictank ............................................................................ 10 -15 Hydraulicpump ........................................................................... IO -16 Controlvalve ............................................................................. IO -38 CLSS ................................................................................... 10 -47 Swingmotor .............................................................................. IO -92 Centerswiveljoint ......................................................................... 10 -95 Travelmotor ............................................................................. 10 -96
Valvecontrol ............................................................................. IO-107Work Equipment, Swing PPC valve ........................................................... 1 O-l 08 TravelPPCvalve .......................................................................... IO-112ServicePPCvalve.. ....................................................................... IO-116 Safetylockvalve .......................................................................... IO-119PPCaccumulator ......................................................................... IO-119PPC shuttle, Travel junction valve ............................................................ 1 O-120 EPC,Solenoidvalve ....................................................................... IO-127Hydrauliccylinder ......................................................................... IO-135 Additional filter for breaker .................................................................. 1 O-l 36Overloadwarningdevice .................................................................... IO-137Hose burst protection valve (boom) ........................................................... 1 O-141Workequipment .......................................................................... IO-144Electrical circuit diagram .................................................................... 1 O-l 45Engine control system ...................................................................... 1 O-l 49Electronic control system ................................................................... 1 O-l 54 Machine monitor system .................................................................... 1 O-l 79
1 l
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STRUCTURE AND FUNCTION ENGINE RELATED PARTS
ENGINE RELATED PARTS
A-A 6 7 8
B-B c-c D-D E-E
1. Drive plate2. Torsion spring3. Stopper pin4. Friction plate5. Damper assembly6. Air cleaner7. Intake connector8. Muffler9. Rear engine mount
10. Front engine mount
OUTLINEThe damper assembly is a wet type.Oil capacity: 0.75 P
X12AD046
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STRUCTURE AND FUNCTION RADIATOR. COOLER. AFTERCOOLER
RADIATOR. OIL COOLER. AFTERCOOLER5 6
1. Reservoir tank2. Oil cooler3. Radiator4. Fan5. Radiator inlet hose6. Radiator outlet hose7. Radiator cap8. Net9. Shroud
SPECIFICATIONSRadiator: CWX4Oil cooler: SF-3
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STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
6
1. Idler 7. Engine2. Center swivel joint 8. Travel speed solenoid valve3. Control valve 9. Swing brake solenoid valve4. Final drive 10. Swing motor5. Travel motor 11. Swing machinery6. Hydraulic pump 12. Swing circle
l X 7HH 27
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STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVEPCXOLC-6
I. Level plug2. Drain plug3. No. 1 sun (13 teeth)ear4. No. 2 sun (19 teeth)ear5. Cover6. No. 2 planet (30 teeth)ear7. No. 2 ring (80 teeth)ear8. Spacer9. No. 1 ring (80 teeth)ear
10. No. 1 planet (33 teeth)ear11. Sprocket12. Floating seal13. Travel motor14. Hub15. Retainer16. No. 1 planetary carrier17. No. 2 planetary carrier
SPECIFICATIONS
Reduction ratio:
- (y ) X (y ) + I= -36.275
ii
SectionA A
X 7HH 29
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STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
-_-_-P
L
bmA-A
I ‘ iY-----*-----.
1. Swing circle inner race (110 teeth)2. Ball3. Swing circle outer race (115 teeth)
a. Inner race soft zone S positionb. Outer race soft zone S position
/
2
/8’
I *w \-_-..d’ 3
L_-.-._._J
I
/ I
B-8
X09DD022
PC200-6, PC2OOLC-6 PC25OLC-6SPECIFICATIONS PC21 OLC-6, PC220LC-6
Reduction ratio 110/115=7.333
Amount of grease 21 P (G2-Ll) 1 34P(G2-Ll) 1
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SWING MACHINERY
XOSDH 24
1. Swing pinion (15 teeth)2. Cover3. Case4. No. 2 planetary carrier5. No. 2 sun (15 teeth)ear
6. No. 2 ring (72 teeth)ear7. Case8. No. 1 ring (72 teeth)ear9. No. 1 sun (21 teeth)ear
10. Oil level gauge12. Cover13. No. 1 planetary (25 teeth)ear14. No. 1 planetary carrier15. Coupling16. No. 2 planetary (28 teeth)ear17. Drain plug
SPECIFICATIONS
(=$)X( 7) = 25.686
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STRUCTURE AND FUNCTION TRACK FRAME. RECOIL SPRING
TRACK FRAME. RECOIL SPRING
A A
1. Idler2. Track frame3. Carrier roller4. Final drive5. Track roller6. Track shoe7. Center guard8. Recoil spring9. Front guard
X14AH022
The dimensions and number of track rollers maydiffer according to the model, but the basic struc-ture is the same.No. of track rollers
Model No. of rollers (each side)
PC200-6
PC2OOLC-6PC21 OLC-6
9
PC22OLC-6 I IO
PC25OLC-6 I 8
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TRACK SHOE
STANDARD SHOE
Item Model PC200-6 PC200LC-6 PC21 OLC-6 PC22OLC-6 PC250LC-6-
Shoe width (triple shoe) 600 mm 700 mm600 mm 700 mm 700 mm
Link pitch 190 mm 190 mm 190 mm 190 mm 203 mm
No. of rollers (each side) 45 49 49 51 50
SELECTION OF TRACK SHOESelect the most suitable track shoe from the following table.
Standard
PC2004 PC220LC-6 PC21 OLC-6 PC22OLC-6, PC25OLC-6
Specifications Category Specifications Category Specifications Category Specifications Category
Option 600 mm triple A 600 mm triple A 600 mm triple A 600 mm triple AOption
Option
-
700 mm triple B 700 mm triple 0 - - 700 mm triple B
800 mm triple C 800 mm triple C - - 800 mm triple C
- - 900 mm triple C - - - -
IO IO
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Category Use Precautions when using
A Rocky ground, normal river Travel in Lo speed when traveling on rough ground withsoil obstacles such as large boulders and fallen trees.
B Cannot be used on rough ground where there are largeNormal soil, soft land obstacles such as boulders and fallen trees.
Travel in Hi speed only on flat ground, and when it is impossibleto avoid traveling obstacles, lower the travel speed to approx. halfof Lo speed.
Use only for ground where “ A” and “ B” sink and are impossibleto use.
Extremely soft ground Cannot be used on rough ground where there are large(swampy ground) obstacles such as boulders and fallen trees.
Travel in Hi speed only on flat ground, and when it is impossibleto avoid traveling obstacles, lower the travel speed to approx. halfof Lo speed.
* Categories “ B” and “ C” are wide shoes, so there Sr When selecting the shoe width, select the nar-are restrictions on their use. Therefore, before rowest shoe possible within the range that willusing, check the restrictions and consider care- give no problem with floatation and ground
fully the conditions of use before recommending pressure.a suitable shoe width. If necessary, give the cus- If a wider shoe that necessary is used, there will
tomer guidance in their use. be a large load on the shoe, and this may lead tobending of the shoe, cracking of the links, break-
age of the pins, loosening of the shoe bolts, orother problems.
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HYDRAULIC PIPING DIAGRAMPC200-6, PC200LC-6PC21 OLC-6, PC22O LC-6PC250LC-6
FOLDOUT I
1. Bucket cylinder2. Arm cylinder3. Boom cylinder4. Hydraulic tank5. LS control EPC valve6. Hydraulic filter7. Filter (for breaker)8. Swing motor9. R.H. travel motor
10. Hydraulic pump11. Control valve12. PPC shuttle. travel junction valve13. Oil cooler14. L.H. travel motor15. Arm holding valve16. Boom holding valve17. PPC safety valve18. L.H. PPC valve19. R.H. PPC valve20. Center swivel joint‘)- Travel PPC valveI
22,23,24
Service PPC valveAccumulatorSolenoid valve
25.26.27.
‘14
24A. LS select solenoid valve24B. 2-stage relief solenoid valve24C. Pump merge-divid er solenoid
valve24D. Travel speed solenoid valve24E. Swing brake solenoid valveL.H. hose burst valveR.H. hose burst valveTiming valve
24c240//
24E
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HYDRAULIC CIRCUIT DIAGRAM (2/2)PC250LC-6 TRAVEL MOTOR
150. 3 / 280.0 cc/rev
-....-JOINT
i I
-i i k(B)i ’
I I ‘ go3 j#O,: L,,
/________ ______ --,--,,,,,--,-,A,,
L----_~~-_~~~--~~~-~~-~~-~ -_ s - w I t
P
(B)
10 14 I
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STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Hydraulic tank2. Bypass valve3. Oil filler cap4. Sight gauge5. Hydraulic oil level sensor6. Suction strainer7. Filter element
6
7X10BV049
SPECIFICATIONSTank capacity: 230 PAmount of oil inside tank: 166 PPressure valveRelief cracking pressure: 0.017 f 0.004 MPa
(0.17 f 0.04 kg/cm?Suction cracking pressure: 0 - 0.0005 MPa
(0 - 0.005 kg/cm?Bypass valve set pressure: 0.103 f 0.02 MPa
(1.05 f 0.2 kg/cm?
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
/6
a. Pump drain port PDFb. Front delivery port PAFc. Rear delivery port PARd. Control pump suction port PGSe. Control pump delivery port PGAf. Front LS pressure port PLSFg. Rear LS pressure port PLSR
h. LS control EPC pressure port PSIGRi. Main pump suction port PSj. LS control EPC pressure port PSIGF
b d
i i
XlOAV240
1 Front main pump2. Rear main pump3. Control relief valve4. Rear TVCoLS valve5. Front TVCoLS valve6. Control pump
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. MAIN PUMP (HPV95+95)
b
Z
fl”0
f
0
o”aOfjf $O) 0 0
0 00 00
0’
u23
0
XlOAV24
a. Pump drain port PDFb. Front delivery port PAFc. Rear delivery port PARd. Front control pressure port PANFe. Rear delivery pressure port PAZRf. Front delivery pressure port PAZFg. Rear delivery pressure port PA1 Rh. Rear control pressure port PENRi. Suction port PSj. Front delivery pressure port PA1 F
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION1. Operation of pump
1) Cylinder block (7) rotates together with shaft(I), and shoe (5) slides on flat surface A.When this happens, rocker cam (4) movesalong cylindrical surface B, so angle a
etween center line X of rocker cam (4) and
the axial direction of cylinder block (7)changes. (Angle a is called the swashplate angle.)
XlOAV 4
2) Center line X of rocker cam (4) maintainsswash plate angle a in relation to the axialdirection of cylinder block (7), and flat sur-face A moves as a cam in relation to shoe(5).
In this way, piston (6) slides on the inside ofcylinder block (7), so a difference betweenvolume E and F is created inside cylinderblock (7). The suction and discharge is car-ried out by this difference F - E.In other words, when cylinder block (7) ro-tates and the volume of chamber E be-comes smaller, the oil is discharged duringthat stroke. On the other hand, the volumeof chamber F becomes larger, and as the
volume becomes bigger, the oil is suckedin.
7 E
3) If center line X of rocker cam (4) is in linewith the axial direction of cylinder block (7)(swash plate angle = 0), the difference be-tween volumes E‘ and F‘ inside cylinderblock (7) becomes 0, so the pump does notcarry out any suction or discharge of oil. (Inactual fact, the swash plate angle never be-comes 0.)
XlOAV 43
XlOAV 44
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. Control of discharge amount
If swash plate angle CI become larger, the differ-ence in volumes E and F becomes larger anddischarge volume Q increases.
0 Swash plate angle c( is changed by servo piston(12).
0 Servo piston (12) moves in a reciprocal move-ment (++) according to the command from theTVC 0 LS valve.This straight line movement is transmittedthrough rod (13) to rocket cam (4), and rockercam (4), which is supported by the cylindricalsurface to cradle (2), moves in a swinging move-ment on the cylindrical surface in ($ direction).
X10AV245
With servo piston (12), the area receiving the pres-sure is different on the left and right, so mainpump discharge pressure (self-pressure) PP is al-ways connected to the chamber receiving thepressure on the small diameter piston side (theself-pressure is brought in).Output pressure PEN of the LS valve is broughtto the chamber receiving the pressure at the largediameter piston end.The relationship in the size of self-pressure PPand the pressure at the small diameter piston end,and the ratio between the area receiving the pres-sure of the small diameter piston and the large
diameter piston controls the movement of theservo piston (12).
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. Front shaft2. Cradle3. Front case4. Rocker cam5. Shoe6. Piston
A A
B B
7. Cylinder block8. Valve plate9. End cap
10. Rear shaft11. Rear case12. Servo piston
XlOAV246
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
Splinh 1‘ 2 Spline
XlOAV ‘ 47
FUNCTION
The engine rotation and torque transmitted tothe pump shaft is converted into hydraulic en-ergy, and pressurized oil is discharged acc-ding to the load.It is possible to change the delivery amount bychanging the swash plate angle.
STRUCTURE
Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber ofcylinder block (7).The cylinder block seals the pressure oil to valveplate (8) and carries out relative rotation. Thissurface is designed so that the oil pressure bal-ance is maintained at a suitable level.The oil inside each cylinder chamber of cylinderblock (7) is sucked in and discharged through
Cylinder block (7) is supported to shaft (1) by aspline, and shaft (1) is supported be the frontand rear bearings.The tip of piston (6) is a concave ball, and shoe(5) is caulked to it to form on unit. Piston (6)
and shoe (5) form a spherical bearing.Rocker cam (4) has a flat surface A, and shoe(5) is always pressed against this surface whilesliding in a circular motion.Rocker cam (4) brings high pressure oil at cylin-drical surface B with cradle (2), which is securedto the case, and forms a static pressure bearingwhen it slides.
valve plate (8).
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STRUCTURE AND FUNCTIONHYDRAULIC PUMP
2. TVC . LS VALVE
d\
a. Port PA2 (Pump delivery pressure inlet port)b. Port PEN (n/C LS valve signal pressure
outlet port)C Port PA1 (Pump delivery pressure inlet port)
d. Port PLS (Control valve LS pressure inlet port)e. Port PSIG (LS control EPC valve pressure inlet
port)
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE1. Locknut2. Plug3. Spring4. Spool5. Sleeve6. Piston7. Plug
A-A
1 2 3 4 5 6 7
B-B
TVC VALUE8. Solenoid9. Piston
10. Sleeve11. Spring12. Spring13. Piston14. Lever15. Valve body
XlOAV 49
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION1.0
2.
LS VALUEThe LS valve detects the load and controls thedischarge amount.This valve controls the main pump discharge amountQ according to the differential pressure A PLS (=PP -PLS) (the difference between main pump pressure
PP and control valve outlet port pressure PLS){called the LS differential pressure}.Main pump pressure PP, pressure PLS {called theLS pressure} coming from the control valve output,and pressure PSIG {called the LS selection pressure}from the proportional solenoid valve enter this valve.The relationship between discharge amount Q anddifferential pressure A PLS, (the difference betweenmain pump pressure PP and LS pressure PLS)(=PP - PLS) changes as shown in the diagram on
right according to LS selector pressure PSIG.When PSIG changes between 0 and 2.94 MPa (0and 30 kg/cm?, the spool load changes accordingto this, and the selector point for the pump dischargeamount changes at the rated central value between0.64 and 2.11 MPa (6.5 and 21.5 kg/cm?.
a
EzEm
PSIG = 2.94 MPa (30 kg/cm?\
PSIG = 0 MPa (0 kg/cm*)
?i?. I I
I I0.64 (6.5) 2.11 21.5) (MPa (kg/cm211
LS differential pressure A PLS
XlOAV2
NC VALUEWhen the pump discharge pressure PPI (self-pressure) and PP2 (other pump pressure) are high,the NC valve controls the pump so that no more oilthat the constant flow (in accordance with the dis-charge pressure) flows even if the stroke of thecontrol valve becomes larger. In this way it carriesout equal horsepower control so that the horsepowerabsorbed by the pump does not exceed the enginehorsepower.In other words, if the load during the operationbecomes larger and the pump discharge pressurerises, it reduces the discharge amount from thepump; and if the pump discharge pressure drops,it increases the discharge amount from the pump.The relationship between the average of the frontand rear pump discharge pressures (PPI + PP2)/2and pump discharge amount Q is shown on theright, with the current given to the NC valve solenoidshown as a parameter. However, in the heavy-dutyoperation mode, there are cases where it is given thefunction of sensing the actual speed of the engine,and if the speed drops because of an increase in the
load, it reduces the pump discharge amount to allowthe speed to recover. In other words, when the loadincreases and the engine speed drops below the setvalue, the command to the TVC valve solenoid fromthe controller increases according to the drop in theengine speed to reduce the pump swash plate angle.
L
Pump discharge pressure PP
XlOAV
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION1.1)
LS VALVEWhen control valve is at neutral position
lfrom outlet port of
controialve)
(from LS control
J valve)
9(Direction of minimum discharge)
The LS valve is a three-way selector valve, withpressure PLS (LS pressure) from the outlet portof the control valve brought to spring chamber i,and main pump discharge pressure PP brought tochamber j of plug (6). The size of this LS pressurePLS + force F of spring (3) and the main pump pres-sure (self pressure) PP determines the position ofspool (4). However, the size of the output pressure
PSIG (the LS selection pressure) of the EPC valvefor the LS valve entering port e also changes the pos-ition of spool (4). (The set pressure of the springchanges.)Before the engine is started, servo piston (1) is pushedto the right by the spring (7) installed to rod (2). (Seethe diagram on the right)When the engine is started and the control lever is atthe neutral position, LS pressure PLS is 0 MPa(0 kg/cm?. (It is interconnected with the drain circuitthrough the control valve spool.)
XlOAV 5
A-AXlOAV253
At this point, spool (4) is pushed to the left, andport d and port c are connected. Pump pressurepp enters the large diameter end of the pistonfrom port h, and the same pump pressure ppalso enters the small diameter end of the piston,so the swash plate is moved to the minimumangle by the difference in area of piston (1).
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
2) Operation in maximum direction for pump discharge amount
Small diameter end
(Direction of maximum discharge) XlOAV254
When the difference between main pump pressurePP and LS pressure PLS, in other words, LS differ-ential pressure A PLS, becomes smaller (for ex-ample, when the area of opening of the controlvalve becomes larger and pump pressure PP drops),spool (4) is pushed to the right by the combined forceof LS pressure PLS and the force of spring (3).When spool (4) moves, port b and port c are joinedand connected to the NC valve. When this happens,the n/C valve is connected to the drain port, so
circuit c - h becomes drain pressure PT. (Theoperation of the n/C valve is explained later.)
For this reason, the pressure at the large pistondiameter end of the servo piston (1) becomesdrain pressure PT, and pump pressure PP entersthe small diameter end, so servo piston (1) ispushed to the right. Therefore, rod (2) moves tothe right and moves the swash plate in the direc-tion to make the discharge amount larger.If the output pressure PSIG of the EPC valve forthe LS valve enters port e, this pressure creates aforce to move piston (5) to the left. If piston (5) is
pushed to the left, it acts to make the set pressureof spring (3) weaker, and the difference betweenPLS and PP changes when ports b and c ofspool (4) are connected.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
3) Operation in minimum direction for pump discharge amount
TVC valve
from outlet port of (from LS control I’ 0 PTcontrol valve) EPC
IDirection of minimum discharge)
The following explains the situation if servo pis-ton (1) moves to the left (the discharge amountbecomes smaller). When LS differential pressuren PLS becomes larger (for example, when thearea of opening of the control valve becomessmaller and pump pressure PP rises), pump pres-sure PP pushes spool (4) to the left.When spool (4) moves, main pump pressure PPflows from port d to port c, and from port h, itenters the large piston diameter end.
XlOAV255
Main pump pressure PP also enters the smallpiston diameter end, but because of the differ-ence in area between the large piston diameterend of servo piston (1) and the small piston di-ameter end, servo piston (1) is pushed to the left.As a result, rod (2) moves in the direction to makethe swash plate angle smaller.If LS selection pressure PSIG enters port e, it actsto make the set pressure of spring (3) weaker.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
4) When servo piston is balanced
control valve) EP((from outlet port of
Let us take the area receiving the pressure at thelarge piston diameter end as Al, the area receiv-ing the pressure at the small end as AO, and thepressure flowing into the large piston diameter asPEN. If the main pump pressure PP of the LSvalve and the combined force of force F of spring(3) and LS pressure PLS are balanced, and therelationship is A0 x PP = Al x PEN, servo piston(1) will stop in that position, and the swash plate willbe kept at an intermediate position. (It will stop at a
position where the opening of the throttle from portb to port c and from port d to port c of spool (4) isapproximately the same. At this point, the pressureof port c is approximately % pump pressure PP.)
XlOAV255
At this point, the relationship between the areareceiving the pressure at both ends of piston (1)is AO:Al = 1:2, so the pressure applied to bothends of the piston when it is balanced becomesPP:PENk 2:l. The position where spool (4) isbalanced and stopped is the standard center, andthe force of spring (3) is adjusted so that it is deter-mined when PP - PLS = 2.11 MPa (21.5 kg/cm?.However, if PSIG (the output pressure of 0 - 2.94MPa (0 - 30 kg/cm? of the EPC valve of the LS
valve) is applied to port e, the balance stop positionwill change in proportion to pressure PSIG betweenPP - PLS = 2.11 - 0.64 MPa (21.5 - 6.5 kg/cm?.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
NC VALVE1) When pump controller is normal
irecli on of maxmum dischargePump contrdkr Tvc proitx
OFF Switch
Resistor
a. When the load on the actuator is small andpump pressures PPI and PP2 are low
(1) Movement of solenoid (1)Command current X from the pump controllerflows to solenoid (1). This command currentchanges the internal force pushing solenoid pushpin (1 I).On the opposite side to the force pushing thissolenoid push pin (11) is the spring set pressure ofsprings (3) and (4) and pump pressure PPI andother pump (see *) pressure PP2. Piston (2)stops at a position where the combined force
pushing piston (2) is balanced, and the pressure(pressure of port c) output from the TVC valvechanges according to this position.
XlOAVZ 7
XiOAV 58
* Other pump pressure.This is the pressure ofthe pump at the opp-osite end.For the Front pump, it isthe Rear pump pres-sure. For the Rearpump, it is the Frontpump pressure.
The size of command current X is determined bythe nature of the operation (lever operation), theselection of the working mode, and the set valveand actual value for the engine speed.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
(Directton
Resistor
b. When load on actuator is small and pump dis-charge pressure is highWhen the load is large and pump discharge pres-sures PPl and PP2 are high, the force pushingpiston (2) to the left becomes larger and piston(2) moves to the position shown in the diagramabove.
When this happens, as shown in the diagramabove, part of the pressurized oil from port bflows out to port d and the pressurized oil flow-ing from port c to the LS valve becomes approxi-mately half of main pump pressure PPI.When port h and port e of the LS valve are con-nected (see 1. LS valve), the pressure from port fenters the large piston diameter end of servopiston (9) and servo piston (9) stops.
XlOAV 59
XlOAV 58
If main pump pressures PPl and PP2 increasefurther and piston (2) moves further to the left,main pump pressure PPI flows to port c and actsto make the discharge amount the minimum.When piston (9) moves to the left, piston (5) is
moved to the right by cam (7) and lever (6). Forthis reason, springs (3) and (4) are compressedpush back piston (2). Because of this force, piston(2) cuts off the connection from port b to port c,and port c and port d are connected. As a result,the pressure at port c =9 rops, and piston (9)stops moving to the left. The position in whichpiston (9) stops when this happens is further to thethe left than the position when pump pressuresPPI and PP2 are low.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
The relation of pump pressures PPI + PP2 andthe position of servo piston (9) forms a bent line Q
because of the double-spring effect of springs (3)and (4). The relationship between pump pres-sures PPI + PP2 and pump discharge amount Qis shown in the figure on the right.
If command voltage X sent to solenoid (1) in-creases further, the relationship between pumppressures PPI and PP2, and pump dischargeamount Q is proportional to the pushing force ofthe solenoid and moves in parallel. In otherwords, if the pushing force of solenoid (1) is
added to the force pushing to the left becauseof the pump pressure applied to the piston (2), therelationship between PP and Q moves from A to Bin accordance with the increase in X.
PPl PP2XlOAV260
Q
P
XlOAV261
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
2) When pump controller is abnormal and TVC prolix switch is ON
?PT
(Direction aximum disch
Batterv
arge)Pump controllc
, “ “ “ “ V _
Resistor
a. When load on main pump is lightIf there is a failure in the pump controller, turnTVC prolix switch ON to switch to the resistorside. In this case, the power source is taken di-rectly from the battery. But if the current is usedas is, it is too large, so use the resistor to controlthe current flowing to solenoid (1).When this is done, the current becomes constant,
so the force pushing on solenoid push pin (11) isalso constant.If main pump pressures PPI and PP2 are low, thecombined force of the pump pressure and theforce of solenoid (1) is weaker that the spring setforce, so piston (2) is balanced at a position to theright.
?I TVC prolix- --{itch
XlOAV 58
XlOAV 6
At this point, port c is connected to the drainpressure of port d, and the large piston diameterend of servo piston (9) also becomes the drainpressure PT through the LS valve. When thishappens, the pressure at the small piston di-ameter end is large, so servo piston (9) moves inthe direction to make the discharge amountlarger.
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
b.
8PT
Direction of minimum discharge) Pump controller TVC prolix
JQzy@gF-
Resstor
When main pump load is heavyIn the same way as in the previous item, whenthe n/C prolix switch is ON, the command cur-rent X sent to solenoid (1) becomes constant. Forthis reason, the force of solenoid push pin (11)pushing piston (2) is constant.If main pump pressures PPI and PP2 increase,piston (2) moves further to the left than when themain pump load is light, and is balanced at aposition towards the left.
In this case, the pressure from port b flows to portc, so servo piston (9) moves to the left (to makethe discharge amount smaller) by the samemechanism as explained in item 2.1)-b. In otherwords, even when the TVC prolix switch is ON, thecurve for the pump pressure P and dischargeamount Q is determined as shown in the diagramfor the value of the current sent to the solenoidthrough the resistor.
XiOAV258
XlOAV263
The curve when the TVC prolix switch in ON iscurve B, which is to the left of curve A for whenthe pump controller is normal.
A when controller is
P
XlOAV264
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STRUCTURE AND FUNCTION HYDRAULIC PUMP
3. CONTROL PUMP (BAR-016)
L
1 Body2. Driven gear3. Housing4. Drive gear
5. Relief valve6. Filter
0b
A-A
SPECIFICATIONSType: BAR-01 6Theoretical delivery: 16.0 cc/revMax. delivery pressure: 3.23 MPa (33 kg/cm?
XlOBH152
a. Suction portb. Delivery port
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STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE9-SPOOL VALVE (STANDARD + 3 SERVICE VALVE)
hh-
U
pi, pii fi &h g‘ s p;j
Y X
r&
/ i ‘ *\ \W b V
XlOBH 44
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STRUCTURE AND FUNCTION CONTROL VALVE
1. 6-spool valve2. Cover 13. Cover 24. Pump merge-divider valve5. Arm counterbalance valve6. No. 1 Service valve7. No. 2 Service valve
8. No. 3 Service valve
a.b.
:Ie.f.g.
h.i.j.k.I.m.n.0.
P.q.r.
t” .’U.
V.
w.
X.
Y.
Port PPI (from rear main pump)Port PP2 (from front main pump)Port A6 (to arm cylinder head)Port B6 (to arm cylinder bottom)Port A5 (to L.H. travel motor)Port B5 (to L.H. travel motor)Port A4 (to swing motor)
Port B4 (to swing motor)Port A3 (to boom cylinder bottom)Port B3 (to boom cylinder head)Port A2 (to R.H. travel motor)Port B2 (to R.H. travel motor)Port Al (to bucket cylinder head)Port Bl (to bucket cylinder bottom)Port A-l (to attachment)Port B-l (to attachment)Port A-2 (to attachment)Port B-2 (to attachment)Port A-3 (to attachment)Port B-3 (to attachment)Port T (to tank)Port Tl (to travel junction valve)Port T2 (to travel junction valve)Port T3 (to travel junction valve)Port T4 (to travel junction valve)
OUTLINEThis control valve consists of the 6-spool valve (an
integrated composition) and 3 service valves. Thepump merge-divider valve and arm counterbalancevalve are installed to this.
Each valve forms one unit with the connectionbolt, and the passages are internally connected, so
the structure is compact and is very easy to service.This control valve consists of one spool for one
item of the work equipment, so it has a simplestructure.
aa.ab.bb.cc.dd.ee.pa.
pb.PC.pd.pe.Pf.Pg.ph.pi.pj.pk.Pl.pmpn.PO.PP.Pq.pr.ff.gg.hh.kk.
Port PLSI (to rear pump control)Port PLS2 (to front pump control)Port TS (to tank)Port PS (from solenoid valve)Port BP (from solenoid valve)Port PX (from solenoid valve)Port PI2 (from arm PPC/EPC valve)
Port PI 1 (from arm PPC/EPC valve)Port PI 0 (from L.H. travel PPC valve)Port P9 (from L.H. travel PPC valve)Port P8 (from swing PPC/EPC valve)Port P7 (from swing PPC/EPC valve)Port P6 (from boom PPWEPC valve)Port P5 (from boom PPWEPC valve)Port P4 (from R.H. travel PPC valve)Port P3 (from R.H. travel PPC valve)Port P2 (from bucket PPC/EPC valve)Port PI (from bucket PPC/EPC valve)Port P-2 (from service PPC valve)Port P-l (from service PPC valve)Port P-4 (from service PPC valve)Port P-3 (from service PPC valve)Port P-6 (from service PPC valve)Port P-5 (from service PPC valve)Port SA (pressure sensor mount port)Port SB (pressure sensor mount port)Port BP3 (from travel PPC)Port BP2 (from arm PPC)
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STRUCTURE AND FUNCTION CONTROL VALVE
MAIN STRUCTURE
1 Spool (arm)2. Spool (L.H. travel)3. Spool (swing)4. Spool (boom)
5. Spool (R.H. travel)6. Spool (bucket)7. Spool (service 1)8. Spool (service 2)
K-K \14
XlOBH145
9. Spool (service 3)10. Spool return spring11. Main unload LS relief valve12. Main relief valve (bucket end group)
13. Sub-unload valve (bucket end group)14. Main relief valve (arm end group)15. Sub-unload valve (arm end group)
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STRUCTURE AND FUNCTION CONTROL VALVE
J J
4 sEE EE
X10BH146
1. LS shuttle valve2. LS select valve3. Pump merge-divider valve (for main)4. Return spring5. Pump merge-divider valve (for LS)6. Return spring7. LS bypass valve
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7-SPOOL VALVE (STANDARD + 1 SERVICE VALVE)* For details of the names of the ports and the main structure, see 9-SPOOL VALVE
c e 9 e k\ \ 7” O
I II\ \\\\pb pd 4 Pf Pih pj PI Pn ee
Y ?
bb,
5’
W a b v XlOBH149
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STRUCTURE AND FUNCTION CONTROL VALVE
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1 2 3 4 5 6 7 9 9 19
XlOBHlBl
1. Suction valve2. Main valve3. Piston4. Piston spring5. Poppet6. Poppet spring
7. Suction valve spring8. Sleeve9. Adjustment screw
10. Locknut
Part No. Set Pressure Use
709-70-74600 24.5 MPa (250 ka/cm? at 5 Plmin For crusher (Okada)
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STRUCTURE AND FUNCTION CLSS
CLSSOUTLINE OF CLSS
Actuators
0I-_------- Control valve 7
I I
II
I Pump merge divider valve 1
I
III
II
I
I
1
IL_J_‘ L__ _--l
I
r2 L _ _ k
__ __Jz TVC valve _
III
I
I
III
III
IIIII
IIIII
I
I II II
I4ervo piston
Features Structure
CLSS stands for Closed center Load SensingSystem, and has the following features.
1) Fine control not influenced by load2) Control enabling digging even with fine control
3) Ease of compound operation ensured by flowdivider function using area of opening of spoolduring compound operations
4) Energy saving using variable pump control
III
&Servo pistonXlODD013
The CLSS consists of a main pump (2pumps), control valve, and actuators for
the work equipment.The main pump body consists of the pumpitself, the TVC valve and LS valve.
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STRUCTURE AND FUNCTION CLSS
Basic principle1) Control of pump swash plate angle
The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS(the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure ofactuator) is constant. (LS pressure APLS = Pump discharge pressure PP - LS pressure PLS)
If LS differential pressure APLS becomes lower than the set pressure of the LS valve(when the actuator load
pressure is high), the pump swash plate moves toward the maximum position; if it becomes higher than theset pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towardsthe minimum position.
Actuatoro f Max.
Control valve
--7---I
/kr I’
I ‘ PLSI ’ w LS passage
Pump passage
I I
%NOpistonm ~
dilferential pressure
2
$P)
5P.c
IS alve sat
pressurej ---- -.
\
LS ifferential pressure I\pLs
XlODDOlS
XlODDO14
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STRUCTURE AND FUNCTION CLSS
OPERATION FOR EACH FUNCTION OF CLSSHydraulic circuit diagram for system
1P,,r_-_I__‘___-
I & 1Tc________-----------.--: ,
P..’ :.____ II.__~______ _ __
I
_I
I___T _-y-.> 1 ________
“ 7 , II II A,10 1’ *_
1___ ___ _____ __
, IIB, 1
.I8
XlODD017
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STRUCTURE AND FUNCTION CLSS
SYSTEM DIAGRAM* This shows actuator (6A) and the stroke end relief in the merge mode.
26
IA. Main pumpIB. Main pump2A. Main relief valve (for power max.)2B. Main relief valve (for power max.)
3A. Sub unload valve3B. Sub unload valve4. Pump merge-divider valve5A. Control valve5B. Control valve6A. Actuator6B. Actuator7A. Check valve7B. Check valve
(1A
,;j:,.,.:.:..:.:.,.:.:.:.:.:.:.:.:..,,,:$::::.:: :::..‘::.:::.j;
w:.+:,,. . :_.: : ‘.
61, ij
8. Pump passage9. LS circuit
10. Tank pressure11. Valve
12. Spring13. Piston14. Clearance filter15. Poppet16. Spring17. Piston18. Piston19. Piston20. LS bypass valve
-1BXlODD 18
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STRUCTURE AND FUNCTION CLSS
3. Introduction of LS pressure* The diagram shows the condition for arm IN.
Upstream pressure ofpressure compensation valve(for spool meter-in downstream)
1. Main pump2. Main spool3. Pressure compensation valve4. Valve5. Ball valve6. LS shuttle valve
XlODD022
FunctionThe upstream pressure (= spool meter-in down-stream pressure) of pressure compensation valve(3) is introduced and goes to shuttle valve (7) asthe LS pressure. When this happens, it is con-nected to port B of the actuator through valve (4),and LS pressure E actuator load pressure. Intro-duction hole a inside the spool has a small diam-eter, so it also acts as a throttle.
OperationWhen spool (2) is operated, the pump pressurepasses through introduction hole a, enters portC, and is taken to the LS circuit. When the pumppressure rises ans reaches the load pressure ofport B, ball valve (5) opens.
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STRUCTURE AND FUNCTION CLSS
5. Pressure compensation valve
1. Main pump2. Valve3. Shuttle valve4. Piston5. Spring6. LS shuttle valve
XlODD024
Function1) During independent operation and at maxi-
mum load pressure (during compound oper-ations, when load pressure is higher thanother work equipment)The pressure compensation valve acts as a loadcheck valve.
OperationIf the pump pressure (LS pressure) is lower thanthe load pressure at port C, shuttle valve (3) in-side pressure compensation valve piston (4)moves to interconnect spring chamber E and portC.From this condition, the force of spring (5) acts tomove piston (4) and valve (2) in the direction ofclosing.
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STRUCTURE AND FUNCTION CLSS
2)
0
6
From LS shuttle valve for otherwork equipment
Upstream pressure of pressurecompensation valve(for spoo meter-in downstream)
Spool meter-in upstream presslreXlODD025
When receiving compensation (during Operationcompound operations, when load pressure Spring chamber E is interconnected with port D.is lower than other work equipment) Piston (4) and valve (2) are actuated by the LSThe pressure compensation valve is closed by circuit pressure from the other work equipmentthe LS pressure of port D, and the spool meter-in at port F in the direction of closing (to the right).downstream pressure of port B becomes the In other words, the valve upstream pressure ifsame as the maximum pressure of the other work port B (= spool meter-in downstream pressure) isequipment. controlled by the LS pressure.The spool meter-in upstream pressure of port Ais the pump pressure, so spool meter-in differen-tial pressure (upstream pressure (pressure of portA) - downstream pressure (pressure of port B))becomes the same for all spools that are beingoperated. Therefore, the pump flow is divided inproportion to the area of the meter-in opening.
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STRUCTURE AND FUNCTION CLSS
s3l 2 A 4 B
XlODDO 7
For travel, swingTravel: No holding pressure is generated at port A in
the travel circuit, so a pressure compensationvalve without a shuttle valve is used.
Swing: The holding pressure at the swing port is low,so a pressure compensation valve without ashuttle valve is used.
Reference: When there is no shuttle valve
If there is no shuttle valve, piston (4) and valve(2) will separate. In this condition, if anotheractuator is operated, the piston acts as anaccumulator, so there is a time lag.
Time
XlODD029
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STRUCTURE AND FUNCTION CLSS
Shuttle valve Al
From LS circuitI I
To actuatorThrottle
\
meter-in downstream pressure
Surface area ratio of pressure compensation valveThe condition of the flow division changes accordingto the ratio of the area of portion Al and portion A2of the pressure compensation valve.Area ratio = A2lAl
When area ratio = 1:Spool meter-in downstream pressure = Max. loadpressure, and oil flow is divided in proportion toarea of opening of spool.When ratio is more than 1:Spool meter-in downstream pressure > Max. loadpressure, and oil flow is divided in a proportionless than the area of opening of spool.When ratio is less than 1:Spool meter-in downstream pressure e Max. loadpressure, and oil flow is divided in a proportionmore than the area of opening of spool.
XlODD030
Area ratio for each part of work equipment
Bucket
L.H./R.H.
travel
Boom
Swing
Arm
Service
Port A I Port B
0 98
(Dump)
0.98
0.95(Raise)
0 2.0 0.98 0 2.0(Curl)
0 2.0 0.98 0 2.0
0 2.0 0.98 0 2.0(Lower)
0 98 0 0.5 0 98 0 0.5
0.95 0 2.0 0.95 0 2.0(Out) (In)
0.98 0 2.0 0.98 0 2.0
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STRUCTURE AND FUNCTION CLSS
7. Boom regeneration circuit
1. Main pump Function2. Main spool3A. Pressure compensation valve3B. Pressure compensation valve4A. Safety-suction valve4B. Suction valve5. Check valve6. LS shuttle valve7. Drain circuit
Cylinder head pressure < cylinder bottompressure (free fall, etc.)A return flow circuit is provided from the cylinderbottom to the cylinder head so that when theboom is lowered, the return flow can be used toincrease the flow of oil from the pump to thecylinder bottom.
8. Regeneration circuit
1)
OperationWhen the cylinder head pressure < cylinder bot-tom pressure, part of the pressurized oil from thecylinder bottom passes through the notch in spool
(2), goes through port B, and enters drain circuit(7). The rest of the oil goes from port C, entersregeneration circuit (8), opens check valve (5),and passes through ports C and D to flow back tothe cylinder head.
XlODD031
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STRUCTURE AND FUNCTION CLSS
2)
RAISE LOWE
XlODD032
Cylinder head pressure > Cylinder bottom pres-sure (digging operations, etc.)Check valve (5) in regeneration circuit (8) acts to
shut off the flow from the cylinder head to thecylinder bottom.
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STRUCTURE AND FUNCTION CLSS
8. Arm regeneration circuit
1 Main pump2. Main spool3A. Pressure compensation valve3B. Pressure compensation valve4A. Safety valve4B. Safety valve5. Arm counterbalance valve6. Piston7. Spool8. Check valve9. LS shuttle valve
IO. Drain circuit11. Regeneration circuit
7 6 XlODD033
Function1) Cylinder head pressure > cylinder bottom
pressureA return flow circuit is provided from the cylinderhead to the cylinder bottom so that when thearm is moved in, the flow of oil to the cylinderbecomes the pump discharge amount + thereturn flow, and this increases the cylinderspeed.
Operation0 When the cylinder head pressure > cylinder bot-
tom pressure, the pressurized oil from the cylin-der head passes through the notch in spool (2),enters port C and opens check valve (8), thenpasses through ports D and E to flow back toto the cylinder bottom.
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X10DD034
2) When load is large 3) Cylinder bottom pressure > Cylinder headDuring arm IN operations, if the load increases pressureand the cylinder bottom pressure exceeds 16.6 0 When the cylinder bottom pressure > cylinder
MPa (170 kg/cm?, counterbalance valve (5) is head pressure, check valve (8) is closed by theactuated to increase the meter-out opening at cylinder bottom pressure and prevents any oilthe cylinder head. This reduces the pressure flowing back from the cylinder bottom to theloss between the cylinder head and the hydraulic head end.tank, and ensures the digging force.
OperationThe cylinder bottom pressure enters port F andpushes piston (6) to the left. Spool (7) movesfully to the left and interconnects port C of regen-eration circuit (11) and tank drain circuit (10). Asa result, the pressure loss in the drain circuit isreduced.
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STRUCTURE AND FUNCTION CLSS
9. Arm counterbalance valve
5
From cylinder head
cylinder bon
3 2 XlODD035
I. Piston2. Spool3. Spring4. Check valve5. Regeneration circuit6. Tank drain circuit
OperationDuring arm IN operations, if the actuating pres-sure at the arm cylinder bottom rises, the pres-sure at port A also rises. When the force re-ceived by piston (1) from the pressure at port Abecomes greater than the force of spring (3),piston (1) moves to the left.Spool (2) is pushed by piston (1) and also movesto the left, so ports B and C are interconnected.When this happens, the pressurized oil from the
cylinder head passes through ports B and C, andflows directly to drain circuit (6). (The pressureloss is removed when draining)When this happens, check valve (4) is closed bythe pressure at port A, so it shuts off regenerationcircuit (5), and prevents the oil from flowing backfrom the cylinder bottom to the head end.
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STRUCTURE AND FUNCTION CLSS
10. Spool stroke modulation(1) Boom raise modulation
@oom raisePC pressure
1. Spool2. Pistonsto: Spool
No arm operation
Boom raise@ PPC pressure
st1: Spool strokeSt2: Piston stroke
Boom and arm simultaneous operation
stroke
XlODD036
FunctionWhen boom RAISE and arm DIG are operatedsimultaneously, good simultaneous operation is
achieved by restriction of boom spool max.stroke.
Operation1. When no arm operation
When boom raises, spool (1) goes to the left(c) by stroke Sto to touch piston (2).
2. When arm digs(I) Arm DIG PPC pressure goes to L.H. ofpiston (2) from port A, and pushes piston (2)to the right (+).(2) When boom raises, spool (1) goes to the left(c), but spool max. stroke is restricted to St1because piston (2) moves by 32.
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STRUCTURE AND FUNCTION CLSS
(2) Arm dig modulation
ArmPPC
Arm digPPC pressure c3
No travel operation
SpoolPiston
Arm and travel simultaneous operation XlODD 37
FunctionWhen machine goes up high slope and arm digs,flow to arm cylinder is restricted by limitation ofarm spool stroke to avoid pressure drop of pump.
F pump flow goes to L.H. travel motor throughtravel junction valve.
Operation1. With no travel operation
When arm digs, spool (1) goes to the left(+) by stroke St0 to touch piston (2).
2. With travel operation(1) Travel PPC pressure goes to the right ofpiston (2) from port A, and pushes piston (2) tothe left.(2) When arm digs, spool (1) goes to the right(c), but spool max. stroke is restricted to St1because piston (2) moves by St2.
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STRUCTURE AND FUNCTION CLSS
(4) Arm dig modulation (Arm dig PPC timing valve)
PIQ
2 From armPPC valve 2 XlODD038
Function OperationIn simultaneous operation of boom and arm, such as When arm digs and boom raises simultaneously,finishing, arm spool speed is delayed to prevent sud- spool is delayed because PPC circuit is reduced byden speed change of arm and machine operates arm timing valve and pressure which forces spoolsmoothly. (1) is reduced.
8. Movement of arm timing valve
Plpressure ,
Eessure ‘ et
During simultaneous operation XlODD039
FunctionReduce arm PPC pressure to M/V for simultaneous
operation of arm dig and boom up.
Operation1. Simple operation of arm dig
PPC pressure goes to port PI and pushes spool(1) to the right against spring (2) and port PIthrough port P2 via B.
2. Simultaneous operation of arm dig and boomUP
(i
(ii)
When boom raises, PPC pressure goes toport P3 and pushes spool (1) to the left.When levers are fully stroked towards armdig and boom raise simultaneously, spool (1)is pushed to the left by force according to thefollowing formula. PI pressure 5 P2 pressure+ spring force (PI pressure = P2 pressure)Then B is intercepted and PPC pressure ofarm dig goes to port P2 from port PI via ori-fice A.
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STRUCTURE AND FUNCTION CLSS
11. Pump merge-divider valve
8’
PS
‘ OFF,
To control valve
To control valve
1. Main spool2. Spring3. LS spool4. Spring5. LS circuit (bucket end)6. LS circuit (arm end)7. LS circuit (arm end)a. LS circuit (bucket end)
P2 Pl
XlODD 4
OperationIi When merging pump flow (when pilot
pressure PS is OFF)Pilot pressure PS is OFF, so main spool (1) ispushed to the left by spring (2) and ports E andF are interconnected.
Function0 This acts to merge or divide (send to its own
control valve group) oil flows Pl and P2 ofpressurized oil discharged from the two pumps.
At the same time, it also carries out merging anddividing of LS circuit pressure.
Therefore, pressurized oil PI and P2 dischargedfrom the two pumps is merged at ports E and F,and is sent to the control valve that demands theoil.In the same way, LS spool (3) is also pushed tothe left by spring (4), so the ports are connectedas follows.
Connected ports: A +-+ D, B * CTherefore, the LS pressure supplied from thespools of each control valve to LS circuits (5), (6),(7), and (8) is all sent to the pressure compensa-tion valve and other valves.
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STRUCTURE AND FUNCTION CLSS
PS
‘ONJ
bucket control valve
To arm control valve
‘ 6
P2 Pl
2) When dividing pump flow (when pilotpressure PS is ON)When pilot pressure PS is ON, main spool (1) is
moved to the right by the PS pressure, and portsE and F are disconnected.Therefore, the pressurized oil discharged fromeach pump is sent to its own control valve group.Pressure PI: To bucket, R.H. travel, boom groupPressure P2: To swing, L.H. travel, arm groupIn the same way, LS spool (3) is also moved tothe right by the PS pressure, and the ports areconnected as follows.Connected ports: B * D, others are not conn-ected. Therefore, LS circuits (5), (6) (7), and (8)are all sent to their own control valve group.
XlODDO 4
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STRUCTURE AND FUNCTION CLSS
11 LS select valve* The diagram shows the situation when the swing
and left travel are operated at the same time.(BP pressure ON)
1. Valve
BP r)'ON,
l
2.... Armpringistoniston pool
5. Swing spool6. L.H. travel spool
8. L.H. shuttle valve
6
8
i XlODD042
FunctionThis valve is used to increase the ease of operat-ing the work equipment. It prevents high pres-sure from being generated when the swing isoperated. It also prevents the high LS pressurefrom the swing circuit from flowing into any otherLS circuit when the swing is operated togetherwith the work equipment.
Operation1) When pilot pressure BP is OFF
Pilot pressure BP is OFF, so piston (3) is pushedto the left by spring (2). If the swing is then oper-ated, swing LS pressure PI passes throughswing spool (5), and enters port A. It pushesvalve (1) to the left and connects ports A andB. Therefore, swing LS pressure PI flows to LSshuttle valve (8).
2) When pilot pressure is ONWhen pilot pressure BP is ON, piston (3) is moved
to the right against spring (2) by the BP pressure.It pushes valve (1) to the right and closes thecircuit between ports A and B. As a result, swingLS pressure PI stops flowing to LS shuttle valve(8), and even if swing LS pressure PI rises to ahigh pressure, it does not influence any other LScircuit.
9. LS circuit
4 3 2 B t A
BP‘ OFF,
Pl
To LS shuttle valveXlQDD043
4 3 2 B 1 A
*BP
‘ ON,
To LS shuttle valve
XlODD044
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STRUCTURE AND FUNCTION CLSS
1.2A.2B.3A.3B.4A.4B.5A.
5B.6.7.8.9.
10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28A.28B.29A.29B.30A.30B.
31.32.33A.33B.34.
Hydraulic tankMain pump (front)Main pump (rear)n/C valve (front)NC valve (rear)LS valve (front)LS valve (rear)Pump merge-divider valve (for main)
Pump merge-divider valve (for LS)Bucket spoolR.H. travel spoolBoom spoolSwing spoolL.H. travel spoolArm spoolPressure compensation valve (bucket)Pressure compensation valve (R.H. travel)Pressure compensation valve (boom)Pressure compensation valve (swing)Pressure compensation valve (L.H. travel)Pressure compensation valve (arm)Safety-suction valveSuction valveLS shuttle valve (bucket)LS shuttle valve (R.H. travel)LS shuttle valve (boom)LS shuttle valve (L.H. travel)LS shuttle valve (arm)Check valve (for boom regeneration circuit)Check valve (for arm regeneration circuit)Arm counterbalance valveMain unload valveLS relief valveMain relief valve (bucket group)Main.relief valve (arm group)Sub-unload valve (bucket group)Sub-unload valve (arm group)
LS select valveLS check valveMain check valve (bucket group)Main check valve (arm group)LS bypass valve
Note: Groups of control valves by main pump circuitBucket group: Bucket, R.H. travel, boomArm group: Swing, L.H. travel, arm
OperationWhen the levers are at neutral, the pump is atthe minimum swash plate angle, and the oil flowis drained from main unload valve (28A).
The LS pressure is connected to hydraulic tank(1) by LS bypass valve (34). The LS differentialpressure A PLS (unload pressure -tank pres-sure) at this point is A PLS > pump LS controlpressure, so the pump swash plate angle is theminimum.
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FOLDPump flow divided, one side actuated, other side neutral
The diagram shows the independent bucket DUMP operation with pump merge.
,
281
f-l
.
\\\
Connection of ports when
pump flow is divided
Connected ports: B - D
Disconnecte d ports: A, C
TS - \I 1 I
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STRUCTURE AND FUNCTION CLSS
Operation
1)0
2)
Pilot pressure PA of pump merge-dividervalve @A) ONBucket groupWhen the bucket is operated, pressurized oilfrom main pump (2B) flows to the bucketgroup. The swash plate angle of main pump(2B) is controlled to match the operation of
bucket spool (6).The LS pressure passing through the inside ofbucket spool (6) goes to main unload spool(28A), and the main unload valve is closed.
Arm groupWhen the pump flow is merged, all spools areat neutral, so the oil flow from the minimumswash plate angle of main pump (2A) is alldrained from sub-unload valve (30B) of thearm group. All spools in the arm group areat neutral, so no LS pressure is generated.If the pump pressure - LS pressure becomesgreater than the set pressure of sub-unloadvalve (3OB), the sub-unload valve is actuatedand the oil is drained. The LS differentialpressure a PLS at this point is a PLS > pumpLS control pressure, so the pump swash plateangle is the minimum.
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STRUCTURE AND FUNCTION CLSS
Operation
1)
0
2)
When pump swash plate angle is at a mini-mum (LS relief valve actuate in standardmode)When the arm OUT is operated, if the loadbecomes larger, the LS pressure passingthrough the inside of arm spool (11) rises.The LS circuit pressure is controlled by LS
relief valve (288).When the difference (a PLS) between thepump pressure and LS pressure becomeslarge, main unload valve (28A) is actuatedto suppress the rise in the main circuit pres-sure and regulate it to the standard moderelief pressure.
The LS differential pressure n PLS at thispoint is a PLS > pump LS control pressure,so the pump swash plate angle is the mini-mum. In other words, the automatic cut-offcontrol is carried out.
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FOLD Pump flow divided bucket DUMP power max. relief
The diagram shows bucket DUMP, relief with the pump flow divided.
t
PLSl
ILI I
1 I /
Connection of ports when
pump flow is divided
Connected ports: B - DDisconnect ed ports: A, C
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STRUCTURE AND FUNCTION CLSS
OperationPilot pressure PA of pump merge-dividervalve (5A) ONPilot pressure PB of LS relief valve (288) ON
I> When the bucket is operated, if the powermax. function is ON, pilot pressure PB actson LS relief valve (28B), so the LS relief valve
is not actuated.
2) When the bucket DUMP is operated and theload pressure becomes greater, pump pres-sure PI and LS pressure PLSI both rise. Pi-lot pressure PB is preventing LS relief valve(28B) from operating at this point, so mainrelief valve (29A) of the bucket group is ac-tuated and controls the relief while the powermax. function is being used.
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FOL Pump flow merged boom RAISE
The diagram shows the boom RAISE w ith the pump flow merged. PLSl-
Pl I -1
8A
\ 88
205FO6072
Connection of ports when pump
flow is merged TS
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STRUCTURE AND FUNCTION CLSS
OperationWhen the boom RAISE is operated, mainpumps (2A) and (2B) are both at the maxi-mum swash plate angle, and main unloadvalve (28A) is closed.At this point, for the meter-in opening ofboom spool (8), even if both pumps are atthe maximum swash plate angle, the LS dif-
ferential pressure is set to be smaller than thepump LS control pressure.In other words, LS differential pressure a PLSis a PLS < pump LS control pressure, so thepump swash plate angle becomes the maximum.
0 In addition, the flow of main pump (2A) passesthrough pump merge-divider valve @A)and flows to boom spool (8).
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STRUCTURE AND FUNCTION CLSS
OperationPilot pressure PA of pump merge-dividervalve (5A) ON
0 When the swing is operated, main pump(2A) of the arm group is at the maximumswash plate angle, and main unload valve(28A) is closed.At this point, for the meter-in opening of
swing spool (9) even if main pump (2A) isat the maximum swash plate angle, the LSdifferential pressure is set to be smaller thanthe pump LS control pressure.In other words, LS differential pressure n PLSis a PLS c pump LS control pressure, so thepump swash plate angle of main pump (2A)becomes the maximum.All spools in the bucket group are at neutral,so main pump (2B) is at the minimum swashplate angle, and sub-unload valve (30A) isactuated. For details of the actuation, see 2.Pump flow merged, one side actuated, otherside neutral.
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FOLDPump flow divided, travel operated independently
The diagram shows the travel operated independently with the pump flow divided.
/8
\TS \
// \ I
\58
Connection of ports when
pump flow is divided
Connected ports: B - D
Disconnecte d ports: A, C
05FO6074
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FOLDPump flow merged, compound ope ration
The diagram shows boom RAISE + arm IN with the pump flow merged. PLSl
Connection of ports when pump I
205FO6075
flow i s merged
Connected ports: A - D, B - C. IdL
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STRUCTURE AND FUNCTION CLSS
Operation1) When the arm and boom are operated
simultaneously, the swash plate angle forboth pumps becomes the maximum.When this happens, the load pressure at theboom RAISE side is higher than at the armside, so the LS pressure passes through ports
E and F of boom spool (8), enters LS shuttlevalve (22) and is sent to the LS circuit. ThisLS pressure is transmitted to port G of armpressure compensation valve (17), and actsto increase the set pressure of the pressurecompensation valve. Because of this, thepressure between port H or arm spool (11)and port I or pressure compensation valve(17) rises, and spool meter-in LS differentialpressure (pump pressure - LS pressure =A PLS) becomes the same as that at the boomend.
2)Because of the above operation, the oil flowis divided in proportion to the size of theopening area of boom spool (8) and theopening area of arm spool (11).Meter-in differential pressure A PLS dur-ing boom RAISE + arm IN is A PLS c boomLS control pressure, so the main pump swashplate angle is set to maximum.
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STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
m
\d c
a. portsb. Port MB (from control valve)C. Port MA (from control valve)d. Port T (to tank)e. Port B (from swing brake solenoid valve)
XlOAV265
Model
item
Type
Theoretical delivery
Safety valve setpressure
PC200-6PC200LC-6 PC22OLC-6PC21 OLC-6 PC25OLC-6
KMFgOAB-2
87.8 cc/rev
27.44 MPa(280 ka/cm*j
Rated speed
Brake releasingpressure
I 2.298 rpm 1 2.403 rDm
1.37 MPa(14 kg/cm2)
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STRUCTURE AND FUNCTION SWING MOTOR
A A
1 Brake spring2. Drive shaft3. Cover4. Case5. Disc6. Plate
7. Brake piston6. End cover9. Piston
10 Cylinder11 Valve plate12. Air bleed plug13. Center shaft14. Center spring15. Safety valve
16. Check valve17. Check valve spring
c-c
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STRUCTURE AND FUNCTION SWING MOTOR
SWING HOLDING BRAKE
OPERATION1) When swing brake solenoid valve is
deactivatedWhen the swing brake solenoid valve is deacti-vated, the pressurized oil from the control pump
is shut off and port B is connected to the tankcircuit.Because of this, brake piston (7) is pushed downin the direction of the arrow by brake spring (I),so disc (5) and plate (6) are pushed together andthe brake is applied.
2) When swing brake solenoid is excitedWhen the swing brake solenoid valve is excited,the valve is switched, and the pressurized oil fromthe control pump enters port b and flows to brakechamber a.The pressurized oil entering chamber a over-comes the force of brake spring (I), and brakepiston (7) is pushed up in the direction of thearrow. Because of this, disc (5) and plate (6)separate, and the brake is released.
Swing brakesolenoid valve
- XlOAV267
solenoid valve
XlOAV268
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STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT4-PORT SWIVEL
A A
1 Cover2. Body3. Slipper seal4. O-ring5. Shaft
Al. From control valve port B2A2. To R.H. travel motor port PBBl From control valve to port B5
Al
Cl
El
A ---I
T2 D2
82 A2 c2
x1 zz 2
82. To L.H. travel motor port PACl. From control valve port A2C2. To R.H. travel motor port PADl . From control valve port A5D2. To L.H. travel motor port PBEl. From travel speed solenoid valveE2. To L.H. and R.H. travel motors port PTl. To tankT2. From L.H. and R.H. travel motors port T
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STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTORPC200-6, PC200LG6PC21 OLC-6, PC220LG6
i A
a. Port PB (from control valve)b. Port PA (from control valve)c. Port T (to tank)d. Pot-t P (from travel speed solenoid valve)
SPECIFICATIONS
Model
Item
Type
Theoreticaldelivery
Eated speed
Brake releasing pressure
Travel speedswitchingpressure
Differentialpressure
D4
xo7zzoo1
PC200-6PC2OOLC-6PC21 OLC-6
PC22OLC-6
HMVl60ADT-2
110.1 c/rev 1 118.4cclrev
160.8 cc/rev
34.79 MPa(355 kg/cm’ )
1,834 rpm 1,780 rpm
1,004 rpm 1,048 rpm
1.18 MPa(12 kg/cm’ )
0.78 MPa(8 kg/cm*)
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STRUCTURE AND FUNCTION TRAVEL MOTOR
245878 17 18 19 20
1. Output shaft 9. Regulator valve2. Motor case 10. Spring3. Ball 11. Brake spring4. Rocker cam 12. Brake piston5. Piston 13. Plate6. Cylinder 14. Disc7. Valve plate 15. Regulator piston
8. End cover 16. Spring
XO7ZZOO
17. Check valve spring18. Check valve19. Counterbalance valve20. Spool return spring21. Safety valve22. Slow return valve
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STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTORPC25OLC-6
x0722003
a. T, port (To tank)b. PB port (From control valve)c. P port (From travel speed solenoid valve)d. PA port (From control valve)e. T, port (To tank)
SPECIFICATIONS
Item Model PC25OLC-6
Ratedspeed
Min.
MaX.
895 rpm
1.430 mm
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STRUCTURE AND FUNCTION TRAVEL MOTOR
245678
B-B
1. Output shaft2. Motor case3. Ball4. Rocker cam5. Piston
6. Cylinder7. Valve plate8. End cover
9. Regulator valve10. Spring11. Brake spring12. Brake piston13. Plate
14. Disc15. Regulator piston16. Spring
D-D 1’ 0 il
x0722004
17. Check valve spring18. Check valve19. Counterbalance valve20. Spool return spring21. Safety valve
22. Slow return valve
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STRUCTURE AND FUNCTION TRAVEL MOTOR
OPERATION OF MOTOR1) Motor swash plate angle (capacity) at maximum
The solenoid valve is deactivated, so the pilotpressure oil from the control pump does not flowto port P.For this reason, regulator valve (9) is pushed tothe right in the direction of the arrow by spring(19).Because of this, it pushes check valve (22), andthe main pressure oil from the control valve go-ing to end cover (8) is shut off by regulator valve(9).Fulcrum a of rocker cam (4) is eccentric to pointof force b of the combined force of the propul-sion force of cylinder (6), so the combined forceof the piston propulsion force acts as a momentto angle rocker cam (4) in the direction of themaximum swash plate angle.
At the same time, the pressurized oil at regulatorpiston (15) passes through orifice c in regulatorvalve (9) and is drained to the motor case.As a result, rocker cam (4) moves in the maxi-mum swash plate angle direction, the motorcapacity becomes maximum.
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STRUCTURE AND FUNCTION TRAVEL MOTOR
OPERATION OF PARKING BRAKE1)
2)
When starting to travelWhen the travel lever is operated, the pres-sure oil from the pump actuates counterbalancevalve spool (19), opens the circuit to parkingbrake, and flows into chamber A of brake piston(72).It overcomes the force of spring (11) and pushespiston (12) to right in the direction of thearrow.When this happens, the force pushing plate (13)and disc (14) together is lost, so plate (13) anddisc (14) separate and the brake is released.
D-7- \\\14 13 A 12 11 22
When stopping travelWhen the travel lever is placed in neutral, coun-terbalance valve spool (19) returns to the neutral. . . . .posrtron and crrcurt to the parking brake IS closed.The pressurized oil in chamber A of brake piston(12) is drained to the case from the orifice in thebrake piston, and brake piston (12) is pushed tothe left in the direction of the arrow by spring(1%As a result, plate (13) and disc (14) are pushedtogether, and the brake is applied.A time delay is provided by having the pressu-rized oil pass through a throttle in slow returnvalve (22) when the brake piston returns, and thisensures that the brake still effective after themachine stops.
control valve
&xo uoo
14 13 12 11 22
lcontrol valve1
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STRUCTURE AND FUNCTION TRAVEL MOTOR
OPERATION OF BRAKE VALVEThe brake valve consists of a check valve, coun-terbalance valve, and safety valve in a circuit asshown in the diagram on the right. (Fig. 1)The function and operation of each component isas given below.
ounterbalance
1) Counterbalance valve, check valveFunction
When traveling downhill, the weight of the ma-chine makes it try to travel faster than the speedof the motor.As a result, if the machine travels with the engineat low speed, the motor will rotate without loadand the machine will run away, which is extremelydangerous.To prevent this, these valves act to make themachine travel according to the engine speed(pump discharge amount).
Operation when pressure oil is suppliedWhen the travel lever is operated, the pressu-rized oil from the control valve is supplied to portPA. It pushes open check valve (18A) and flowsfrom motor to inlet port MA to motor outlet portMB.However, the motor outlet port is closed by checkvalve (18B) and spool (19), so the pressure at thesupply side rises. (Fig. 2)The pressurized oil at the supply side flows fromorifice El in spool (19) and orifice E2 in the pis-ton to chamber Sl. When the pressure in cham-ber Sl goes above the spool switching pressure,spool (19) is pushed to the right in the directionof the arrow.As a result, port MB and port PB are connected,the outlet port side of the motor is opened, andthe motor starts to rotate. (Fig. 3)
l
l
(Fig. 2)
,Travel ontrol
valve
(Fig. 3)
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STRUCTURE AND FUNCTION TRAVEL MOTOR
Operation of brake when traveling downhillIf the machine tries to run away when travelingdownhill, the motor will turn under no load, sothe pressure at the motor inlet port will drop, andthe pressure in chamber Sl through orifices Eland E2 will also drop. When the pressure inchamber Sl drops below the spool switching
pressure, spool (19) is returned to the left in thedirection of the arrow by spring (20), and outletport MB is throttled.As a result, the pressure at the outlet port siderises, resistance is generated to the rotation of themotor, and this prevents the machine from run-ning away.In other words, the spool moves to a positionwhere the pressure at outlet port MB balancesthe pressure at the inlet port and the force gener-ated by the weight of the machine. It throttles theoutlet port circuit and controls the travel speedaccording to the amount of oil discharged from
the pump. (Fig. 4)
2) Safety valve (2-way operation, 24age setsafety valve
FunctionWhen travel is stopped (or when traveling down-hill), the circuits at the inlet and outlet ports ofthe motor are closed by the counterbalance valve,but the motor is rotated by inertia, so the pressureat the outlet port of the motor will become ab-normally high and damage the motor or piping.The safety valve acts to release this abnormalpressure and sent it to the inlet port side of themotor to prevent damage to the equipment.
Operation in both directions
Ii When pressure in chamber MB has becomehigh (when rotating clockwise)When the travel is stopped (of when travelingdownhill), chamber MB in the outlet port circuitis closed by the check valve of the counterbal-ance valve, but the pressure at the outlet portrises because of inertia. (Fig. 5)
If the pressure goes above the set pressure, theforce produced by the difference in area betweenDl and D2 [rr/4(Dl* - D2’ > X pressure] overcomes
the force of the spring and moves the poppet tothe left, so the oil flows to chamber MA in thecircuit on the opposite side. (Fig. 6)
Travel controlvalve
(Fig. 4)XO7ZZO12
xo7zzo13
(Fig. 5)
D2
/Poppet
(Fig. 6)
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STRUCTURE AND FUNCTION TRAVEL MOTOR
2) When pressure in chamber MA has becomehigh (when rotating counterclockwise)When the travel is stopped (or when travelingdownhill), chamber MA in the outlet port circuitis closed be the check valve of the counterbal-ance valve, but the pressure at the outlet portrises because of inertia. (Fig. 7)
If the pressure goes above the set pressure, theforce produced by the difference in area betweenDl and D3 [n/4(D3’ - Dl’ > X pressure] overcomesthe force of the spring and moves the poppet tothe left, so the oil flows to chamber MB in thecircuit on the opposite side. (Fig. 8)
Operation of mechanism for varying set pressure1) When starting travel (high pressure setting)
When the travel lever is operated, the pressurizedoil from the pump actuates counterbalance valvespool (19), and opens the pilot circuit to the safetyvalve. The oil passes from chamber G to passageH and flows into chamber J, pushes the pistonto the right in the direction of the arrow, and comp-resses the spring to make the set load larger.Because of this, the set pressure of the safetyvalve is switched to the high pressure setting, anda large drawbar pull is made available.
xo7zzo15
(Fig. 7)
I
/Poppet XO7ZZO16
Fig. f9
Piston1
Travel ontrol
(Fig. 9)
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STRUCTURE AND FUNCTION TRAVEL MOTOR
2) When stopping travel (low pressure setting)When the travel lever is placed at neutral, thepressure in chamber PA drops and counterbal- Piston Spring
ante valve spool (19) returns to the neutral posi-tion. While the counterbalance valve spool isreturning to the neutral position, the pressurizedoil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. Thepiston moves to the left in the direction of thearrow, and the set load becomes smaller. Be-cause of this, the set pressure of the safety valveis switched to the low pressure setting in order torelieve the shock when reducing speed.
[Set pressure of safety valve]
When starting, when traveling When stopping
High pressure setting Low pressure setting37.73 MPa (385 kg/cm*) 27.44 MPa (280 kg/cm*)
Travel control valve
. ,-/- XO7ZZO18
(Fig. 10)
IO 106
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STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROLPC200-6, PC2OOLG6PC21 OLC-6, PC22OLC-6PC25OLG6
1
2.3.4.5.6.7.
8.9.
D
Travel PPC valve 10. Control valveService PPC valve 11. PPC shuttle valveService pedal 12. AccumulatorL.H. travel lever 13. Solenoid valveR.H. travel lever 14. L.H. work equipmentR.H. PPC valve leverR.H. work equipment 15. Safety lock valvelever 16. L.H. PPC valveLS control EPC valve 17. Safety lock leverHydraulic pump 18. Timing valve
i
\16
17
Lever positionsA. NeutralB. Boom RAISEC. Boom LOWERD. Bucket DUMPE. Bucket CURLF. NeutralG. Arm INH. Arm OUT
18
IO
/”
12
13
XlOAZo
I. Swing RIGHTJ. Swing LEFTK. NeutralL. Travel REVERSEM. Travel FORWARDN. LOCK0. FREE
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STRUCTURE AND FUNCTION WORK EQUIPMENT . SWING PPC VALVE
WORK EQUIPMENT. SWING PPC VALVEPC200-6, PC2OOLC-6PC21 OLC-6, PC22OLC-6PC25OLC-6
XOQDH 25
a. Port P (from control pump)b. Port T (to tank)c. Port P2 (L.H.: Arm IN/R.H.: Boom RAISE)d. Port P4 (L.H.: Swing LEFT/R.H.: Bucket DUMP)e. Port PI (L.H.: Arm OUT/R.H.: Boom LOWER)f. Port P3 (L.H.: Swing RIGHT/R.H.: Bucket CURL)
IO 108
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STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
6
I
9
10
1 Spool2. Metering spring3. Piston
4. Disc5. Nut (for connecting lever)
D-D
X09DH026
7. Joint8. Plate9. Retainer
10. Body11. Filter
1o-1 09
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STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
OPERATION1) At neutral
2)
Ports A and B of the control valve and ports P,and P, of the PPC valve are connected to drainchamber D through fine control hole f in spool(1). (Fig. 1)
During fine control (neutral + fine control)When piston (4) starts to be pushed by disc (5),retainer (9) is pushed; spool (1) is also pushedby metering spring (2), and moves down.When this happens, fine control hole f is shutoff from drain chamber D, and at almost the sametime, it is connected to pump pressure chamberP,, so pilot pressure oil from the control pumppasses through fine control hole f and goes fromport P, to port A.When the pressure at port P, becomes higher,spool (1) is pushed back and fine control hole fis shut off from pump pressure chamber P,. Atalmost the same time, it is connected to drainchamber D to release the pressure at port P,.When this happens, spool (1) moves up or downso that the force of metering spring (2) is balancedwith the pressure at port P,. The relationship inthe position of spool (1) and body (10) (finecontrol hole f is at a point midway between drain
hole D and pump pressure chamber Pp) does notchange until retainer (9) contacts spool (1).Therefore, metering spring (2) is compressedproportionally to the amount of movement of thecontrol lever, so the pressure at port P, also risesin proportion to the travel of the control lever.In this way, the control valve spool moves to aposition where the pressure in chamber A (thesame as the pressure at port P,) and the forceof the control valve spool return spring arebalanced. (Fig. 2)
Control valve
X09DH027
4 :
7Jr\ r
X09DH028
(Fig. 2)
10 I 0
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STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
3) During fine control (when control lever isreturned)When disc (5) starts to be returned, spool (1) ispushed up by the force of centering spring (3)and the pressure at port P,.When this happens, fine control hole f is conn-ected to drain chamber D and the pressure oil
at port P, is released.If the pressure at port P, drops too far, spool (1)is pushed down by metering spring (2), and finecontrol hole f is shut off from drain chamber D.At almost the same time, it is connected to pumppressure chamber P,, and the pump pressureis supplied until the pressure at port P, recoversto a pressure that corresponds to the leverposition.When the spool of the control valve returns, oilin drain chamber D flows in from fine controlhole f ’ n the valve on the side that is not working.The oil passes through port P, and enters cham-ber B
tofill the chamber with oil. (Fig. 3)
4) At full strokeWhen disc (5) pushes down piston (4), and ret-ainer (9) pushes down spool (l), fine control holef is shut off from drain chamber D, and is conn-ected with pump pressure chamber P,.Therefore, the pilot pressure oil from the control
pump passes through fine control hole f and flowsto chamber A from port P,, and pushes the controlvalve spool.The oil returning from chamber B passes fromport P, through fine control hole f ’ and flows todrain chamber D. (Fig. 4)
X09DH029
(Fig. 3.)
Control valve
X09DH030
0%. 4)
1 l 1
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STRUCTURE AND FUNCTION TRAVEL PPC VALVE
TRAVEL PPC VALVE
D D
b’C
e
XlOBH 55
a. Port P (from control pump)b. Port T (to tank)c. Port PI (L.H. travel REVERSE)d. Port P3 (R.H. travel REVERSE)e. Port P2 (L.H. travel FORWARD)f. Port P4 (R.H. travel FORWARD)
IO 112
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STRUCTURE AND FUNCTION TRAVEL PPC VALVE
6-
5’
A A
c-c
1. Piston 5. Valve2. Plate 6. Metering spring3. Collar 7. Centering spring4. Body 8. Bolt
D-D
XlOBH156
IO 113
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STRUCTURE AND FUNCTION TRAVEL PPC VALVE
OPERATION
1. At neutralPorts A and B of the control valve and ports PIand P2 of the PPC valve are connected to drainchamber D through fine control hole f in spool (1).(Fig. 1)
2. Fine control (neutral + fine control)When piston (4) starts to be pushed by disc (5),retainer (9) is pushed. Spool (1) is also pushed bymetering spring (2) and moves down.When this happens, fine control hole f is shut offfrom drain chamber D. At almost the same time,it is connected to pump pressure PP, and the pilotpressure of the control pump is sent from port Athrough fine control hole f to port PI. When thepressure at port PI rises, spool (1) is pushedback. Fine control hole f is shut off from pumppressure chamber PP. At almost the same time,it is connected to drain chamber D, so the pres-sure at port PI escapes.As a result, spool (1) moves up and down untilthe force of metering spring (2) is balanced withthe pressure of port PI.The relationship of the positions of spool (1) andbody (10) (fine control hole f is in the middlebetween drain hole D and pump pressure cham-ber PP) does not change until retainer (9) con-tacts spool (1).
Therefore, metering spring (2) is compressed inproportion to the travel of the control lever, so thepressure at port PI also rises in proportion to thetravel of the control lever.In this way, the spool of the control valve moves toa position where the pressure of chamber A(same as pressure at port PI) and the force of thereturn spring of the control valve spool are bal-anced. (Fig. 2)
Control valve
XlOBH157
(Fig. 1)
ii&Control va
(Fig. 2)
IO 114
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STRUCTURE AND FUNCTION
Fine control (control lever returned)When disc (5) starts to be returned, spool (1) ispushed up by the force of centering spring (3)and the pressure at port PI.Because of this, fine control hole f is connectedto drain chamber D, and the pressurized oil atport PI is released.
If the pressure at port PI drops too much, spool(1) is pushed up by metering spring (2), so finecontrol hole f is shut off from drain chamber D.At almost the same time, it is connected to pumppressure chamber PP, so the pressure at port PIsupplies the pump pressure until the pressurerecovers to a pressure equivalent to the positionof the lever.When the control valve returns, oil in drain cham-ber D flows in from fine control hole f ’ of the valveon the side that is not moving. It passes throughport P2 and goes to chamber B to charge the oil.(Fig. 3)
4) At full strokeDisc (5) pushes down piston (4), and retainer (9)pushes down spool (1). Fine control hole f is shutoff from drain chamber D, and is connected topump pressure chamber PP. Therefore, the pilotpressure oil from the control pump passesthrough fine control hole f and flows to chamberA from port PI to push the control valve spool.The return oil from chamber B passes from portP2 through fine control hole f ’ and flows to drain
chamber D. (Fig. 4)
TRAVEL PPC VALVE
XlOBH1(Fig. 3)
XlOBH16(Fig. 4)
IO I 5
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STRUCTURE AND FUNCTION SERVICE PPC VALVE
SERVICE PPC VALVE
1. Pin2. Cam3. Ball4. Piston5. Cover6. Sleeve7. Centering spring8. Metering spring9. Spool
10. Body
a. Port T (to tank)b. Port P (from control pump)c. Port A (to service valve P,)d. Port B (to service valve PJ
dXlOBHlGl
IO 116
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STRUCTURE AND FUNCTION SERVICE PPC VALVE
OPERATION
At neutralThe pressurized oil from the control pumpenters from port P and is blocked by spool(9).Port A and B of the control valve and port aand b of the PPC valve are connected todrain port T through fine control hole X ofspool (9).
When operatedWhen cam (2) is moved, metering spring (8)is pushed by ball (3), piston (4) and sleeve (6),and spool (9) is also pushed down by this.As a result, fine control hole X is shut off fromthe drain circuit. At almost the same time, finecontrol portion Y is connected with port a, and thepressurized oil from port A of the control valve.
XlOBH 62
XlOBH 63
IO 117
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STRUCTURE AND FUNCTION SERVICE PPC VALVE
When the pressure at port a becomes higher,spool (9) is pushed back by the force actingon the end of the spool. When tine controlportion Y closes, fine control hole X is conn-ected to the drain circuit at almost the sametime.As a result, spool (9) moves up and down to
balance the force at port a and the force atmetering spring (8).Therefore, metering spring (8) is compressed inproportion to the amount the control lever ismoved. The spring force becomes larger, sothe pressure at port a also increases in propor-tion to the amount the control lever is operated.In this way, the control valve spool moves to aposition where the pressure of port A (the sameas the pressure at port a is balanced with theforce of the return spring of the control valvespool.
XlOBH 64
IO 118
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STRUCTURE AND FUNCTION SAFETY LOCK VALVE. PPC ACCUMULATOR
SAFETY LOCK VALVE
PPC ACCUMULATOR
1. Lever2. Body3. Seat4. Ball
5. End cap
XlOBH165
6-
XlOBH166
1. Gas plug2. Shell3. Poppet4. Holder5. Bladder6. Oil port
SPECIFICATIONSGas capacity: 400 cc
1 l 9
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
PPC SHUTTLE. TRAVEL JUNCTION VALVE
1. PPC shuttle valve2. Travel junction valve
XlOBH167
OUTLINEThe PPC shuttle valve and travel junction valveform a combined structure.
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STRUCTURE AND FUNCTION PPC SHUTTLE TRAVEL JUNCTION VALVE
PPCSHUTTLEVALVE
n
P
r
u
X
ba
cb
ee
XlOBH168
FUNCTIONThis sends the PPC valve output pressure orEPC valve output pressure to the control valveand travel junction valve. It is provided with amount port for the pressure switch for detect-ing the pilot pressure.
IO 121
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
a. Port PI 1 (from swing PPC valve)b. Port P21 (from swing PPC valve)c. Port P31 (from bucket PPC valve)d. Port P41 (from bucket PPC valve)e. Port P51 (from boom PPC valve)f. Port P61 (from arm PPCYEPC valve)g. Port PLS (from LS select valve)
h. Port P71 (from arm PPC/EPC valve)i. Port P81 (from boom PPC/EPC valve)j. Port PA1 (from R.H. travel PPC valve)k. Port PBI (from L.H. travel PPC valve)I. Port PC1 (from L.H. travel PPC valve)m. Port P91 (from R.H. travel PPC valve)n. Port PI2 [to control valve (swing)]0. Port P22 [to control valve (swing)]p. Port P32 [to control valve (bucket)]q. Port P42 [to control valve (bucket)]r. Port P52 [to control valve (boom)]s. Port P62 [to control valve (arm)]t. Port P72 [to control valve (arm)]
u. Port P82 [to control valve (boom)]v. Port PA2 [to control valve (R.H. travel)]w. Port PB2 [to control valve (L.H. travel)]x. Port PC2 [to control valve (L.H. travel)]y. Port P92 [to control valve (R.H. travel)]zl. Port PR (to travel junction valve)z2. Port PF (to travel junction valve)aa. Port Al (mount port for swing oil pressure switch)bb. Port A8 (mount port for bucket DUMP oil pressure switch)ca. Port A2 (mount port for arm OUT oil pressure switch)cb. Port A4 (mount port for arm IN oil pressure switch)da. Port A5 (mount port for boom RAISE oil pressure switch)db. Port A7 (mount port for boom LOWER oil pressure switch)ee. Port A6 (mount port for travel oil pressure switch)
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
33
2 2
F-F A-A
G G B-B
J-J(2PLACES)
K-K(2PLACES
L__--- --...___J
N-N
L-L E-E
AA-AA XlOBH169
1. Body2. Plug3. Ball
IO 123
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE
e f
1. Body2. Plug3. Spring4. Spool
d
A A XlOBH170
a. Port Tl (from R.H. travel control valve)b. Port T2 (from L.H. travel control valve)c. Port T3 (from R.H. travel control valve)d. Pot-t T4 (from L.H. travel control valve)e. Port PF (from PPC shuttle valve)f. Port PR (from PPC shuttle valve)
IO 124
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
STRAIGHT-TRAVEL SYSTEM
R.H. PPC valveBoom Bucket
PPC shuttle va lve assembly
r.&-I--------A-+-Bucket CURL
FORWARD
L.H. travel motor R.H. travel motor
L
FUNCTION
XlODD045
A travel junction valve is installed between thetravel valve and travel motor to compensate forany difference in the oil flow to the left and righttravel circuits when traveling in a straight line.Because of this, the flow of oil to the left andright travel motors when traveling in a straight
line is almost the same, so there is no traveldeviation.The travel junction valve interconnects the travelcircuits when the straight-travel is operated inde-pendently or when the straight travel + anotheractuator are operated simultaneously.
When steering, if the difference in the movementof the travel levers is more that approximately10 mm, the travel junction valve is switched, andthe left and right travel circuits are shut off.
IO 125
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STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE
OPERATIONA: PPC output pressure (R.H. travel REVERSE or
L.H. travel FORWARD)B: PPC output pressure (R.H. travel FORWARD or
L.H. travel REVERSE)
When traveling in a straight line in forward or
reverseWhen traveling forward (or in reverse), there isno difference in the pilot pressure from the PPCshuttle valve (the output pressure of each PPCvalve), so the spool is balanced in the middle.In this condition, the R.H. FORWARD and L.H.FORWARD, and R.H. REVERSE and L.H.REVERSE are interconnected through the spool.
When steering in forward or reverseWhen the steering is operated in forward (or re-verse), if the difference in the pilot pressure fromthe PPC shuttle valve becomes greater than theswitching pressure (spring force), the spool movesto the right or left and the L.H. and R.H. forwardand L.H. and R.H. reverse passages are sepa-rated. Because of this, a difference in pressure iscreated in the L.H. and R.H. circuits, and thesteering can be operated.
From control valve From ppc From control valve(L.H. REVERSE) shutt,e va,ve (L.H; FORWARD)
From control valve(R.H. REVERSE)
From control valve(R.H. FORWARD) XlODD046
From control valve(L.H. REVERSE) From ppc
From control valve(L.H. FORWARD)
I shuttle valve I
From control valve From control valve(R.H. REVERSE) (R.H. FORWARD) XlODD047
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
EPC . SOLENOID VALVELS SELECT, PUMP MERGE-DIVIDER, 2 STAGE RELIEF, TRAVEL SPEED,SWING BRAKE SOLENOID VALVE
a
1. LS select solenoid valve2. 2-stage relief solenoid valve3. Pump merge-divider solenoid valve4. Travel speed solenoid valve
5. Swing brake solenoid valve
a.b.
::
e.f.9.h.i.j.
To tankFrom control pumpTo PPCYEPC valveFrom PPC shuttle valve
To LS select valveTo LS relief valveTo pump merge-divider valveTo L.H. and R.H. travel motorTo swing motorTo accumulator
XlOBH 7
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
1. Connector2. Variable core3. Coil4. Cage5. Spool
6. Block7. Spring
OPERATION
i XlOBH172
When solenoid is deactivatedThe signal current does not flow from the con-troller, so coil (3) is deactivated.For this reason, spool (5) is pushed to the right inthe direction of the arrow by spring (6).As a result, the circuit between ports P and Acloses and the pressurized oil from the controlpump does not flow to the actuator.At the same time, the pressurized oil from theactuator flows from port A to port T, and is thendrained to the tank.
X1 DD 48
When solenoid is excitedWhen the signal current flows from the controllerto coil (3), coil (3) is excited.For this reason, spool (5) is pushed to the left in IM
the direction of the arrow.As a result, the pressurized oil from the controlpump flows from port P through the inside ofspool (5) to port A, and then flows to the actua-tor.At the same time, port T is closed, and this stopsthe oil from flowing to the tank.
i XlODD 49
IO 128
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
LS CONTROL EPC VALVE
a 2 3 4 5 6
b
1. Body 5. Coil2. Spool 6. Plunger3. Spring 7. Connector4. Push pin
i
XlOBH173
a. Port C (to LS valve)b. Port T (to tank)c. Port P (from control pump)
1O l 9
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STRUCTURE AND FUNCTION EPC SOLENOID VALVE
FUNCTIONThe EPC valve consists of the proportional sole-noid portion and the hydraulic valve portion.When it receives signal current i from the valvecontroller, it generates the EPC output pressurein proportion to the size of the signal, and outputsit to the control valve.
OPERATION1. When signal current is 0 (coil deactivated)
There is no signal current flowing from the con-troller to coil (5), coil (5) is deactivated.For this reason, spool (2) is pushed to the right inthe direction of the arrow by spring (3).As a result, port P closes and the pressurized oilfrom the control pump does not flow to the LSvalve.At the same time, the pressurized oil from the LSvalve passes from port C through port T and isdrained to the tank.
2.94(30)
2.45_(25)
il
?
1.96_
~ = (20)2 “E??ca CD 1.47_5 Y (15)
s T
sr 0.98.(10)
0.49_(5)
200 400 600 800 1000 mA
Current i (mA) XlODD050
LS valve9 I
‘ ~ ,,: :/:/::,:.:j
XlODDOSl
1 o-1 30
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
When signal current is very small (coil excited)When a very small signal current flows to coil (5),coil (5) is excited, and a propulsion force is gener-ated, which pushes plunger (6) to the left in thedirection of the arrow.Push pin (4) pushes spool (2) to the left in thedirection of the arrow, and pressurized oil flows
from port P to port C.When the pressure at port C rises and the load ofspring (3) + the force acting on the surface a ofspool (2) becomes greater than the proportionforce of plunger (6), spool (2) is pushed to the rightin the direction of the arrow. The circuit betweenport P and port C is shut off, and at the same time,port C and port T are connected.As a result, spool (2) is moved to the left or rightuntil the propulsion force of plunger (6) is balancedwith the load of spring (3) + pressure of port C.Therefore, the circuit pressure between the EPCvalve and the LS valve is controlled in proportion
to the size of the signal current.
When the signal current is maximum (coilexcited)When the signal current flows to coil (5), coil (5)is excited.When this happens, the signal current is at itsmaximum, so the propulsion force of plunger (6)is also at its maximum.For this reason, spool (1) is pushed to the left in thedirection of the arrow by push pin (4).As a result, the maximum flow of pressurized oilfrom port P flows at its maximum to port C, and thecircuit pressure between the EPC valve and LSvalve becomes the maximum.At the same time, port T closes and stops the oilfrom flowing to the tank.
-7 XlODD0
IO 131
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
BOOM HOLDING VALVE
* For machine equipped with arm holding valve, the structure and function of the arm holding valve is the sameas this valve.
B-B
4
5
I 1-1 II I 1
A-A
0 0
0 0
H0 0
00
XlOBH174
1. Safety-suction valve2. Pilot spring3. Pilot spool4. Poppet spring5. Poppet
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
OPERATION
1) At boom RAISEWhen the boom is raised, the main pressure fromthe control valve pushes poppet (5) up in thedirection of the arrow.Because of this, the main pressure from the con-
trol valve passes through the valve and flows tothe bottom end of the boom cylinder.
2) Boom lever at NEUTRALWhen the boom is raised and the control lever isreturned to NEUTRAL, the circuit for the holdingpressure at the bottom end of the boom cylinderis closed by poppet (5), and at the same time, theoil flowing into poppet (5) through orifice a ofpoppet (5) is closed by pilot spool (3). As a result,
the boom is held in position.
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STRUCTURE AND FUNCTION EPC . SOLENOID VALVE
3) At boom LOWERWhen the boom is lowered, the pilot pressurefrom the PPC valve pushes pilot spool (3) and thepressurized oil in chamber b inside the poppet isdrained.When the pressure at port C, rises because ofthe pressurized oil from the bottom end of the
boom cylinder, the pressure of the pressurizedoil in chamber b is lowered by orifice a.If the pressure in chamber b drops below the pres-sure at port V, poppet (5) opens, the pressurizedoil flows from port C, to port V, and then flows tothe control valve.If any abnormal pressure is generated in the circuitat the bottom end of the boom cylinder, safety valve(1) is actuated.
iYgg?JXlODD 56
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STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
SPECIFICATIONSUnit: mm
Item
Outside diameter ofpiston rod
Boom Arm Bucket
PC200-6PC200LC-6 PC22OLC-6
I
PC21 OLC-6 PC25OLC-6
130
I
140
Inside diameter ofcylinder
Stroke
90 1 95 1 80 90
I
1,285 1,285
Max. stroke
Min. stroke
Width across flatsof piston nut
95 95
135
I-
140 115 130
1,490 1,635 1,120 1,020
3,565 3,870 2,800 2,625
2,075 2,235 1,680 1,605
95 95 95 95
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STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER
ADDITIONAL FILTER FOR BREAKER* FOR MACHINES EQUIPPED WITH BREAKER
I. Head cover2. Element3. Case4. Drain plug5. Valve
6. Spring7. Spring set plug
XlOBV051
SPECIFICATIONSRated pressure : 6.86 MPa (70 kg/cm?Flow . 107Plmin
.elief valvecracking pressure : 0.34 + 0.049 MPa
(3.5 f 0.5 kg/cm?Filter mesh size : 6wFiltering area : 3160 cm*
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STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE
OVERLOAD WARNING DEVICE1. OUTLINE
Battery-.-
Buzzer
Boom controlvalve
/
Hydraulicpu/mps
FUNCTIONThis device is installed to warn the operatorwhen the machine is close to tipping over whenit lifts an excessive weight while being usedas a crane.
STRUCTURE
When an excessive weight is lifted, the oilpressure goes up at the bottom side of theboom cylinders. When this happens, thepressure switch senses the rising pressure,turns the pressure switch on, and lights themonitor lamp to warn the operator. When themonitor lamp lights, immediately lower theweight to the ground or bring the arm closerin to the operator to prevent the machine fromtipping over.
XO8BTOOl
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STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE
Control panel
Overload warning pilot lamp
\‘ \
i\
I 4
r’ =.8Bs88
XllAH003
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STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE
3. ADJUSTING PRESSURE OF THE OILPRESSURE SWITCHScrew D: Pressure range adjustment screw
To make an adjustment so that theoil pressure switch acts normallywhen checking the operation of theoverload warning device.
Turning to the left makes the pres-sure range wider.
Screw E: Zero point adjustment screwTurning to the right one completeturn raises the pressure by 57 kg/cm*.Each complete turn to the left lowersthe pressure by 57 kg/cm’ .
A When an adjustment is required, contact your
Komatsu distributor and have him make theadjustment.
1. Body2. Bourdon tube3. Eccentric disc4. Microswitch5. Lever and roller6. Adjustment screw (E)7. Adjustment screw (D)
\Screw E XO8BTOO4
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)
HOSE BURST PROTECTION VALVE (BOOM)
High pressure fromcontrol valve (v port)
Pilot signal(Pi port)
&3Jpad caution
To cylinder portKY port)
FUNCTION
This valve prevents sudden uncontrolledlowering of the boom, when lifting, due tothe burst of a hose in the boom cylinder line.In such a condition this valve will hold theload until the operator lowers the boom in acontrolled way using the normal wrist control.
To tank (T port)
1. Body2. Spool3. Relief valve4. Check valve
XlOBH175
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM
OPERATIONBOOM RAISE
During boom raising the pilot signal fromwrist control operates control valve spool todirect high pressure oil to port V of hoseburst valve.This pressure lifts check valve (4) from seat
and high pressure oil flows in the bottom of thecylinder, raising the boom
BOOM LOWERDuring boom lowering, the pilot signal reversesthe front through the control valve spool. Highpressure oil flows to the head side of the cylinder.Oil in the bottom side of the cylinder flows throughthe port C, of the valve but cannot flow past thecheck valve. The pilot signal also opens the spool(2) of the hose burst valve and allows oil to flowback to tank.
v port
.~,:.~._:.:,.,...____.._.:_>>:.:..,:.:._.........c:.:.:.:.:.: ..A...... . . . . . . . . . . ..‘.....I....-‘”
~
Boom control
w XlODD057
XlODD058
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STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)
When hose burst occurs (Operation to lower safety)The sudden loss of pressure at port V will causecheck valve (4) to re-seat and so the valve islocked.The boom can be lowered in a controlled way byoperating the wrist control in the normal way.
v port\
mtrol
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STRUCTURE AND FUNCTIONWORK EQUIPMENT
WORK EQUIPMENT
X1722023
1. Arm2. Bucket cylinder3. Arm cylinder4. Boom5. Boom cylinder6. Bucket
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ELECTRICAL CIRCUIT DIAGRAM (112)
(TO2/2)
I 2/2) 2/2) 2/2) 2
?=BLUENWHOI
LTO
FOLDOUT 24
EN- HO
(TO2) 2/2 1 2/2)
IO-1450
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ELECTRICAL CIRCUIT DIAGRA M (2/2)
-
-
--
-
-Z-
TOl / 2 )
(TOl / 2 )
(TO1/21
(TOl / 2 )
t -_-_ ---___ _________-
I
1 I
IO-1460
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ELECTRICAL WIRING DIAGRAM FOLDPC200-6, PC200LC-6PC21 OLC-6, PC22O LC-6PC25OLG6
i /
P /;i _
l96
12
13
14
15
16
I O
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FOLD
483
\55
56
$8205FO629 I
1. Fuel level sensor2. Working lights3. Hydraulic oil level sensor4. LS control EPC valve5. Rear pump pressure sensor6. Front pump pressure sensor7. Rear pump TVC valve8. Front pump TVC valve9. Rear working light
10. Governor motor11. Engine speed sensor12. Engine oil pressure sensor (Hi)13. Engine oil pressure sensor (Lo)14. Air cleaner clogging sensor15. Coolant level sensor16. Window washer motor17. Travel alarm18. Horn (high tone)19. Horn (low tone)20. Battery relay21. R.H. head light22. Battery23. Wiper motor24. Horn switch25. R.H. additional light26. Room lamp27. L.H. additional light28. L.H. knob switch29. Alternator30. Coolant temperature sensor31. Electrical i ntake air heater32. Engine oil level sensor
36. Fuse box37. Caution buzzer38. Starting switch39. Fuel control dial40. Cigarette lighter41. Swing lick switch42. Wiper switch43. Light switch44. Buzzer cancel switch45. Service meter46. Speaker47. Kerosene mode connector48. Air conditioner control panel49. Engine throttle controller50. Pump controller51. Radio52. TVC prolix resisto r53. Wiper motor controller54. Additional light relay55. Light relay56. Monitor panel57. Swing lock prolix switch58. TVC prolix switch59. Swing oil pressure switch60. Bucket CURL oil pressure switch61. Bucket DUMP oil pressure switch62. Arm IN oil pressure switch63. Boom LOWER oil pressure switch64. Arm OUT oil pressure switch65. Travel oil pressure switch66. Boom RAISE oil pressure switch67. Swing brake solenoid valve68. Travel speed solenoid valve69. Pump merge-divider solenoid valve70. 2-stage relief solenoid valve71. LS select solenoid valve
67205F06292
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
1. Battery relay2. Battery3. Starting switch4. Fuel control dial5. Governor motor6. Starting motor7. Engine throttle controller8. Fuel injection pump
X12BV078
FUNCTIONThe engine can be started and stopped simplyby using the starting switch.A dial type engine control is used to control theengine speed. The engine throttle controllerreceives the control signal from the fuel controldial, sends a drive signal to the governor motor,and controls the angle of the governor lever in thefuel injection pump.At the same time, the engine throttle controlleralso receives signals from other controllers tocontrol the engine speed.
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
1. OPERATION OF SYSTEMStarting engine
When the starting switch is turned to the STARTposition, the starting signal flows to the startingmotor, and the starting motor turns to start theengine.When this happens, the engine throttle controller
checks the signal from the fuel control dial andsets the engine speed to the speed set by the fuelcontrol dial.
uel control dial
IThrottle
IPower source)-__
signal)X12BV079
Engine speed controlThe fuel control dial sends a signal to the enginethrottle controller according to the position of thedial. The engine throttle controller calculates theangle of the governor motor according to thissignal, and send a signal to drive the governormotor so that it is at that angle.When this happens, the operating angle of thegovernor motor is detected by the potentiometer,and feedback is sent to the engine throttle con-troller, so that it can observe the operation of thegovernor motor.
uel control dial
X12BV080
Stopping engineWhen the starting switch is turned to the STOPposition, the engine throttle controller drives thegovernor motor so that the governor lever is setto the NO INJECTION position.
When this happens, to maintain the electric powerin the system until the engine stops completely,the engine throttle controller itself drives the batteryrelay.
uel control dial
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
2. COMPONENTS OF SYSTEM1) FUEL CONTROL DIAL
HIGH A--i
Front of machine
6
A-AComposition of circuit
X12BV082
FUNCTIONThe fuel control dial is installed at the bottom of themonitor panel. A potentiometer is installed under
the knob, and when the knob is turned, it rotatesthe potentiometer shaft.When the shaft rotates, the resistance of the vari-able resistor inside the potentiometer changes, andthe desired throttle signal is sent to the enginethrottle controller.The shaded area in the graph on the right is theabnormality detection area and the engine speedis set at low idling.
1. Knob2. Dial3. Spring4. Ball5. Potentiometer6. Connector
0 0.25 1 4 4.75 5 Voltage
Characteristics of throttle voltage X12BV
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
2) GOVERNOR MOTOR
FUNCTION
The motor is rotated and the governor lever of thefuel injection pump is controlled by the drive signalfrom the engine throttle controller.A stepping motor is used for the motor which pro-vides the motive power. In addition, a potentio-meter for giving feedback is installed to allowobservation of the operation of the motor.The rotation of the motor is transmitted to thepotentiometer through a gear.
1. Potentiometer2. Cover3. Shaft4. Dust seal5. Bearing6. Motor7. Gear
8. Connector
X12BV085
OPERATION
Motor stationaryBoth A phase and B phase of the motor are con-tinuous, and a holding torque is generated in themotor.
Motor rotatingA pulse current is applied to the A phase and Bphase from the engine throttle controller to givesynchronous rotation with the pulse.
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STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
CN-EOl
X12BV088
Input and output signalsCN-EOI
No. Name of signal I Input/output
Controller power source (24V) I -
2
3
4 Auto deceleration
5
6
7
8
9
Controller power source (24V)-
Network circuit (-)-
I Input
Potentiometer power source (5V) I -
Starting switch ON signal
Fuel control dial
Input
Input
Model selection 1
Model selection 3
Input
Input
Governor motor drive A (+)
Governor motor drive B (+)
output
output
No. Name of signal Input/output
12 GND Input
13 Battery relay drive output
14 Network circuit (pump +)-
5 Network circuit (monitor +)-
16 Potentiometer GND-
17 Governor motor potentiometer signal
18 Model selection 2
Input
Input
9 Model selection 4
20 Governor motor drive A (-)
Input
output
121 Governor motor drive B (-) output
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ELECTRONIC CONTROL SYSTEMCONTROL FUNCTION
Electronic control system
X12BV087
Pump 2% engine mutual control function
2I I
Pump and valve control functionI
~ Power maximizing function
3
Swift slow-down function
4
Auto-deceleration function
5
Engine automatic warming-up, overheatprevention function
Swing priority function
7
Swing control system
8
- Travel control function
Self-diagnostic function
* For details of the self-diagnostic function, seeTROUBLESHOOTING.
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. PUMP AND ENGINE MUTUAL CONTROL FUNCTION
F ue l c on tr o d a
II Work equipment levers
L H K no b s wi tc h
M on t o r p an e X12BV
FUNCTIONThere are five modes available for selection withthe working mode switch on the monitor panel.These modes are the heavy-duty operation ( H/O)mode, general operation (G/O) mode, finishingoperation (F/O) mode, and the breaker operation(B/O) mode. It is possible to select the mostsuitable engine torque and pump absorptiontorque to match the nature of the work.
The pump controller detects the actual enginespeed and the speed set by the engine governorthrough the fuel control dial in accordance withthe pump absorption torque set for each mode, andcarries out control so that the pump absorbs all ofthe torque at each output point of the engine.
Engine torque cotve Engine horsepower curve
UO+ H/O2 Power max.05
~~
: G/O, F/O, B/O‘6I.5 L/O
Engine speed N Engine speed N
. Pump output curve
Pump discharge amount Q X
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Lifting operation (L/O) mode
Matching point in lifting operation mode:60 % partial output point
Engine speed N
Power maximizing mode
Pump discharge amount 0
XlZBV092
When the lifting operation mode is selected, theengine speed is automatically lowered to the par-tial position.In this condition, control is carried out in the sameway as for the general operation, finishing opera-
tion, and breaker operation modes to match theload in the pump.In this way, the fuel consumption is reduced andthe fine control ability is improved.
Engine speed N Engine speed N Pump discharge a mount Q
XlZBV093
Matching point in power max. mode: When the pump load increases, the engine speeddrops.When this happens, the pump discharge is reducedto prevent the engine speed from going down andto ensure that the engine is used at near the rated
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
3)
Pump control function when traveling
Engine speed N Pump discharge a mount Q
X12BV094
When the machine travels in the heavy-duty opera-tion (H/O) mode, the engine speed rises, and thepump is controlled in the same way as when in thepower maximizing mode.
Engine speed N Pump discharge a mount Q
X12BV095
When the machine travels in any mode other than
the heavy-duty operation (H/O) mode, the workingmode and engine speed are kept as they are, andthe pump absorption torque is increased.
Control function when WC prolix switch is ON
P: ON (Prolix)
N: OFF (Normal)~__I,.____,
Even if any abnormality should occur in the con-troller or sensor, the TVC prolix switch can beturned ON to provide an absorption torque moreor less equivalent to the general operation (G/O)mode, thereby allowing the machine to maintain itsfunctions.
Pump discharge amount 0
X12BVO96
In this case, it is designed to allow a constant cur-rent to flow from the battery to the TVC valve, sooil pressure sensing is carried out only by the TVCvalve.
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
2. PUMP AND VALVE CONTROL FUNCTION
Solenoid ,- - - - 7valve I ra,L--------7
Fuel control dial
Ingine throttle O~Xldkr
I
ump merge-divider valv
Pump controller
Yi
. /Monitor panel
X12BV097
FUNCTIONThe following two functions are available toprovide the optimum matching under variousworking conditions: a 2-stage relief functionwhich increases the digging power, and a finecontrol mode function which improves the easeof fine control.
IO 160
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1)
2)
3)
LS control functionThe switching point (LS set differential pressure)for the pump discharge amount inside the LSvalve is changed by changing the output pressurefrom the LS control EPC valve to the LS valveaccording to the engine speed and operating con-dition of the actuator.
Because of this, the timing of starting the dischargeamount from the pump can be optimized, to giveexcellent ease of compound operation and tinecontrol.
Cut-off functionFor details of the operation, see CLSS
S-stage relief functionThe relief pressure for normal operation is 31.85MPa (325 kg/cm?, but when the 2-stage relieffunction is actuated, the relief pressure rises toapproximately 34.79 MPa (255 kg/cm?.Because of this, the hydraulic pressure is increasedby one stage.
Actuating conditions for 2-stage relief function
Conditions Relief pressure
. When traveling31.85 MPa
. When swing lock switch is ON (325 kg/cm*)
. In lifting operation (L/O) mode0
. When power max. function or 34.79 MPaswift slow-down function are (355 kg/cm’ )actuated
EPC pressure at2.94 MPa (30 kg/cm’ )
0 MPa (0 kg/cm’ )
LS set differential pressure
X12BV09
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
4) Fine control node functionWhen the finishing operation (F/O) mode is selec-ted from the working mode, the pump LS valve iscontrolled, and the pump discharge amount is re-duced to improve the ease of fine control and theprecision when finishing.
Relationship between working mode and pumpdischarge amount (for independent operation)
Actuator
Mode
Heavy-duty operation (H/O)
General operation (G/O)
Finishing operation (F/O)
Lifting operation (UO)
Breaker operation (B/O)
Boom ArmBucket
RAISE LOWER IN OUT
100 1 40 1 100 / 100 1 50
__I00 5050> 40 500 1000 40 3550)
1 40 I 100 I 100 I 50
5
40 (50)
35
50
Breaker
60
***
The figures in () are for the PC200The figures in < > are for when arm IN is operated.In each working mode, the full flow of the pump atthe set engine speed is taken as 100%.
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
3. POWER MAXIMIZING, SWIFT SLOW-DOWN FUNCTION
Fuel control
Pump controller
Monitor panel
X12BV099
FUNCTIONThis function provides an increase in the diggingpower for a certain time or switches the workingmode to the lifting operation (L/O) and reduces thespeed. It is operated using the L.H. knob switch tomomentarily match the operating conditions.
* The power max. function and swift slow-down functionare operated with the same switch. Only one of thesefunctions can be selected at any time; they cannot bothbe operated together.
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1) Power maximizing functionDuring digging operations, when that extra bitof digging power is needed (for example, whendigging up boulders), the L.H. knob switch canbe pressed to raise the hydraulic pressure byapprox. 10% and increase the digging force.If the L.H. knob switch is pressed ON when the
working mode is at H/O or G/O, each functionis automatically set as follows.
Workingmode
Enginepump control
2-stage relieffunction
Actuatingtime
2) Swift slow-down functionDuring normal operations, if it is desired to carry outlifting operations or finishing operations for a mo-ment, the working mode can be switched to liftingoperation (L/O) mode by operating the L.H. knobswitch.If the L.H. knob switch is pressed ON when theworking mode is at H/O or G/O, each function isautomatically set as follows.
Working mode Actuating time
I Lifting operation While switch is kept pressed I
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
4. AUTO-DECELERATION FUNCTION
R.H. work equipment lever
BoomA &ucket
Monitor panel
=
Engine
Governor motor
Main pump
Fuel control dial 3
Engine throttlecontroller
1L.H. travel OTravel lever’
I I pressure [i switch ,
I In Pump controller
1 1
X12BVlOO
FUNCTIONIf all the control levers are at neutral when waitingfor work or waiting for a dump truck, the enginespeed is automatically reduced to a midrange speedto reduce fuel consumption and noise.If any lever is operated, the engine speed returnsimmediately to the set speed.
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
OPERATIONControl levers at neutral
When control lever is operatedif any control lever is operated when the engine
If the engine is running at above the decelerationactuation speed (approx. 1400 rpm), and all thecontrol levers are returned to neutral, the enginespeed drops immediately to approx. 100 rpmbelow the set speed to the No. 1 deceleration pos-
tion.If another 4 seconds passes, the engine speed isreduced to the No. 2 deceleration position (approx.1400 rpm), and is kept at that speed until a leveris operated.
speed is at No. 2 deceleration, the engine speedwill immediately rise to the speed set by the fuelcontrol dial.
Speed (rpml
No. 1 deceleration
No. 2 deceleration
(1,400)III>
4 Less than 2 Less--
than 1
i ILevers at neutral Lever operated
se4
XlZBVlOl
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
5. AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION
(Coolant temperature signal)
I 1
IEngine
Coolant temperature
Governor motor
Fuel control dial 1
Main pump
/LS valve
TTf TVCva vel
t’ =m&OS 0I 5 5 ‘ ZL 5 B 1 .”
a
A c a .?3 ,G
(Network signal)- Engine throttle - .: c
controllerPump controller
(Network signal)c
uu
X12BV102
FUNCTIONIf the coolant temperature is low, this automaticallyraises the engine speed to warm up the engine afterit is started. (Automatic warming-up function)In addition, if the coolant temperature rises too highduring operations, it reduces the load of the pumpto prevent overheating. (Engine overheat preventionfunction)
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1) Engine automatic warming-up functionAfter the engine is started, if the engine coolanttemperature is low, the engine speed is auto-matically raised to warm up the engine.
Conditions for actuation (both are necessary)
Conditions for cancellation (any one)
1 Coolant temoerature: 30°C or above
X12BV103
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
2) Engine overheat prevention functionThis function protects the engine by loweringthe pump load and engine speed to preventoverheating when the engine coolant temp-erature has risen too far.This system is actuated in two stages. Thefirst stage is when the water temperature is
between 102°C and 105” C, and the secondstage is when the water temperature is 105°Cand above.
Normal operation (coolant temperature below 102°C)-
6-st85Ebz
L
Coolant temperature:Below 102°C
(Coolant temperaturegauge: reen range)
1st stage (Coolant temperature between 102°C and 105°C)
Action. remedy
Coolant temperature:Between 102°C and
(Coolant temperaturegauge: Red range)
Working Pc2Cro-e. PC22oLC-emode
kwckw,general,finishing,breaker
Mode kept as it is,output reduced
Lifting Lifting operation keptas is
l-l
2nd stage (Coolant temperature 105°C and above)
Actuation condition Actuation, remedy
Coolant temperature:
105°C and above
(Coolant temperaturegauge: Red range)
I aution buzzer SoundsI
11 Cancel condition I
Ioolant temperature: Below 102’ C I
When the above condition ismet, the system returns to thecondition before the overheatprevention function was
actuated (automatic reset).
3temporarily to low idling position
When the above conditions aremet, the system returns to thecondition before the overheatprevention function wasactuated (manual reset).
X12BV104
1 l 9
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
6. SWING PRIORITY FUNCTIONThere is a SWING ACCEL switch on the monitorpanel for the boom/swing priority selection mode.This switch can be turned ON or OFF to changethe matching of the boom RAISE and swing op-erations.The oil flow is divided and sent to the swing tomatch the swing angle to allow compound op-erations to be carried out easily.Boom/swing priority selection mode OFF:
90” swing and loading of dump truckBoom/swing priority selection mode ON:
180” swing and loading of dump truck
X12BV106
STD Swing priority
90 180
Swing angle ( o ) X12BV105
The change in the matching between the boom When boom/swing priority selection mode is OFFRAISE and swing is carried out by changing the l-l r-lsignal to the pump merge-divider valve.
.bmP merge divider valve
pcqX12BV107
Boom RAISE and swing are parallel
When boom/swing priority selection mode is ON
Pump merge divider valve
The boom RAISE and swing use separate pumps, soswing is independent
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
7. SWING CONTROL FUNCTION
Work equipment lever
Control valve
Pump merge- 1 IJ
divider valve ,,
h”nn;mr n=n.aI . T
Control pump
(Swing lock switch signal)
(Drive signal)
Pump controller (Swing lever signal)- .”
I 1 I
X12BV109
FUNCTIONThe system is provided with a swing lockand swing holding brake function.
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1) Swing lock, swing holding brake functionThe swing lock (manual) can be locked at
Lock Lock Function Operationswitch lamp
any desired position, and the swing holdingbrake (automatic) is interconnected with the When swing lever is placed at
swing, so it prevents any hydraulic drift after Swing neutral, swing brake is applied
the swing is stopped.OFF OFF holding after approx. 4 set; when swing
brake lever is operated, brake is
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
* Operation of swing lock prolix switchIf any abnormality should occur in the con-troller, and the swing holding brake is notactuated normally and the swing cannot beoperated to cancel the swing lock and allowthe swing to be operated.
* Even when the swing lock prolix switch is turnedON, the swing lock switch stays ON and theswing brake is not canceled.
* When the swing brake is canceled, the swinghas only a hydraulic brake operated by thesafety valve, so if the swing is stopped on aslope, there may be hydraulic drift.
2) Hydraulic oil quick warm-up function whenswing lock switch in ONWhen the swing lock is turned ON, the relief pres-sure rises from 31.85 MPa (325 kg/cm?. If thework equipment is relieved in this condition, the
hydraulic oil temperature will rise more quicklyand the warming-up time can be reduced.
ON ONSwinglock
Swing lock is actuated and swingis held in position. Even whenswing lever is operated, swing lockis not canceled and swing doesnot move.
Swing lockProlix switch
Swing lockswitch
Swing brake
ON (when controller is OFF (when controller isabnormal) normal)
ON OFF ON OFF
Swinglockapplied
Swinglockcanceled
Swinglockapplied
Swingholdingbrakeapplied
XlZBVllO
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
8. TRAVEL CONTROL FUNCTION
~-------]rf~i Travelmotor /Travel lever 1
I 1
n n _ . . 1
2%egulator
I, Oil pressure;switch I
tf--- ’
Fuel controldial
Hi
I J5egulator
t- Travel peedsolenoid valve
48 ,-
I
Control pump :
:
,: M - III1
00P0(1-c
L-_--------*-A
(Pressure sensor(Drive signal1
00000(Drive signal1
Engine throttlecontroller (Throttle signal)
Pump controller IPressure sensor signal1
- ,:’ C (Switch signal) 6 “A I- 4’
&“ &
c
XlZBVlll Monitor panel
FUNCTIONWhen traveling, the pump control is carriedout, and the travel speed can be selectedmanually or automatically to give a travelperformance that suits the nature of the workat the jobsite.
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1)
*
2)0
ii)
iii)
Pump control function when travelingIf the travel is operated in any working modeother than the heavy-duty (H/O) mode, thisincreases the pump absorption torque whilekeeping the working mode and engine speedas they are.For details, see PUMP AND ENGINE MUTUAL
CONTROL SYSTEM.
Travel speed selection functionManual selection using travel speed switchIf the travel speed switch is set to Lo, Mi, or Hi,the pump controller controls the pump flow andmotor volume at each speed range as follows toswitch the travel speed.Automatic selection according to engine speedIf the engine speed is reduced to below 1400 rpmby the fuel control dial:0 If the machine is traveling in Lo, it will not
shift even if Mi or Hi are selected.If the machine is traveling in Mi, it will notshift even if Hi is selected.If the machine is traveling in Hi, it will auto-matically shift to Mi.
Automatic selection according to pump dischargepressureIf the machine is traveling with the travel speedswitch at Hi, and the load increases, such as whentraveling up a steep hill, if the travel pressure con-tinues at 33.32 MPa (340 kg/cm? for more than0.5 set, the motor volume is automatically switchedand the travel speed changes to Mi.(The travel speed switch stays at Hi.)The machine continues to travel in Mi, and whenthe load is reduced, such as when the machinetravels again on flat ground or goes downhill, andthe travel pressure stays at 17.64 MPa (180kg/cm? or less for more than 0.5 set, the motorvolume is automatically switched and the travelspeed returns to Hi.
Travelspeedswitch
(Lowtpeed)Mi
(Mid-range
speed)
Hi(High speed)
Pumpflow (%)
Motorvolume
80 80 100
Max. Min. Min.
Travelspeed(km/h)
PCZOO-6 PCZOO-6 PCZOO-6PCZOOLC-6 PC2OOLC-6 PC2OOLC.6PC21OLC-6 PC250LC-6 PC21OLG6 PC21OLC.6 PC25OLC-6PC22OLC-6 PC22OLC.6 PC22OLC.6
PC25OLG6
I 3.0 I 2.2 I 4.1 I 5.5 I 5.1
Hic
‘ 0$z:55C 1Mi ---------
I I
I I1 I
1 I I
17.64 (180) 33.32 1340)
Travel pressure (MPa (kg/cmz))X12BV112
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
9. COMPONENTS OF SYSTEM1 ENGINE SPEED SENSOR
1. Wire
2. Magnet3. Terminal4. Housing5. Connector
2) PPC OIL PRESSURE SWITCH
Composition of circuit
XlZBV113
FUNCTION
The engine speed sensor is installed to the ringgear portion of the engine flywheel. It counts elec-trically the number of gear teeth that pass in frontof the sensor, and sends the results to the pumpcontroller.This detection is carried out by a magnet, and anelectric current is generated every time the geartooth passes in front of the magnet.
1. Plug2. Switch3. Connector
SPECIFICATIONSComposition of points : N.O. pointsActuation (ON) pressure : 0.49 f 0.1 MPa
(5.0 f 1 .O kg/cm?Reset (OFF) pressure : 0.29 f 0.05 MPa
(3.0 f 0.5 kg/cm?
FUNCTIONThere are 8 switches installed to the PPC shuttlevalve. The operating conditions of each actuatoris detected from the PPC pressure, and this is sentto the pump controller.
a bYz i?XlZBV114
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
3) PUMP PRESSURE SENSOR
X12BV115
FUNCTIONThis sensor is installed to the inlet port circuitof the control valve. It converts the pump dis-charge pressure to a voltage and sends this tothe controller.
Insulation layer
Gauge layer
OPERATIONWhen the pressurized oil entering from the pres-sure introduction portion pressurizes the diaphragmof the pressure detection portion, the diaphragmdeflects and changes shape.A gauge layer is installed to the face opposite thediaphragm, and the resistance of the gauge layerconverts the deflection on the diaphragm into anoutput voltage and sends it to the amp (voltageamplifier).The voltage is further amplified by the amplifier andis sent to the pump controller.Relationship between P (kg/cm? and outputvoltage(V).V = 0.008 X P + 1 .O* 1 kg/cm* = 0.098 MPa
Diaphragm(stainless steel)
XlZBVll6
0 loo 200 300 400 500
Pressure P g/cm’) X12BV117
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
PUMP CONTROLLER
CN-CO2 CN-CO3 CN-CO1
\ i I
X12BV118
nput and output signalsCN-CO1 :N-CO2 ZN-CO3
it :,; IGND Nameofsignal No. I Name of signal I IInput/
outputo Name of signal
Input/output
1 Swing switch Input_
2 GND
3 LS select solenoid Outpui
2 Boom LOWER switch input
3 Travel switch Input
4 1 Pump merge-divider solenoid 1Outpui 4 1 oom RAISE switch I lwt I26 I Auto deceleration Ioutput I
26 Speed sensor (+) Input
27 Network circuit (monitor +)_
6 Travel speed solenoid
7 LC control EPC (-)
Outpui
Outpui
1 utpui 8 I Bucket DUMP switch I Input 28 I Monitor circuit (engine +) I - I
Controller power source 24V
Controller power source 24V
g I Swing lock switch I Input 29 1 Pressure sensor 1 (GND) I - I30 Pressure sensor 2 (GND)
31 I --_
0 Service switch
11 Model selection 5
Input
Input
12 ILS bypass solenoid IOutpui 12 I Swing lock prolix switch I Input
16 IModel selection 4 I Input I 36 I _ I - I6 TVCI (+)
17 ITvcP +)
Outpui
I Outpui 17- -
18 L.H. knob switch Input
I - I
I - I
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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
5) TVC PROLIX RESISTOR
1. Resistor2. Connector
SPECIFICATIONResistance; 30 0
6)
7)
8)
FUEL CONTROL DIAL, GOVERNOR MOTOR,
ENGINE THROTTLE CONTROLLER* See ENGINE CONTROL SYSTEM.
MONITOR PANEL* See MONITORING SYSTEM.
NC VALVE* See HYDRAULIC PUMP.
XlZBVllS
FUNCTIONThis resistor acts to allow a suitable currentto flow to the TVC solenoid when the TVCprolix switch is ON.No current flows when the NC prolix switchis OFF.
9) LS CONTROL EPC VALVE
LS SELECT SOLENOID VALVEPUMP MERGE-DIVIDER SOLENOID VALVEZ-STAGE RELIEF SOLENOID VALVETRAVEL SPEED SOLENOID VALVESWING BRAKE SOLENOID VALVE* See EPC, SOLENOID VALVE
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEMMonitor panel
Sensor signal
I=
H O G/O F/O L/O B C
f? l-l
I--
J
Power sourceSensors
u
Buzzer signal
Banery XllAJlOl
FUNCTIONThe machine monitor system uses the networkcircuits between the controllers and sensors in-stalled to all parts of the machine to observe thecondition of the machine. It processes this infor-mation, and displays it on a panel to inform theoperator of the condition of the machine.The content of the information displayed on themachine can broadly be divided as follows.1. Monitor portion
This gives an alarm if any abnormalityoccurs in the machine.
2. Gauge portionThis always displays the coolant tempera-ture and fuel level.
3. Time display1) This normally displays the time,.2) If this is set to the machine data moni-
toring mode, internal data from eachcontroller, including the monitor panelitself, are displayed.
3)
4)
5)
*
If it is set to the trouble data memorymode, the trouble data for each con-troller, including the monitor itself, aredisplayed.It displays that the system has been setto the governor motor adjustment modeand automatic vibration offset adjustmentmode.In emergencies, it displays abnormalitiesin any controller.For details of the content of the displayand the method of operation, see TROU-BLESHOOTING.
The monitor panel has various built-in mode se-lector switches, and also functions as the controlpanel for the electronic control system.
Controllers
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. MONITOR PANEL
OutlineThe monitor panel consists of the time display,monitor display, and mode selector switches.It has a built-in CPU (Central Processing Unit),and processes, displays, and outputs the datafrom the sensors and controllers.The time display and monitor display panels usea liquid crystal display (LCD).The mode switches are flat sheet switches.
CN-POP
CN PO1
XllAJlO2
Input and output signals
CN PO1 CN PO2
XllAJ103
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
SWITCHES1. Working mode switch2. Auto-deceleration switch3. Boom/swing priority mode switch4. Travel speed switch5. Power max./Swift slow-sown switch
2
XllAJlOS
Switch actuation tableThe switch portion consists of five mode selectionswitches, and the condition of the machine changeseach time that any switch is pressed. The LEDabove the switch lights up to display the present Symbol item Action
condition of the machine.
rl)i ;g;:‘ NG H/O ti G/O t) F/O c) L/O ti B/O
+
aKNOBBUl-rON POWER UP t) SPEED DOWN
=
ON tf OFF
Hi tf Mi t) Lo
OFF H ON
* The bold letters indicate the default positionof the switch when the starting switch isturned ON.
XllAJ1 6
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
2. SENSORS
The signals from the sensors are input directlyto the monitor panel.The contact type sensors are always connectedat one end to the chassis GND.
Name of sensorI
Type of sensorI
When normal When abnormal
Coolant level I Contact type I ON (close) OFF (open)
Engine oil level Contact type I ON (close) OFF (open)
Hydraulic oillevel
Contact type ON (close) OFF (open)
Engine oilpressure
Contact type OFF (open) ON (close)
Coolanttemperature
Resistance type -
Fuel level I Resistance type I I-
Air cleanerclogging
Contact type ON (close) OFF (open)
COOLANT LEVEL SENSOR
1. Subtank2. Float3. Sensor4. Connector
XllAJ107
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
2) ENGINE OIL LEVEL SENSOR
1 2 31. Connector2. Bracket3. Float4. Switch
Composition of circuitXllAJlO8
3) HYDRAULIC OIL LEVEL SENSOR
ls=ZXll JlOS
4) ENGINE OIL PRESSURE SENSOR (COMMON FOR BOTH LoAND Hi)
1. Connector2. Plug3. Switch4. Float
1. Plug2. Contact ring3. Contact4. Diaphragm5. Spring6. Terminal
Composition of circuit
Xll JllO
Actuation (ON) pressureLo: 0.05 f 0.02 MPa
(0.5 f 0.2 kg/cm? or lessHi: 0.15 f 0.02 MPa
(1.5 f 0.2 kg/cm? or less
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STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
5) COOLANT TEMPERATURE SENSOR1 2 3 1. Connector
2. Plug3. Thermistor
XllAJlll
6) FUEL LEVEL SENSOR
l--~L-_:T-_:~~;=-_-_
c cfkComposition of circuit
1. Float2. Connector3. Cover4. Variable resistor
7) AIR CLEANER CLOGGING SENSOR
EMPTY
XllAJ112
Actuation (OFF) pressure: -7.47 f 0.49 kPa(-762 f 50 mm H,O)
Composition of circuitXllAJ113
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20 TESTING AND ADJUSTING
Table of judgment standard values .......................................................... 20- 2Standard value table for electrical parts ....................................................... 20-14Tools for testing, adjusting and troubleshooting ................................................ 20-23
Measuringenginespeed ................................................................... 20-24 Measuring intake manifold pressure ......................................................... 20-25 Measuring intake air restriction .............................................................. 20-26 Measuring lubricating oil pressure ........................................................... 20-27 Measuring fuel (filter) inlet restriction ......................................................... 20-28 Measuring blowby pressure ................................................................ 20-29 Measuring engine back pressure ............................................................ 20-30 Measuringexhaustcolor ................................................................... 20-31 Measuring coolant temperature ............................................................. 20-32 Measuringvalveclearance ................................................................. 20-33 Checking and adjusting belt tension for air conditioner compressor ................................ 20-34 Adjustingenginespeedsensor .............................................................. 20-35 Testing and adjusting governor motor lever stroke .............................................. 20-36 Testing clearance of swing circle bearing ..................................................... 20-37 Testing and adjusting track shoe tension ...................................................... 20-38 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ..................... 20-39 Testing and adjusting TVC valve output pressure (servo piston input pressure) ....................... 20-42 Testing and adjusting LS valve output pressure (servo pistion input pressure) and LS differential pressure . 20-44 Testing and adjusting control pump circuit oil pressure .......................................... 20-47 Testing EPC valve, solenoid valve output pressure .............................................. 20-49 Measuring PPC valve output pressure and testing PPC shuttle valve ............................... 20-51 Adjusting work equipment Swing PPC valve ................................................. 20-53 Adjustingtravellever ...................................................................... 20-54 Testing travel deviation .................................................................... 20-55 Testing location causing hydraulic drift of work equipment ........................................ 20-56 Measuringoilleakage ..................................................................... 20-58 Releasing remaining pressure in hydraulic circuit ............................................... 20-59
Bleedingair ............................................................................. 20-60Troubleshooting .......................................................................... 20-63
A When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety
pins and blocks to prevent the machine from moving.A When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.A When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed when
the coolant is still hot, the coolant will spurt out and cause burns.A Be careful not to get caught in the fan, fan belt, or other rotating parts.
20 I
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
TABLE OF JUDGEMENT STANDARD VALUE
. FOR ENGINE
Machine Model PC200-6, PC200LC-6 PC22OLC-6PC21 OLC-6 PC25OLC-6
S6D102-1 SAGDI 02-I
Standard Permissible Standard Permissible
Value Value Value Value2130 f 60 2130 + 60 2300 f 60 2300 f 60
2050 + 60 2050 + 60 2120 f 60 2120 + 60
2050 f 60 2050 f 60 2120 f 60 2120 f 60
1710260 1710&60 1800~60 1800*60
10661?60 1066260 1066+60 1066260
145J2200 145J2200 174J2300 174J2300
850- 1100 850- 1100 960 - 1020 960 - 1020
380 635 380 635
69 (0.70) 69 (0.70)207 (2.11) 207 (2.11)
(03345) (OZ5)
114 508
69 (0.70) 69 (0.70)207 (2.11) 207 (2.11)
(03345) (OY5,
114 508
76 76 76 76
100 100 100 100
0.25 0.25 0.25 0.250.51 0.51 0.51 0.51
Engine model
Item Measurment ConditionsI
Unit
Low idle in H/O mode
Engine speeds
Engine ratingRated gross powerrated speed
kWJrpm
intake manifoldpressure
At rated speed *j,I
mm Hg
Intake air restrictionNew element - At allspeeds
mm H,O
flith SAE 15W-40 oil andcoolant temperature inoperating range:Minimum at low idleMinimum at rated speed**
kPa(kg/cm*)
Lubricating oilpressure
Fuel filter inletrestriction
Maximum restriction kPa(kg/cm’ )
Service tool orifice size of5.613 mm (0.221 in) andcoolent temperature inoperating range:4t rated speed **
Blowby pressure mm H,O
Exhaust backpressure
Vlaximum at any condition mm Hg
Coolanttemperature
Vlaximum operating:emperature
Engine cold:ntake valvesExhaust valves
alve clearance mm
* For further detailed information, refer to Engine Shop Manual.* * Rated speed for S6D102-1 - 1950 rpm ; for SAGDI 02-I - 2100 rpm.
20-2a
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
FOR CHASSIS* The standard values and permissible value shown in this table are all values for H/O (heavy-duty
operation) mode.
TMachine model
PC200-6, PC200LC-6, PC2lOLC-6, PC22OLC-6, PC25OLC-6
Standard value I Permissible value
Jnit
‘ pm
Cate-gory
Measurement conditionstem
Speed when auto-deceleration isoperated
Boom control valve
Arm control valve
Bucket controlvalve
Swing control valve
Travel control valve
Boom control lever
Arm control lever
Bucket control
leverSwing control lever
Travel control lever
Play of control lever
Boom control lever
Arm control lever
Bucket controllever
Swing control lever
Travel control lever
) Engine at high idling) Hydraulic oil temperature:
45-55°CbCoolant temperature:
Within operating rangeB -pump relief: Arm relief
BArm relief) Travel lever operated in
small movements) Engine at high idle
4
4
,
4
,
,
4
4
4
4
- 4
,
,
,
,
,
(
2,100 f 100 2,250 f 100 - -
D Fuel control dial at MAX.DControl lever at neutral 1,400 f 120
a b P
9.5 f 0.5 9.5 f 0.5 -
aI
b
-
nm
nm
9.5 f 0.5 9.5 f 0.5
I XlOBH107
b Center of lever knobI Read max. value to end of
travelmEngine stopped# Excluding neutral play
85* IO I Max. 95 Min. 75
85* IO I Max. 95 Min. 75
85i IO
IMax. 95 Min. 75
85*10 I Max. 95 Min. 75
115* 12 I Max. 127 Min. 103
Max. 10
15.7 f 3.9(1.6 f 0.4)
15.7 f 3.9(I .6 f 0.4)
Max. 15
Max. 24.5(Max. 2.5)
Max. 24.5(Max. 2.5)
Engine at high idleOil temperature: 45 - 55” CFit push-pull scale to centerof control lever knob tomeasureMeasure max. value to endof travel
12.7 f 2.9I
Max. 21.6(1.3 f 0.3) (Max. 2.2)N
:kg) 12.7 f 2.9I
Max. 21.6(1.3 f 0.3) (Max. 2.2)
Lever 24.5 f 5.9I
Max. 39.2(2.5 f 0.6) (Max. 4.0)
Pedal 74.5 f 18.6(7.6 f 1.9)
Max. 107.8(Max. 11)
20 3
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Item Measurement conditions
Unload pressure H/O mode
Boom
Arm
Bucket
Swing
Travel
Control pump
LS differentialpressure
Applicable model
Oil temp: 45 - 55 “ CEngine at high idlingAll levers at neutral
s Hydraulic oi l temp: 45 - 55 “ C
Relief pressure with engine athigh idling (Relieve only circuit tobe measured)n H/O modeFigures in 1 1 re used whenpower max function is used
(reference)Pump outlet port pressure
*I : For travel, measure oilpressure for relief on one side.
*2: For swing, measure oilpressure with swing lockswitch on.
*3: The boom pressure is the oilpressure at RAISE and at thehigh pressure setting (active
mode)Hydraulic oiltemp: 45 - 55 “ CEngine at highidlingn H/O mode
Levers inneutral
Travelspeed HI,rotatingunder noload
Unit
JlPakg/cm’ )
PC200-6, PC200LC-6, PC21 OLC-6PC22OLC-6, PC25OLC-6
Standard value
3.92 f 0 98
(40~10)
31.85 + 0.98(325 + 10)
2.94+;= (30 +; )
2.94 + 0 98
(30 f 10)
2.16 f 0.098(22 f 1)
Permissible value
3.92 + 0.98
(40*10)
Max 33.81
Min 30.38
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Cate-gory
Item
Swingbreakangle
Timetaken tostart
swing
Timetaken toswing
Hydraulicdrift ofswing
Leakagefromswingmotor
Machine Model
Measurement conditions
Work equipment posture - Max. reach
Engine at high idlingHydraulic oil temp: 45 - 55°CStop after swinging one turn and measuredistance that swing circle moves
Work eqipment posture -Maxreach
90”
PO0326
Engine at high idlingHydraulic oil temp: 45 - 55°Cn H/O mode
Time taken to swing 90” and180” from startinq positions r
180”
Work equipment posture - Max. reach
Engine at high idlingHydraulic oil temp: 45 - 55°Cn H/O mode
Swing on turn, and measure time taken toswing next 5 turns
Engine stoppedHydraulic oil temp: 45 - 55°CSet machine on 15” slope, and set upperstructure at 90” to the side.Make match marks on swing circle outerrace and track frame.Measure distance that match marksmove aoart after 5 min.
Engine at high idlingHydraulic oil temp: 45 - 55°CSwing lock switch ON
s Relieve swing circuitn.
PC200-6, PC2OOLC-6, PC21OLC-6, PC22OLC-6,PC25OLC-6
Standar
PC200PC2OOLCPC21 OLC
lalue
PC22OLCPC25OLC
Max 100 Max 130
3.1 f 0.3
4.4 f 0.8
24 f 3.5
3.2 + 0.3
4.5 ? 0.8
24 f 3.5
Max 5
Permissible value
PC200PC2OOLCPC21 OLC
Max 130
Max 3.7
Max 5.6
Max 30
PC220LCPC25OLC
Max 160
Max 3.8
Max 5.7
Max 30
Max IO
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
rachine model PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6
Unit Standard value Permissible valueate-gory
Measurement conditions
PC200PC200LCPC21 OLC
PC220LCPC200
PCZOOLCPC21 OLC
PC22OLC
STD: STD:43-61 45-63
LC: LC:46.5 - 66.5 46.5 - 68.5
STD: STD:50*7 52 f 7
LC: LC:54.5 f 8 56.5 f 8
o
Mi
Hi
Lo
Mi
Hi
STD: STD:31 -44 32.5 - 45.5
LC: LC:34-47 32.5 - 49
STD:25.5 - 31.5
LC:27.5 - 35
20-28
STD: STD:36.5 + 5.5 38 + 5.5
LC: LC:39.5 + 5.5 41.5 f 5.5
STD: STD:27.5 f 2 2922
LC: LC:30 f 2.5 31 f 2.5
iecravel;peed1)
rravelspeed2)
B Engine at high idlingB Hydraulic oil temp: 45 -
55°CB In H/O modeB Raise track on one
side at a time, rotateone turn, thenmeasure time taken for5 turns with no load
STD:27-33
LC:28.5 - 36
20-283.5 f 3.5 23.5 ? 3.5
iec 172 2.5 17k2.5 14.5-21 14.5-21D Engine at high idling
Hydraulic oil temp: 45 -55°CB In H/O mode
Run up for at least1Om, and measuretime taken to travelnext 20 m on flatground
13+1 13*1-T- 12-15 12-15
D Engine at high idlingHydraulic oil temp: 45 - 55°CRun up for at least 10 m, and
fravelfevia-ion
im Max 200 300
measure time taken to travelnext 20 m on flat groundUse a hard horizontal surface.
I_ 1 m _I moio7
* Measuer dimension X
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
PC25OLC-6achine model
Cate-gory
Item Measurement conditions Unit Standard value Permissible value
Lo
Mi
Hi
Lo
Mi
Hi
83 f 5 78-93
45*3 42-50ravel speed(1)
et
Set
mm
Engine at high idlingHydraulic oil temp: 45 -55°Cn H/O mode
Raise track on one side at atime, rotate one turn, thenmeasure time taken for 5turns with no load
36?2 34-40
30-393+3
17?2
14?2
Travel speed(2)
15.5 - 21.5
Engine at high idlingHydraulic oil temp: 45 -55°Cn H/O mode
Run up for at least 10 m,and measure time taken totravel next 20 m on flatground
12-18
Engine at high idlingHydraulic oil temp: 45 - 55°CRun up for at least 10 m, and
300raveldeviation
Max 200
*
measure time taken to travelnext 20 m on flat groundUse a hard horizontal surface.
L20m . 1
I+IOmPa0107
Sr Measuer dimension 1;
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Cate-gory
Machine Model
lydraulic drift of.avel
.eakage ofavel motor
Total workequipment(hydraulicdrift at tipof bucketteeth)
z BoomE.n
cylinder
%
(amount ofretraction
Yb
of cylinder)
3zG ArmL cylinderg (amount of
eextension
Rof cylinder)
I
Bucketcylinder(amount ofretractionof cylinder)
Measurement conditions Unit Standard value Permissible value
Engine stoppedHydraulic oil temp: 45 -55°CStop machine on 12”slope with spocketfacing straight up theslope.Measure the distancethe machine moves in 5min.
Lock‘ DinPoD1W
Engine at high idlingHydraulic oil temp: 45 -55°CLock shoes and relievetravel circuit.
Posture for measurement
-
Place in above posture andmeasure extension orretraction of each cylinderand downward movement attip of bucket teeth.Bucket: Rated loadHorizontal, flat ground
0 Levers at neutralEngine stoppedHydraulic oil temp: 45 -55°CStart measuring immediatelyafter setting.Measure hydraulic driftevery 5 min, and judgefrom results for 15 min.
ie
min.
r PC200-6, PC2OOLC-6, PC21OLC-6, PC22OLC-6,PC25OLC-6
PC200PC2OOLCPC21 OLC
PC22OLC
PC25OLC
13.6 20 27.2 40
Max. 600 Max. 900
Max. 18 Max. 27
Max. 160 Max. 240
Max. 35 Max. 53
0
PC200PC2OOLCPC21 OLC
PC22OLC
PC25OLC
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
T PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6,PC25OLC-6
Machine model
Jnit
;ec
Permissible valueeasurement conditions Standard valueate-gory
PC220PC250
PC200 PC21 0 PC220PC250
Max 4.3
Max 3.5
Max 4.7
PC200
i.5 + 0.4
PC21 0
4.5 f 0.4
loombucketSeth in:ontactAthlround
5:ylinderully&ended
\rm>ylinderullyetracted
1IlIly&ended
3.4 * 0.4 Max 4.3 Max 5.3
) Engine at high idlingB Hydraulic oil temp:
45-55 “ CB In H/O mode
Max 3.2 Max 3.8.4 f 0.3.8 + 0.3
1.6 0.4
.9 t 0.3
3.1 f 0.3
3.8 f 0.4 Max 4.5 Max 4.7.8? 0.4
3.1 + 0.3P Engine at high idli ngB Hydraulic oil temp:
45-55-cb In HI0 mode
Max 3.5 Max 3.6 Max 3.7.0 f 0.3
bucket:ylinderullyetracted
I%_rlly&ended
Max 3.5.9 f 0.4
2.2 f 0.3
Max 3.6
Max 2.7
Max 3.6
Max 2.8
.8 f 0.4
.I f 0.3
2.8 f 0.4
2.1 + 0.3b Engine at high idlingB Hydraulic oil temp:
45-55°CB In HI0 mode
Max 2.7
Max 1 .O Max 1.2Lower boom and measuretime taken from pointwhere bucket contactsground to point wherechassis rises from theground
b Engine at low idlingB Hydraulic oil temp: 45 -
55°C
Max 1 O Max 2.8oII.5
. Stop arm suddenly andmeasure time for arm tostop
b Engine at low idlingHydraulic oil temp: 45 -55°C
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
achine model PC2004 PC2OOLC-6, PC21OLC-6,PC220LC-6. PC250LC-6
Unit Standard value Permissible valueate-gory
Measurement conditions
BEi= Bucket Max 1 O Max 3.6et
XT/nin
Stop bucket suddenly andmeasure time taken forbucket to stop at bottomand then start againEngine at low idlingHydraulic oil temp: 45 -55°C
Cylinders
Centerswivel joint
Hydraulic oil temp: 45 -55°CEngine at high idlingRelieve circuit to be
measured
20.5
50
Engine at high idlingHydraulic oil temp: 45 -55°C
f Use a hard horizontalsurface
PC200‘ C200LC‘ C21 OLC‘ C22OLC
PC200‘ C2OOLC‘ C21OLC‘ C22OLC
‘ C250LC ‘ C250LC
I- 20m clavel deviation whenIrk equipment andvel are operated
kF10m PoOlM
nm
Wax 200 Max 400 Vlax 220
PC200‘ C2OOLC‘ C21OLC
Max440
‘ C22OLC‘ C25OLC
k Measure dimension 2’
PC200‘ C2OOLC‘ C21OLC
‘ C22OLC‘ C25OLCHydraulic oil temp: 45 -
55°CB Measure with engine at
rated speedD At rel ief valve set pressure
3.14 MPa (32 kg/cm’ )
Controlpump
Main pump
Vlin 27.2 Min 29.9 vlin 24.5 Min 26.9
ee next page ee next page
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Cate-
goryPCZOO, PC210: Discharge amount of main piston pump (in H/O mode)
0 9.8 (100) 19.6 (ZOO) 29.4 (300) 34.3 (350)
Pump discharge pressure = %$& (MPa (kg/cm2))
Pump speed: At 2200 rpm, TVC current 180 mA
Check Point
As desired
Test pump discharge Discharge Average pressure Standard value for Judgementpressure (MPa pressure of other (MPa (kg/cm’ )) discharge amount standard lower
(kg/cm*)) pump (MPa Q (Urnin) limit Q (Umin)
(kg/cm’ ))
P, P, P,+ P, See graph See graph2
* As far as possible, bring pump discharge pressure P, and P, as close as possible to the average pressure whenmeasuring.The error i s large near the point where the graph curves, so avoid measuring at this point.
* When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specifiedspeed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurment, anduse them as a base for calculating the pump discharge amount at the specified speed.
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Cate-gory
PC220, PC250: Discharge amount of main piston pump (in H/O mode)
I0 (0) 9.8 100) 19.6 (200) 29.4 (300) 34.3 (350)
Pump discharge pressure = v (MPa (kg/cm*))
Pump speed: At 2300 rpm, TVC current 180 mA
Check PointTest pump discharge
pressure (MPa(kg/cm*))
Discharge Average pressure Standard value for Judgementpressure of other (MPa (kg/cm’ )) discharge amount standard lower
pump (MPa Q (Umin) limit Q (Umin)
(kg/cm’ ))
As desired P, P* P,+ P,2
See graph See graph
Sr As far as possible, bring pump discharge pressure P, and P, as close as possible to the average pressure whenmeasuring.The error is large near the point where the graph curves, so avoid measuring at this point.
Sr When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specifiedspeed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurment, anduse them as a base for calculating the pump discharge amount at the specified speed.
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Flow control characteristics of WC valve (STD)A The values in this table are used as reference values when carrying out troubleshooting.
Cate-gory
Item
Time taken forswing forboom RAISEand startingswing
PC00246
Engine at high idlingHydraulic oil temp: 45 - 55°Cn H/O mode
Load the bucket with the rated load and measurethe time taken from the position of starting theswing to the point of passing the QO’ position.
Unit
et
PC200PC2OOLCPC21 OLC
4.2 f 0.4
PC220LCPC250LC
4.6 f 0.4
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
system
Component
‘ uel control dial
Jlotor
‘ ower sourcefoltage
‘ uel controllial
‘ otentiometer
Warming-upiianal
ConnectorNo.
E06 (male)
04 (male)
iO5 (male)
rletwork
Inspec-tion
method
Judgement table Measurementconditions
$ If the condition is as shown in the table below, it is5
1) Turn startingnormal switch OFF.
8 If the condition is as shown in the table below, it is6
1) Turn startingnormal switch OFF.
IE Between (1) - (2) 0.25 - 7 k n
2) Disconnectconnector E04.
?z Between (2) - (3) 0.25 - 7 k f282 Between (1) - (3) 4-6kQ
If the condition is as shown in the table below, it is 1) Turn startingswitch OFF.
8
IIBetween (1) - (2) 2.5 - 7.5 0
2) Disconnect
Econnector E05.
0If the condition is as shown in the table below, it is 1) Turn starting
= normal switch ON.2S Between (1) - (12) 20-30V
2) Insert
3TAadapter.
B Between (2) - (12) 20-30V.c I I I)
1) Turn starting
I f the condition is as shown in the table below, it is 1) Turn startingnormal switch ON.
D Low idling 2.9 - 3.3 v 2) Insert
= BetweenT-adapter
9n
(17) - (16) Hgh idling 0.5 - 0.9 v
7is I,
8
II
IBetween (5) - (16) 4.75 - 5.25 V
IThere must be no network error messages on the monitordisplay.
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
system
Component
ruto-ecelerationignal
Governorlotor
lattery relay
Aodel IO1
ielection female)
ConnectorNo.
io1
Inspec-tion
method
Judgement table
If the condition is as shown on the table below, i t isnormal.
If the condition is as shown on the table below, it isnormal.
Between (10) - (20) 1.8 - 4.6 U
Between (11) - (21) 1.8 - 4.6 u
If the condition is as shown on the table below, it isnormal.
Between (13)- (12) 20-30U
Sr This is only for 2.5 set after the starting switch isoperated ON-OFF: at other times it must be 0 U.
PC200PC2OOLCPC21 OLC
PC22OLCPC25OLC
Between 8)- 12)seecton I
No continutiy ContinuityI
Between 19) 12) No continutiy NoSelectIon continutiy
Measutementconditions
1) Turn startingswitch ON.2) InsertT-adapter.
1) Turn startingswitch ON.2) InsertT-adapter.
1) Turn startingswitch ON.2) InsertT-adapter.
1) Turn startingswitch OFF.2) Disconnectconnector EOI
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Measurement conditionsystem
Connector No.Judgement table
Jetworkmonitor,engine, throttle:ontrol)
,f the condition is as shown on the tableoelow. it is normal.
1) Turn starting swithchDN.2) Insert T-adapter.03
Between (7). (8) - (15) I 4-8V I
1) Turn starting switchDFF.
2) Disconnect connectorE07.
If the condition is as shown on the tableoelow, it is normal.
r ~~etween female (1) - (2) 1 500-1000n I
Betweem female (1) - Min. 1 M nchassis I
ingine speediensor
1) Start engine2) Insert T-adapter.
Measure with AC range
Between (1) - (2) 0.5 - 3.0 vLO7
1) Screw in rotation sensor until it contactsring gear, then turn back one turn.2) It must work normally when adjusted asabove.
1) Start engine (chargeaccumulator)2) Disconnect connectorsSO1 - S08.
Travel so13oom raise SO24rm out so33oom lower
so44rm in so53ucket curl
SO63ucket dump
so7Swina SO8
If the condition is as shown on the tablebelow, it is normal.
‘ PC oil,ressure switch
Between (I), (2) -chassis
Min 1 M fI
If the condition is as shown on the tablebelow, it is normal.
1) Start engine2) Turn fuel control dial toMAX position.3) Insert T-adapter.etween (1) - (2) 18-28V>ump pressure
sensorCO7 (rear)CO8 (front)
Between (1) -(3) 1-1
1) Turn starting switchOFF.2) Disconnect connectorco2.
If the condition is as shown on the tablebelow, i t is normal.
Between (9) -CND 1 SsS 1 ,% 1O2 (female)wing lock
switch
When Max10switch is
ON
If the condition is as shown on the tablebelow, it is normal.
I Between (1) - (2) 1 IO-220
1) Set TVC prolix switchOFF.2) Turn starting switchOFF.3) Disconnect connectorsco4, Cl 3.
1) Turn starting switchOFF.2) DisconnectconnectorV04.
CO4 (rear)(male)Cl 3 (front)(male)
WC valveBetween (2) - chassis Min 1 MC2
If the condition is as shown on the tablebelow, it is normal.
Swing brakesolenoid valve 1 Between(l)-(2) 1 20-600 1V04 (male)
Between (2) - chassis Min 1 MfI
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
Measurementystem
Component Connectorno.
Inspec-tion
method
Judgement table
1 ravel speedS lenoid valve
‘ 06 (male) If the condition is as shown on the table below, itIS normal.
1) Turn starting switchDFF.2) Disconnectconnector V06.
2 -stage reliefS olenoid valve
LS selectS olenoid valve
ump merge-d ivider solenoidv alve
L S control EPCalve
I Between (1) - (2) 1 20-600 1
1 Between (2) - chassis 1 Min 1 MD 1
‘ 05 (male) If the condition is as shown on the table below, itis normal.
I Between (1) - (2) 1 20 - 60 G 1
1) Turn starting switchDFF.2) Disconnectconnector VO5
Between (2) -chassis I Min 1 MD I
‘ 02 (male) If the condition is as shown on the table below, itis normal.
1) Turn starting switchOFF.2) Disconnectconnector V02.Between (1) - (2) 1 20-600 1
Between (2) - chassis I Min I MD I
‘ 03 (male) 1) Turn starting switchOFF.2) Disconnectconnector V03.
If the condition is as shown on the table below, itis normal.
Between (1) - (2) 1 20-600 1
Between (2) - chassis I Min I Mf2 I1) Turn starting switchOFF.2) Disconnectconnector Cl 0.
If the condition is as shown on the table below, itis normal.
-
Powersourcevoltage
L.H. knobswitch
Modelselection
-
:I 0 (male)
Between (1) - (2) 7-14G
Between (2) - chassis Min 1 MD
If the condition is as shown on the table below, itis normal.
Between (12) (13) -(3), (4)
If the condition is as shown on the table below, itis normal.
If the condition is as shown on the table below, itis normal.
PC200PC2OOLCPC21 OLC
PC22OLCPC25OLC
Between(13) - GND
Between(14) - GND
Between(15) - GND
Between(16) - GND
No Continuitycontinuity
No Nocontinuity continuity
Continuity Continuity
No Nocontinuity continuity
1) Turn starting switchON.2) Insert T-adapter.1
1) Turn starting switchON.2) Insert T-adapter.
:02
1) Turn starting switchON.2) Disconnectconnector C02.
:02 (female)
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
system
Inspec-tion
method
Judgement table Measurementconditions
Component Connector
I No.
-1) Start engine.2) Insert T -adapter.3) Place allevers at neutral.
f the condition is as shown on the table below, it is normal.
n1
f the condition is as shown on the table below, it is normal.
Standard mode ZO-28VBetween
Kerosene mode (17)-GND o-2v
,f the condition is as shown on the table below, it is normal.-ligh idling speed (rpm)
Auto-decelerationoutput signal
co3
Kerosenemode
co2
1) Turn starttingswitch ON.2) Insert T-adapter.
1) Turn starttingswitch ON.2) Set monitoroanel tomonitoring code10or 16.3) OperateNorking modeswitch and L.H.knob switch.
HI0 (working)
PC200PC210
Approx 2230
PC220PC250
Approx 2420I 1
H/O (traveling) Approx 2420 Approx 2530
I G/O I pprox 2100 I Approx 2200 IF/O Approx 2100 Approx 2200
L/O Approx 1700 Approx 1750
No. 2throttlesignal
Monitoringcode 16,lO
Power MaxIApprox 2420
IApprox 2530
(HIO)(GIO) ISwift slow-down
(H/O)(G/O)Approx 1700 Approx 1750
If the condition is as shown on the table below, it is normal. 1) Start engine.2) Turn swinglock switch OFF.3) Set swinglock prolix switchOFF.4) InsertT-adapter.
Swing brakesolenoidvalve co1
-I-If the condition is as shown on the table below, it is normal 1) Start engine
2) Insert T-adapter.3) Turn fuelconrtol dial toMax postion.4) Travel onlevel ground.
Travel brakesolenoid co1valve
1) Turn startingswitch ON.2) Insert T-adapter.3) Chargeaccumulator.
If the condition is as shown on the table below, it is normal.
All levers at nuetral ZO-30VBetween
Travel lever (14)-U), (2) o-3voperated
2-stagereliefsolenoidvalve
co1
i the condition is as shown on the table below, it is normal. 1) Turn startingswitch ON.2) Insert T-adapter.3) Chargeaccumulator.
LS select
solenoidvalve co1
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
sys-tem
Component Connector No.
-‘ umpnerge-dividersolenoidJalve
TVC valve[defaultJalue)
LS controlEPC valveldefaultvalue)
co2
co1
co1
I
I
L
Inspec-tion
method
Judgement table
If the condition is as shown on the table below, it isnormal.
If the condition is as shown on the table below, it isnormal.
Working in G/O mode.
I PC200 PC220PC21 0 PC250 I
Front:between510?80mA 410t80mA
If the condition is as shown on the table below, it isnormal.
Working in G/O mode.
Between (15)-(7) 900 f8
Measurementconditions
1) Turn startingswitch ON.2) Insert T-adapter.
1) Turn startingswitch ON.2) Turn fuel controldial to MAXpostion.
1) Turn startingswitch ON.2) Turn feul controldial to MAX
postion.
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
sys
temComponent
Suage
T onnector No. Inspectionmethod
Judgement table
If the conditions is as shoen in the table below, it is normal.Suages
Coolant:emp guage
Measureresistance
betweenPO2
(female)(12) - PO1(famale)
(11)
Fuel levelguage
betweenPO1
(female)(11) - PO2(female)
(11)
Position of guage Display level resistance (Monitor paneldisplay input resistance)
Starting swtich ON Starting switch OFF
Rightside
Dlsplayposition
Left side
Min. - Max. (k0)
0 - 0.646
4.119 - 4.681
4.456 - 5.063
8III
4.820 - 5.744
-11 34.927 - Disconnection I
Position of guagedisplay
Starting swtich ON
Display level resistance (Monitor panelinput resistance)
Starting switch OFF
Rightside
Displayposition
Left side
4
Min. -Max. (kf2)
0 - 13.82
8III
29.18 - 35.22
72.98-91S
638.00 - Disconnection
Measurementconditions
1) Insert a dummyresistance with thestarting switch OFF,or measure theresistance of thesensor.2) Check the displaywith the startingswitch ON.
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
system
Component ConnectorNo.
nspec-tion
nethod
Judgement table Measurementconditions
letweenllternatorsrminal Rnd chassis
When engine is running (half throttle or above)I
1) Start engine.+27.5 - 29.5 Vternator
&If the battery is old, or after starting in cold areas, thevoltage may not rise for some time.
If the condition is as shown in the table below, it is normal. 1) Start engine.
If the condition is as shown in the table below, it is normal.
Between female (l)-(2)
Between female (2)-chassis
500-1000n
Min 1 MD
1) Turn startingswitch OFF.2) Disconnectconnector E07.
Qr cleaneriloggingiensor
II male)‘ I 2 (female)
Engine speediensor Measure with AC range
I Between (l)-(2) 0.5 - 3.0 V
1) Start engine.2) Insert T-adapter.
io7
2aa
1) Screw in rotation sensor until it contacts the ring gear,then turn back one turn.2) It must work normally when adjusted as above.
If the condition is as shown in the table below, it is normal.I
1) Turn startingswitch OFF.
Above LOW level in reservoir tank MaxlfIII
2) Disconnectconnector P08.oolant level
sensorBelow LOW level in reservoir tank Min 1 MC?
3) Insert T-adapterinto connector atsensor end.
‘ 08 (male)
If the condition is as shown in the table below, it is normal. II) Turn startingswitch OFF.2) Disconnectconnector PO53) Drain oil, thenremove sensor.4) Insert T-adapterinto sensor.+ Connect the T-adapter to theconnector andsensor flange.
V’ EFBLPOOO02ngine oil
evel sensor ‘ 05 (male)
q-)/as’ LizBLPGOOO3
If the condition i s as shown in the table below, it is normal. 1) Turn starting
Zoolantemperaturesensor
‘ 07 (male)
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TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES
sys
temComponent
Engine oil
xessuresensor
Fuel levelsensor
Hydraulic oillevel sensor
Air cleanercloggingsensor
ionnector No.
_
‘ 06 (male)
‘ 09 (male)
VI (female)‘ 12 (male)
nspec-tion
nethod
Judgement table
f the condition is as shown in the table below, it isiormal.Low pressure sensor
11
High pressure sensor
If the condition is as shown in the table below, it isnormal.
the condition is as shown in the table below, it isxmal.
I I
Raisefloat 1 Maxi C? ~r
Lower float Min 1 MD
the condition is as shown in the table below, it isormal.
Air cleaner normal
IContinuity
Air cleaner clogged No continuity
Measurmentconditions
I) Install oil pressureneasuring guage.?) Remove wiringlarness terminal.3) Start engine.1) Put tester in:ontact between
sensor terminal screw2nd chassis.
I) Trun startingswitch OFF.2) Disconnect:onnector P06.3) Drain fuel, then‘ emove sensor.1) Insert T-adapter
nto sensor.k Connect the T-adapter to the:oonnector andsensor flange.
I) Trun startingswitch OFF.2) Disconnect:onnector PO9.3) Drain oil, then‘ emove sensor.4) Insert T-adapter
nto sensor.
1) Start engine.2) Disconnect PI 1,P12.3) Put tester incontact withconnector at sensorend to measure.
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TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTNG
Check or measurmentitem
jymbol Part No. Part Name Remarks
I I II1 I799 203 8001 1Multi-tachometer L: 60 - 2,000 rpm
I I
t 799-203-8901 IClamp setDigital display
hH: 60 - 19,999 rpm
Engine speeds0 Kit part no. : 799-203-9000
Intake manifold pressure See Engine Shop ManualSee Engine Shop Manualntake air restriction
Lubricating oil pressure
Fuel filter inlet restriction
Blow-by pressure
-- I Pressure aauae 1See Engine Shop Manual
Vacuum gauge See Engine Shop Manual
See Engine Shop Manualool, adapter &manometer
Mercury manometer
Digital temperature guage
Exhaust back pressure See Engine Shop Manual
See Engine Shop Manualoolant temperature
Feeler gaugealve clearance
Exhaust gas color11 1799 2649000 Smoke detector Discoloration:
0 - 70% with standard color% x 1 I 0 = Bosch indexmoke meter
790-261-I 311
Pressure gauge: 2.45 (25), 5.88 (60) 39.2 (400)58.8 (600) MPa (kg/cm’ )
Pressure gauge: 68.6 MPa (700 kg/cm*)
Hydraulic tester
Digital hydraulic tester
Hydraulic gauge 0.98 MPa (10 kg/cm*)
Both male and female 14 x 1.5 (female PT I/8)
Both male and female 18 x 1.5 (female PT I/8)
Both male and female 22 x 1.5 (female PT I/8)Adapter
4 799-401-2700
t-k90-261-I 360
5 790-261-I 370
07003-31419
Differential pressuregauge
Oil pressure
Both male and female 14 x 1.5 (female PT l /8)dapter
Nut For 14 x 1.5 blind
For blindasket
161 -I79A-2640020
Hose
1-1 Push-pull scaleIO-294N(O-30kg)
0-490N(O-50kg)perating force H
Stroke, hydraulic drift I Scaleommerciallyavailable
Commerciallyavailable
~ top watchork equipment speed
Measuring voltage andresistance values
Troubleshooting of wiringharnesses and sensors
K 79A-2640210
799-601-2600
Tester
T-adapter boxI
2-
Adapter assembly Kit part no.: T-adapter kit 799-601-8000
I31 ~ dapter
~ lowmeter kitain pump delivery M 1790-303-l 003
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TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
A
1.
2.
When removing or installing the measuring equip-
ment, be careful not to touch any high tempera-ture parts.Measure the engine speed under the followingconditions.
Coolant temperature: Within operating range
Hydraulic oil temperature: 45 - 55 CInstall the digital optical tachometer using the instruc-tions supplied with it.Start the engine, and measure the engine speedwhen it is set to the conditions for measuring.1) Measuring at low idling and high idling:
Measure the engine speed with the fuel controldial set to low idling and high idling.* When measuring at high idling with the work
equipment operated, operate the work equip-ment lever, but not enough to make the workequipment move.
* When measuring at high idling with the travel
(power max.) operated, operate the travel le-ver, but not enough to make the machinemove.
2) Measure the speed at near the rated speed.i) Set the working mode to the H/O mode.ii) Set the power max./swift slow-down switch
to the power max. position.iii) Run the engine at high idling, set the L.H.
knob switch to the ON or OFF position, oper-ate the arm lever, and measure the speedwhen the arm circuit is relieved.* Measuring speed when work equipment
is operated: L.H. Knob switch OFF* Measuring speed when travel is oper-
ated: L.H. Knob switch ON3) Measuring speed at pump relief:
Run the engine at high idling and measure theengine speed when each pump is relieved.* For details of the pump to relieve, see the
TABLE OF JUDGEMENT STANDARDVALUE.
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TESTING AND ADJUSTING MEASURING INTAKE MANIFOLD PRESSURE
MEASURING INTAKE MANIFOLD PRESSURE
* Refer to ENGINE SHOP MANUAL for tools and properprocedure
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TESTING AND ADJUSTING MEASURING INTAKE AIR RESTRICTION
MEASURING INTAKE AIR RESTRICTION
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING LUBRICATING OIL PRESSURE
MEASURING LUBRICATING OIL PRESSURE
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING FUEL (FILTER) INLET RESTRICTION
MEASURING FUEL (FILTER) INLET RESTRICTION
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING EINGINE BACK PRESSURE
MEASURING ENGINE BACK PRESSURE
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR
l
A
1.
When measuring in the field when there is no air orpower supply, use smoke checker GI; when record-ing official data, use smoke meter G2.Raise the coolant temperature to the operating rangebefore measuring.
When removing or installing the measuring equip-
ment, be careful not to touch any high temperaturepart.
Measuring with handy smoke checker GI1) Fit filter paper in tool GI.2) Insert exhaust gas intake port into the exhaust
pipe, accelerate the engine suddenly, and at thesame time operate the handle of tool GI to catchthe exhaust gas on the filter paper.
3) Remove the filter paper and compare it with thescale provided to judge the condition.
2. Measuring with smoke meter G2 I
\
1)
2)
3)
4)
5)6)
7)
Insert probe 0 into the outlet port of exhaust pipe (I),then tighten the clip to secure it to the exhaust pipe.Connect the probe hose, accelerator switch plug, andair hose to tool G2.* The pressure of the air supply should be less than
1.47 MPa (15 kg/cm?Connect the power cord to the AV 1 OOV outlet.* When connecting the port, check first that the
power switch of tool G2 is OFF.Loosen the cap nut of the suction pump, then fit thefilter paper.* Fit the filter paper securely so that the exhaust gas
does not leak.Turn the power switch of tool G2 ON.Accelerate the engine suddenly, and at the sametime, depress the accelerator pedal of tool G2 andcatch the exhaust gas color on the filter paper.Lay the filter paper used to catch the exhaust gascolor on top of unused filter paper (10 sheets ormore) inside the filter paper holder, and read theindicated value.
G2
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TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE
MEASURING COOLANT TEMPERATURE
* Refer to ENGINE SHOP MANUAL for tools and properprocedure.
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TESTING AND ADJUSTING MEASURING VALVE CLEARANCE
MEASURING VALVE CLEARANCE
* Refer to ENGINE SHOP MANUAL for tools and proper Iprocedure.
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CHECKING AND ADJUSTING BELT TENSIONTESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR
CHECKING AND ADJUSTINGBELT TENSION FOR AIRCONDITIONER COMPRESSOR
CHECKING1. Remove belt guard 0.
2. Press compressor drive belt midway between fanpulley and compressor pulley. The belt should nor-mally deflect by about 15 - 18 mm when pressedwith the finger (with a force of approxiamately 6kg).
ADJUSTING1.2.
3.4.
5.
6.7.
Lossen two nuts and bolts 0.Carefully lever compressor housing as shown totighten belt to tightness criteria. Tighten lower boltto hold in position.Tighten upper bolt.Check each pulley for damage, wear of the V-grooveand wear of the V-belt. In particular, be sure to checkthe V-belt is not touching the bottom of the V-groove.Replace belt if it has streched, leaving no allowance foradjustment, or if there is a cut or crack on the belt.Refit belt guard.When the new belt is set, readjust after operating forone hour.
X13EM006
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TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEEDSENSOR
1 Screw in until the tip of sensor (1) contacts gear (2).2. When gear (2) contacts sensor (I), turn back one turn.3. Tighten locknut (3).* Be particularly careful when securing the sensor wiring
to ensure that no excessive force is brought to bear on
the wiring.* Be careful not to let the tip of the sonsor be scratched or
to let any iron particles stick to the sensor tip.
XlZAD058
1 2
\q
*;,_ 3
I-LClearance
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TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
TESTING* Use the governor motor adjustment mode.1. In the time mode display, keep the time switch +
travel speed R.H. switch + working mode R.H.switch pressed for 2.5 seconds.
2. In this condition, check the governor lever and
spring rod.3. After checking, repeat the procedure in Step 1) tofinish the governor motor adjustment mode.
ADJUSTING1. Turn the starting switch OFF, then remove the nut
and disconnect joint (1) from governor lever (4).2. Repeat the procedure in Step 1 - 1) above to set to
the governor adjustment mode.3. Set governor lever (4) to a postion where it contacts
the full speed stopper (5) of the injection pump, thenadjust the length of spring assembly (2) and rod (3),and connect joint (1) with the nut.
4. From the above position, turn joint (1) back 4 turns,and secure in position with locknut (6).
* CautionWhen the spring assembly is removed and the startingswitch is at the OFF position, if the governor motor leveris moved suddenly, the governor motor will generateelectricity, and this may cause a failure in the enginethrottle controller.
Engine governor lever
Low idle stop
ull s@ed
View “A”
L
I- I
X12AD061
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TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWINGCIRCLE BEARING
Method of testing clearance of swing circle bearingwhen mounted on machine1.
2.
3.
4.
5.
A
6.
Fix a magnet-type dial gauge to the outer circle (orinner circle) of the swing circle, and put the tip of theprobe in contact with the inner circle (or outer circle).Set the dial gauge at the front or rear.
Extend the work equipment to the maximum reach,and set the tip of the bucket to the same height as the
bottom of the revolving frame.When this is done, the upper structure will tilt forward,so the front will go down and the rear will rise.
Set the dial gauge to the zero point.
Set the arm more or less at right angles to the groundsurface, then lower the boom until the front of themachine comes off the ground.
Read the value on the dial gauge at the point. Thevalue on the dial gauge is the clearance of the swingcircle bearing.
When carrying out the measurment, do not put your
hand or feet under the undercarriage.
Return to the condition in Step 2, and check that thedial gauge has returned to the zero point. If it has notreturned to the zero point, repeat Steps 2 to 5.
eve wngframe
Outerir le
or
73nnnerir le
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TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACKSHOE TENSION
TESTING1. Raise the track frame using the arm and boom, and
measure the clearance between the bottom of thetrack frame and the top of the track shoe.0 Clearance: 303 f 20 mmMeasurement positionPC200 : 4th track roller from sprocketPC2OOLC : 5th track roller from sprocketPC21OLC : 5th track roller from sprocketPC22OLC : Midway between the 5th and 6th
track roller from sprocketPC25OLC : Midway between the 4th and 5th
track roller from sprocket
ADJUSTING* If the track shoe tension is not within the standard
value, adjust as follows.1. When the tension is too high:
Loosen plug (1) gradually, and release the grease.A There is danger that the plug may fly out under
the high internal pressure of the grease, so neverloosen plug (1) more than one turn.
* If the grease does not come out easily, move themachine backwards or forwards slowly.
2. If track is too loose:Pump in grease through grease fitting (2).+r If the grease cannot be pumped in easily, move
the machine backwards and forwards slowly.
/Track frame
\Track shoe
X15AD008
I X15AD009
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TESTING AND ADJUSTING HYDRAULIC PRESSURETESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTINGHYDRAULIC PRESSURE IN WORKEQUIPMENT, SWING, TRAVELCIRCUIT
MEASURING* Hydraulic oil temperature when measuring: 45 -
55°CA Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then put the safety lock lever in the LOCK posi-tion.Remove pressure pick-up plug (1) or (2) (Threaddia. = IOmm, Pitch = 1.25 mm) from the circuit tobe measured, then install oil pressure gauge CI(58.8 MPa (600 kg/cm?).
Measuring main unload pressure* Unload pressure when front and rear pump flows
are merged.Measure the oil pressure in H/O mode with theengine at high idling and the control levers atneutral.
Measuring sub-unload pressure* The unload pressure in the circuit which is not
under load when the front and rear pump flowsare divided.
1. Set to H/O mode + boom/swing priority selectionmode ON.
2. Measure the pressure in the pump circuit on theopposite side when the arm or bucket circuit is
relieved.Arm relief: Load on front pump, rear pumpunloaded.
Bucket relief: Load on rear pump, front pumpunloaded.
Measuring pump relief pressure1. When LS relief valve is actuated
When hydraulic pressure is 31.9 MPa (325 kg/cm?1)
*
Measure the pressure when each actuatorexcept the travel actuator is relieved in H/Omode with the engine at high idling.Note that the set pressure of the safety valvefor the swing motor and head end of the boomis lower that the LS relief pressure, so the valvemeasured will be the relief pressure of thesafety valve.If the swing lock switch is ON, the pressure willrise, so always keep the lock switch OFF whenmeasuring.
XlOZZO 4
Table 1 Combination of pumps and actuatorscontrolled when flow from front andrear pump is divided.
Pump
Front pump
Controlled actuator
Arm cylinder0 Swing motor %
L.H. travel motor
Boom cylinder %Rear pump Bucket cylnder
R.H. travel motor
g The set pressure of the safety valve at the
head end and the swing motor is lower thanthe set pressure of the main relief valve.
I
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TESTING AND ADJUSTING HYDRAULIC PRESSURETESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
2. When pressure rises to 34.8 MPa (355 kg/cm?*V
2)
Main relief valve actuated.When travel is operated.Measure the hydraulic pressure when thetravel is relieved on each side seperately inH/O mode with the engine at high idling.* To relieve the travel circuit, put block 0
under the track shoe grouser, or put block
0 between the sprocket and frame to lockthe track.
When power max. function is actuated.When measuring the oil pressure in G/O orH/O mode with the engine at high idling andthe power max. function actuated, relieve oneof the boom, arm, or bucket circuits, and mea-sure the oil pressure.
ADJUSTING
1. LS relief valve1) Loosen nut (1) so that elbow (2) can move.2) Loosen locknut (3), then turn holder (4) to adjust.
j, Turn the holder to adjust as follows.To INCREASE pressure, turnCLOCKWISETo DECREASE pressure, turnCOUNTERCLOCKWISE.
2. Main relief valveLoosen locknut (I), then turn adjustment screw(2) to adjust. XlOZZO27
Turn the adjustment screw to adjust as follows.To INCREASE pressure, turn CLOCKWISE.To DECREASE pressure, turn COUNTER-CLOCKWISE. 1
* Amount of adjustment for one turn of adjust-ment screw: 12.6 MPa (128 kg/cm?.
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TESTING AND ADJUSTING HYDRAULIC PRESSURETESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
3. Swing motor safety valveLoosen locknut (I), then turn adjustment screw(2) to adjust.jl Turn the adjustment screw to adjust as follows.
To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.
I x1 zz 3
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TESTING AND ADJUSTING TVC VALVE OUTPUTTESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING TVCVALVE OUTPUT PRESSURE (SERVOPISTON INPUT PRESSURE)
MEASURING* Hydraulic oil temperature when measuring : 45 - 55°C
Measure the oil pressure when the circuit is relievedin the power max. mode.1) Remove pressuremeasurement plugs (l), (2), (3),and (4) (Thread dia. = 10 mm, Pitch = 1.5 mm), andinstall oil pressure gauge Cl.* Install a 39.2 MPa (400 kg/cm? gauge to the
servo valve end, and a 58.8 MPa (600 kg/cm?gauge to the pump outlet port end.
2) Set the swing lock switch ON.3) Set the working mode to H/O mode.4) Run the engine at high idling, turn the L.H. knob
switch ON, and measure the oil pressure when thearm IN circuit is relieved.* Check that the servo piston input pressure is %
of the pump discharge pressure.
[Reference]If there is any abnormality in the LS valve or servopiston, the servo piston input pressure will be almostthe same or 0 of the pump discharge pressure.
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TESTING AND ADJUSTING TVC VALVE OUTPUTTESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)
ADJUSTING* If the load becomes larger, the engine speed will
drop. Or if the engine speed remains normal, thework equipment speed will drop. In such cases, ifthe pump discharge pressure and LS differentialpressure are normal, adjust the TVC valve as follows.* There are two sets, so adjust both the front and
rear to the same angle.
1. Loosen locknut (3), and if the speed is slow, turnscrew (4) to the left; if the engine speed drops, turnthe screw to the right.* If the screw is turned to the left, the pump absor-
ption torque will be increased, and if it is turned tothe right, the pump absorption torque will bereduced.There is also a connection with the angle, so seeNote below.
* The adjustment range for the screw is a maximumof 90” to both the left and right.
2. After completing the adjustment, tighten the locknut.
- Locknut: 29.4 f 4.9 Nm (3.0 f 0.5 kgm)
Note: The screw is an eccentric cam, so if it is turnedfrom position @ in the graph, the stroke of theservo piston will move as shown in the graph. If itis turned on full turn, it will return to the originalposition, but the screw will become looser, sothere will be play in the screw. Therefore, turn thescrew a maximum of 90” to the left and right fromthe position @ set when the machine was ship-ped.
az .ZE :z- . Position when
assembled
“ 90 180 320
Rotation position of eccentric pin ( ’ )
x1ozzo35
Position of screw when shipped
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TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVOTESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LSVALVE OUTPUT PRESSURE (SERVOPISTON INPUT PRESSURE) AND LSDIFFERENTIAL PRESSURE* Hydraulic oil temperature when measuring: 45 - 55°CMeasuring1. Measuring LS valve output pressure (servo piston
input pressure)1) Remove pressure measurement plugs (l),(2),(3),
and (4) (Thread dia. = 10 mm, Pitch 1.5 mm), andinstall oil pressure gauge Cl.j, Install a 39.2 MPa (400 kg/cm? gauge to theservo valve end, and a 58.8 MPa (600 kg/cm?gauge to the pump outlet port end.Oil pressure when travel is rotating under no loadon one side.i) Set the working mode to H/O mode, and set
the travel speed switch to Hi.ii) Use the work equipment to raise the track
assembly on one side.iii) Measure the oil pressure with the engine at
high idling and the travel lever operated to theend of its stroke to rotate the track under noload.Run the engine at high idling, operate the travellever to the end of its stroke, and measure theoil pressure when the working mode and travelspeed are switched as shown in Table 1.
-able 1
Working Travelmode lever
l-
H/O mode Neutral
HI0 mode Full
Pumppressure (MPa
(kg/cm*))
3.72 f 0.69 3.72 f 0.69(38 f 7) (38 f 7)
8.82 f 1.96(90 f 20)
ervo
piston inletPort
pressure(MPa
(kg/cm*))
4.41 f 0 98
(45+ 10
Remarks
Aboutsame
pressure
About %of
3ressure
-
l’
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TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVOTESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
2. Measuring LS differential pressure1) Measuring with a differential pressure gauge.
i) Remove oil pressure measurment plugs (5)and (6) (Thread dia. = 10 mm, Pitch = 1.5 mm),and install differential pressure gauge C4.
ii) Set to the conditions in Table 2 and measurethe LS differential pressure.
able 2
..,,.,,,,. Operation
HI0 mode I MAX
H/O mode MAXI-Levers at
neutral
2.16+0.1(22 f 1)
Travel speed:Hi
Travel circuitunder no load
(lever fullyoperated)
2) Measuring with oil pressure gauge
* The maximum differential pressure is 2.94 MPa(30 kg/cm?, so measure with the same gauge.
i) Remove oil pressure measurement plugs (5)and (6) (Thread dia. = 10 mm, Pitch = 1.5 mm),and install the plug inside hydraulic tester CI.
ii) Install oil pressure gauge CI (58.8 MPa (600kg/cm?) to the measurement plug for thepump discharge pressure.jr Use a gauge with a scale in units of 0.98
MPa (10 kg/cm?. (If no 58.8 MPa (600kg/cm? pressure gauge is available, a39.2 MPa (400 kg/cm? pressure gaugecan be used.)
iii) Set to the conditions in Table 2 and measurethe pump discharge pressure.* Stand directly in front of the indicator and
be sure to read it correctly.iv) Remove oil pressure gauge CI, then install to
the LS pressure measurement plug.v) Set to the conditions in Table 2 and measure
the LS pressure.+r Stand directly in front of the indicator and
be sure to read it correctly.Pump discharge pressure - LS pressure =Differential pressure.
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TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVOTESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
ADJUSTING1. Adjusting LS valve
When the differential pressure is measured under theconditions above, and the results show that the differ-ential pressure is not within the standard value, adjustas follows.1) Loosen locknut (7) and turn screw (8) to adjust the
differential pressure.* Turn the screw to adjust the differential pres-
sure as follows.To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.
2) After adjusting, tighten locknut (7).- Locknut : 29.4 f 4.9 Nm (3.0 f. 0.5 kgm)
Note: Always measure the differential pressurewhile adjusting.
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TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
TESTING AND ADJUSTINGCONTROL PUMP CIRCUIT OILPRESSURE
MEASURINGj, Hydraulic oil temperature when measuring: 45 - 55°C1. Remove pressure pick-up plug (1) (Thread dia.=
1 Omm, Pitch = 1.25 mm), and install oil pressureguage CI (5.88 MPa (60 kg/cm?).
2. Start the engine and measure with engine at highidling.
* When testing for internal leakage of the equipment inthe control circuit, use the parts given below to shut offthe circuit for the follwing sections when measuring therelief pressure.
No. Section of hydraulic circuit shut off Component that can bechecked
1 Control pump outlet port Control pump
2 Solenoid valve inlet port Solenoid valve
3 Travel PPC valve inlet port Travel PPC valve
4 R.H. PPC valve inlet port R.H. PPC valve
5 L.H. PPC valve inlet port L.H. PPC valve
* Items No. 2 and below can be checked if the equip-ment in the previous number is normal.
* Use the following parts to shut off the circuit.For elbowSleeve nut : 07221-20210,07221-20315
07221-20422Plug : 07222-00210,07222-00315
07222-00414For hosePlug : 07376-50210,07376-50315
07376-50422
c1’ +3
XiOAV271
STD/FiipC R.H. PPC -‘ L.H.PPCI
Solenoid valve
valve valve valve
Accumulator
XlOAV273
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TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
ADJUSTING1. Loosen locknut (2) and turn adjustment screw (3) to
adjust.* Turn the adjustment screw as follows.
To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.
* Amount of adjustment for one turn of adjustmentscrew: 0.53 MPa (5.4 kg/cm?.
- Locknut : 63.7 f 9.8 Nm (6.5 f 1 .O kgm)
* After completion of adjustment, repeat theprocedure in Item 1 to check the set pressureagain.
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TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
TESTING EPC VALVE, SOLENOIDVALVE OUTPUT PRESSURE
MEASURING* Hydraulic oil temperature when measuring: 45 - 55°C1. Measuring output pressure of LS control EPC valve
1) Disconnect output hose (1) of the LS control EPCvalve, then use adapter C3 in the oil pressuregauge kit to install oil pressure CI (5.88 MPa (60kg/cm?).
2) Measure the output pressure under the conditionsin Table 1.
Table 1
Operation andworking mode
All control leversat neutral
Enginespeed (rpm)
Min 1,500
Output pressure(MPa (kg/cm*)
2.94 (30)
[Reference]Current (A)
900 f 30
H/O mode orG/O modeTravel circuit atneutral, any Min 2,000
0 (0)0
work equipmentlever is operated
j, Monitoring code 10 or 40 for engine speedMonitoring code 15 for LS control EPC current
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TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
2. Measuring output pressure of ON/OFF solenoid valve1) Disconnect outlet hose (2) of the solenoid valve,
then use adapter C3 in the oil pressure gauge kitto install oil pressure gauge CI (5.88 MPa (60kg/cm?).
2) Measure the output pressure under the conditionsin Table 2.
-r
r
able 2Name of
IMeasurement conditions Operating
ICondition of
IOil pressure
IRemarks
solenoid condition solenoid (MPa (kg/cm*))
Swingbrakesolenoid
Swing or work equipment operated
All levers except travel at neutral(5 set after returning to neutral)
Brake cancelled
Brake actuated
ON Min 2.74(Min 28)
OFF 8 (8)
Travelspeedsolenoid
Travel speed swi tch at Hi or MiEngine speed 1500 rpm or aboveTravel lever operated
Travel speed swi tch at Lo or enginespeed 1500 rpm or below
Travel speed Hi
Travel speed Lo
ON
OFF
Min 2.74(Min 28)
8 (0)
Motor swashplate angle atminimum
Motor swashplate angle atmaximum
2-stagerelief
Swing lock switch ON + work equipmentlever ooerated
Pressure rise ON Min 2.74(Min 28)
solenoidI I I .
All levers at neutral Normal pressure OFF 8 (0)
LS selectsolenoid
Swing lock switch OFF, compoundoperation of swing + travel or arm OUTor boom RAISE
All levers at neutral
LS circuitdivided
LS circuit notdivided
ON
OFF
Min 2.74(Min 28)
8 (8)
Divided only forcompoundoperations ofswing + travel,arm OUT, boomRAISE
1 I I I
Pumo 1 ever at neutral. or boom. arm bucket 1 low from front 1 OFF I 0 (0) Imerge-dividersolenoid
operated independently
Travel or swing operated independently
and rear pumpsmerged
Flow from frontand rear pumpsdivided
ON
. I
Min 2.74(Min 28)
LS pumpmerge-dividervalve actuated atsame time
The basic pressure of the LS select solenoid valve issupplied from the PPC shuttle valve. Therefore, theoil pressure is not supplied unless one of the travelor arm OUT or boom RAISE is operated.Operation of solenoid valveON: Contunuous (oil pressure generated)OFF: Not continous (oil pressure: 0)
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TESTING AND ADJUSTINGMEASURING PPC VALVE OUTPUT PRESSURE
AND TESTING PPC SHUTTLE VALVE
MEASURING PPC VALVE OUTPUTPRESSURE AND TESTING PPCSHUTTLE VALVE
* Hydraulic oil temperature when measuring: 45 - 55°C
1. Measuring PPC valve output pressure1)
2)3)
4)
Disconnect the hose of the circuit to be measured(see next page).Install adapter C3 between the hose and elbow.Install oil pressure gauge CI (5.88 MPa (60kg/cm?) to adapter C3
Run the engine at high idling, operate the controllever of the circuit to be measured, and measurethe oil pressure.
2. Checking PPC shuttle valveIf the output pressure at the control valve end is low,check for leakage of oil from the PPC shuttle valve asfollows.1) Disconnect the hose between the PPC valve and
the shuttle block at the block end.2) Install an adapter for measuring the oil pressure
to the tip of the hose, then install blind plugs tothe tip and shuttle block end.
3) Operate the control lever and measure the outputpressure.
j, If the output pressure becomes normal, there isleakage from the PPC shuttle valve; if there is nochange, the PPC valve is defective.
3. Checking defective operation of PPC shuttle valve1) Remove the oil pressure switch, fit adapter Cs,
then install oil pressure gauge CI (5.88 MPa (60kg/cm?).
2) Operate the applicable lever.If no oil pressure is generated or if oil pressure isgenerated when another lever is operated, theoperation of the PPC shuttle valve is defective.
PPC hose
PPC
CS’
XlOAV282
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TESTING AND ADJUSTINGMEASURING PPC VALVE OUTPUT PRESSURE
AND TESTING PPC SHUTTLE VALVE
Oil pressure switch location diagramShuttle block seen from rear of machine
Swing608)
Bucket CURL(SO6)
Arm OUT603)
Boom RAISE602)
D&&nXlOAV283
0Circuit diagram
IC_i__._- )
XlOAV284
1. Swing PPC shuttle valve2. PPC shuttle valve for LS select3. PPC shuttle valve for OUT, boom RAISE4. PPC shuttle valve for L.H. travel FOWARD, R.H. travel
REVERSE
5. Travel PPC shuttle valve6. PPC shuttle valve for R.H. travel
FORWARD, L.H. travel REVERSE
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TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT. SWING PPC VALVE
ADJUSTING WORK EQUIPMENT.SWING PPC VALVE
*
A
1.2.3.
4.
5.
If there is excessive play in the work equipment orswing lever, adjust as follows.Lower the work equipment to the groud and stop
the engine. Loosen the oil filler cap slowly to releasethe pressure inside the hydraulic tank. Then set thesafety lock lever to the LOCK position.
Remove the PPC valve.Remove boot (1).Loosen locknut (2) then screw in disc (3) until it con-tacts the 4 heads of piston (4).* When doing this, do not move the piston.Secure disc (3) in position, then tighten locknut (2) tothe specified torque.
- Locknut : 107.8 i 9.8 Nm (11 f 1 kgm)
Install boot (1).* With the above adjustment, the clearance be-
tween disc (3) and piston (4) becomes 0.
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TESTING AND ADJUSTING ADJUSTING TRAVEL LEVER
ADJUSTING TRAVEL LEVER
1.
2.
3.
4.
Use bolt (2) to install lever (1) to the PPC valve.* When doing this, install so that clearance @ is
35.3 f 1 mm.In this condition, move left and right travel levers (3)forward and backwards, and check that the levers arefitted securely in the stopper (bolt head) of the PPC
valve.Check also that cover (3) is not contacting portion @.* If it is contacting, adjust with the PPC mounting
bolt or cover mounting bolt.Install damper (4) and adjust so that dimension @ is157.2 f 1 mm when the lever is at neutral.
I - I
XlOAV286
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TESTING TRAVEL DEVIATIONTravel posture
j, When traveling on level ground.1. Set the machine in the travel posture.
* For the travel posture, extend the bucket and armcylinder rods fully, and hold the boom angle at45” .
2. Travel for 1 Om, then measure the deviation when
traveling for the next 20m.* Set to H/O mode and measure with the engine athigh idling.
Ir Install the hydraulic pressure gauge and measure x14zzoo1
the pump discharge pressure at the same time.
to travel for thewhole distance
Make a mark Make a mark at the10 m midway point
‘ Make a mark
dimension a at this point Mark
x14zzoo2
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TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSINGHYDRAULIC DRIFT OF WORKEQUIPMENT
* If there is any hydraulic drift in the work equipment(cylinders), check as follows to determine if the causeis in the cylinder packing or in the control valve.
1. Checking for defective cylinder packing1) Checking boom and bucket cylindersi) Set in the same posture as when measuring
hydraulic drift, and stop the engine.ii) Operate the boom control lever to RAISE or
the bucket control lever to CURL.If the lowering speed increases, the pack-ing is defective.If there is no change, the boom holdingvalve (boom) or the control valve (bucket)is defective.
2) Checking arm cylinder
0
ii)
Operate the arm cylinder to move the arm infully, then stop the engine.Operate the control lever to arm IN.
If the lowering speed increases, the pack-ing is defective.If there is no change, the control valve isdefective.
* If the pressure in the accumulator hasdropped, run the engine for approx. IOseconds to charge the accumulator againbefore operating.
[Reference] If the cause of the hydraulic drift is in thepacking, and the above operation is carriedout, the downward movement becomesfaster for the following reasons.
1) If the work equipment is set to the above posture(holding pressure applied to the bottom end), the oilat the bottom end leaks to the head end. However,the volume at the head end is smaller that the volumeat the bottom end by the volume of the rod, so theinternal pressure at the head end increases becauseof the oil flowing in from the bottom end.
2) When the internal pressure at the head end increases,the pressure at the bottom end also rises in proportionto this. The balance is maintained at a certain pres-sure (this differs according to the amount of leakage)by repeating this procedure.
3) When the pressure is balanced, the downward move-
ment becomes slower. If the lever is then operatedaccording to the procedure given above, the circuit atthe head end is opened to the drain circuit (the bottomend is closed by the check valve), so the oil at thehead end flows to the drain circuit and the downwardmovement becomes faster.
Boom, bucket checking posture
Y1?FRO26
Arm checking posture
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TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
Checking boom holding valveSet the work equipment at the maximum reach, and
the top of the boom horizontal, then stop the engine.Lock the work equipment control levers and releasethe pressure inside the hydraulic tank.1) Disconnect pilot hose (1) of the boom holding
valve, and install a blind plug in the hose.* Blind plug: 07376-50315j, Leave the boom holding valve end open.
2) Start the engine, charge the accumulator, thenstop the engine.
3) Operate the boom control lever to the LOWERposition.* If any oil leaks from the port that is left open,
the boom holding valve is defective.3. Checking PPC valve
If the hydraulic drift differs when the safety lock leveris in the LOCK of FREE position, (engine running), thePPC valve is defective.
_.
X17FR028
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TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE
* Hydraulic oil temperature when measuring: 45 - 55°C1. Work equipment cylinder* If the hydraulic drift of the work equipment is outside
the standard value, measure the leakage inside thecylinder as follows, and judge if the cause of thehydraulic drift is in the cylinder or in the control valve.
If the leakage is withing the standard value, theproblem is in the control valve.If the leakage is greater than the standard value,the problem is in the cylinder.Fully extend the rod of the cylinder to be meas-rued, then stop the engine.Disconnect piping (1) at the head end, the blockthe piping at the chassis end with a blind plug.Be careful not to disconnect the piping at the
bottom end.
0
0
1)
2)
A
3)
4)
Start the engine and apply the relief pressure tothe bottom end of the cylinder with the engine athigh idling.
Continue this condition for 30 seconds, thenmeasure the oil leakage for the next OI minute.
X17FRO29
Bucket cylinder
Posture for measuring boom cylinder
Posture for measuring arm. bucket cylinder
X17FR032
X17FR033
Arm ylinder
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TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2. Swing Motor1)
2)3)
4)
*
Disconnect drain hose (1) from the swing motor,then fit a blind plug at the tank end.Set the swing lock switch ON.Start the engine and operate the swing relief withthe engine at high idling.Continue this condition for 30 seconds, thenmeasure the oil leakage for the next one minute.After measuring, swing 180” and measure again.
3. Travel motor1) Disconnect drain hose (2) from the travel motor,
then fit a blind plug at the hose end.2) Fit block 0 under the track shoe grouser, or fit
block 0 between the sprocket and frame to lockthe track.
3) Start the engine and operate the travel relief withthe engine at high idling.
A When measuring the oil leakage from the
travel motor, mistaken operation of the
control lever may lead to a serious acc-ident, so always use signals and checkwhen carrying out this operation.
4) Continue this condition for 30 seconds, thenmeasure the oil leakage for the next minute.
* When measuring, move the motor slightly (tochange the position between the valve plate andcylinder, and piston and cylinder), and measureseveral times.
RELEASING REMAINING PRESSUREIN
*
1.
2.
3.
HYDRAULIC CIRCUITIf the piping between the hydraulic cylinder and thecontrol valve is disconnected, release the remainingpressure from the circuit as follows.The travel circuit is an open circuit, so there is noremaining pressure. It is enough to remove the oilfiller cap.Loosen the oil filler cap slowly to release the pressureinside the tank.Operate the control levers.* When the levers are operated 2 -3 times, the pres-
sure stored in the accumulator is removed.Start the engine, run at low idling for approx. 5 min-utes, then stop the engine and operate the controllevers.* Repeat the above operation 2 - 3 times to release
all the remaining pressure.
X17FR03
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TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIROrder of operations and procedure for bleeding air (Note 2)
Air bleeding item 1 Air bleeding procedure
Nature of work
Replace hydraulic oil0 Clean strainer
Replace return filter element
Replace, repair pumpRemove suction piping
Replace, repair control valve
Replace cylinderRemove cylinder piping
Replace swing motorReplace swing motor piping
Replace travel motorswivelRemove travel motorswivelpiping
0 0 0
Replace EPC valveNote 1: Bleed air from the swing and travel motors only when the oil inside the motor case had been drained.
0 0 0
Note 2: Perform only those procedures marked with a 0 for each tvoe of work.
I. Bleeding air from pump1) Loosen air bleed plug (I), and check that oil
oozes from the plug.2) When oil oozes out, tighten plug (1).
- Plug : 17.15 +2.45 Nm
(1.75 f 0.25 kgm)$r If no oil oozes out from the air bleed plug:3) Leave plug (1) loosened and remove hose (2) and
elbow (3).
4) Pour in oil through the elbow mount hole untiloil oozes out from plug (1).
5) Fit elbow (3) and install hose (2).6) Tighten air bleed plug (1)
- Plug : 17.15 1t2.45 Nm
(1.75 f 0.25 kgm)* Precations when starting the engine
After completing the above procedure and start-ing the engine, run the engine at low idling for 10minutes.
* If the coolant temperature is low and automaticwarming-up is carried out, cancel it by using thefuel control dial after starting the engine.
Ylfi77fiAl
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2. Bleeding air from hydraulic cylinders
1)
2)
3)
4)
Start the engine and run at idling for approx. 5minutes.Run the engine at low idling, then raise and lowerthe boom 4 - 5 times in succession.* Operate the piston rod to approx. 100 mm
before the end of its stroke. Do not relievethe circuit under any circumstances.
Run the engine at high idling and repeat Step 2).After that, run the engine at low idling, and oper-ate the piston rod to the end of its stroke to relievethe circuit.Repeat Steps 2) and 3) to bleed the air from thearm and bucket cylinders.j, When the cylinder has been replaced, bleed
the air before connecting the piston rod.Be particularly careful not to operate thecylinder to the end of its stroke when the pistonrod had been connected to the LOWER end ofthe boom cylinder.
3. Bleeding air from the swing motor1) Run the engine at low idling, loosen air bleed plug
(I), and check that oil oozes out.* If no oil oozes out from the air bleed plug:2) Stop the engine, and pour oil into the motor case
from plug (1).3) Tighten air bleed plug (1).QZ Plug: 166.6 f 19.6 Nm (17 f 2 kgm)
4. Bleeding air from travel motorRun the engine at low idling, loosen air bleed plug (2),and when oil oozes out, tighten the plug again.
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TROUBLESHOOTINGPoints to remember when troubleshooting ....................Sequence of events in troubleshooting .......................Precautions when carrying out maintenance ...................Checks before troubleshooting ..............................Connector types and mounting locations ......................Connector table for connector pin numbers ...................Explanation of control mechanism for electrical system ..........
Display method and special functions of monitor panel ..........Method of using judgement table ............................Details of troubleshooting and troubleshooting procedure ........Troubleshooting of engine throttle controller system (E mode) ....Troubleshooting of engine (S mode) .........................Troubleshooting of pump controller system (C mode) ...........Troubleshooting of pump controller input signal system (F mode) .Troubleshooting of hydraulic and mechanical system (H mode) ...Troubleshooting of machine monitor system ...................
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TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securly fitted.
A When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting any troubleshooting.A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and toprevent reoccurrance of the failure.When carrying out troubleshooting, an inportant point is of course to understand the structure and function.However, a short cut to effective troubleshooting is to ask the operator various questions to form some ideaof possiable causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurryto disassemble the components.
If components are diassembled immediately anyfailure occurs:
Parts that have no connection with the failureor other unnecessary parts will be diassem-bled.It will become impossible to find the cause ofthe failure.
It will also cause a waste of manhours, parts, oroil or grease, and at the same time, will also losethe confidence the user or operator.For this reason, when carrying out troubleshoot-ing, it is necessary to carry out thorough priorinvestigation and to carry out troubleshooting inaccordance with the fixed procedure.
2. Points to ask user or operator1)
2)
3)
4)6)
6)
Have any other problems occured apart fromthe problem that has been reported?Was there anything strange about the ma-chine before the failure occured?Did the failure occure suddenly, or were thereproblems with the machine condition beforethis?Under what conditions did the failure occur?Had any repairs been carried out before thefailure?When were these repairs carried out?Has the same kind of failure occurred before?
3. Check before troubleshooting1) Check the oil level.2) Check for any external leakage of oil from the
piping or hydraulic equipment.3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.5) Other maintenance items can be checked ex-
ternally, so check any item that is consideredto be necessary.
4. Confirming failureConfirm the extent of the failure yourself, andjudge whether to handle it as a real failure oras a problem with the method of operation,etc.* When operating the machine to reenact
the troubleshooting symptoms, do notcarry out any investigation or measur-ment that may make the problem worse.
5. TroubleshootingUse the results of the investigation and in-spection in items 2 - 4 to narrow down thecauses of failure, then use the troubleshootingflowcharts to locate the postion of the failureexactly.-k The basic procedure for troubleshooting
is as follows.1) Start from the simple points.2) Start from the most likely points.3) Investigate other related parts or
information.6. Measures to remove the root cause of failure
Even if the failure is repaired, if the root causeof the failure is not repaired, the same failurewill occure again.
To prevent this, always investigate why theproblem occured. Then, remove the rootcause.
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TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLSHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop @-“; m Jobsite
step1 xamination, confirmation of syrnptoms~
1) When a request for reparrs is recerved,
first ask the following points.
. Name of customer
. Type. serial number of machme
. Detarls of jobsite. etc.
2) Ask questrons to gain an outline of the
problem.
* Conditron of failure. Work being arried out at the time
of the failure
\
Ring Ring--------
’ Operating envwonment
* Past history. details of maintenance,
etc.
1 I Look at the troubleshooting sectron of the
shop manual to find locations of possrble
causes
step 3
1 reparation of troubleshootmg tools]
1 I Look at the table of troubleshooting tools
in tlie shop manual and prepare the
necessary tools.
* T-adapter. Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the
necessary replacement parts.
Drive and operate the machrne to confirm
the condition and judge rf there is really a
Was there anything strange about the
machine before the failure occurred?
Did the failure occur suddenly’
Had any repairs been carried out before thefailure?
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maitain the performance of the machine over along period, and to prevent failures or other troublesbefore they occur, correct operation, maintenanceand inspection, troubleshooting, and repairs mustbe carried out. This section deals particularly withcorrect repair procedures for mechatronics and is
aimed at improving the quality of repairs. For thispurpose, it gives sections on “ Handling electricequipment” and “ Handling hydraulic equipment”(particlularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLINGELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectorsWiring harnesses consist of wiring connectingone component to another component, conn-ectors used for connecting and disconnectingone wire from another wire, and protector or
tubes used for protecting the wiring. Comparedwith other electrical components fitted in boxesor cases, wiring harnesses are more likely to beaffected by the direct effects of rain, water, heat,or vibration. Furthemore, during inspection andrepair operation they are frequently removed andinstalled again, so they are likely to suffer defor-mation or damage. For this reason, it is nec-ssary to be extremely careful when handlingwiring harnesses.
Main failures occuring in wiring harness(1) Defective contact of connectors (defective
contact between male and famale). Problemswith defective contact are likely to occur becausethe male connector is not properly inserted intothe female connector, or because one or bothof the connectors is deformed or the position isnot properly inserted into the female connector,or because one or both of the connectors is de-formed or the position is not correctly aligned, orbecause there is corrosion or oxidization of thecontact surfaces.
Improper insertion
=3X$&$&
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
(2)
(3)
(4)
(5)
Defective compression or soldering of connectorsThe pins of the male and female connectors arein contact at the compressed terminal or sold-ered portion, but there is excessive force on thewiring, and the plating peels to cause improperconnection or breakage.
Disconnections in wiringIf the wiring is held and the connectors are pulled
apart, or components are lifted with a crane withthe wiring still connected, or a heavy object hitsthe wiring, the compression of the connector maybe lost, or the soldering may be damaged, or thewiring may be broken.
High pressure water entering connectorThe connector is disigned to make it difficult forwater to enter (drip-proof structure), but if high-pressure water is sprayed directly on the conn-ector, water may enter the connector dependingon the direction of the water jet. The connectoris designed to prevent water from entering, but
at the same time, if the water does enter, it isdifficult for it to be drained. Therefore, if watershould get into the connector, the pins will beshort-circuited by the water. If any water getsin, immediately dry the connector or take otherappropriate action before passing electricitythrough it.
Oil or dirt stuck to connectorIf oil or grease are stuck to the connector and anoil film is formed on the mating surface betweenthe male and female pins, the oil will not let theelectricity pass, so there will be a defective con-tact. If there is oil or grease stuck to the conn-ector, wipe it off with a dry cloth or blow dry withair, and spray it with a contact restorer.* When wiping the mating portion of the conn-
ector, be careful not to use excessive force ordeform the pins.
* If there is water or oil in the air, it will increasethe contamination of the points, so clean withair from which all the water and oil has beenremoved.
XOSDD060
XOSDD061
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectorsand wiring harnesses
(1)
(2)
Disconnecting connectorsHold the connectors when disconnecting.When disconnecting the connectors, hold theconnectors and not the wires. For connectorsheld by a screw, loosen the screw fully, thenhold the male and female connectors in eachhand and pull apart. For connectors which havea lock stopper, press down the stopper with yourthumb and-pull the connectors apart.
Action to take after removing connectorsAfter removing any connector, cover it with a /
Lock
I - X08DD064
vinyl bag to prevent any dust, dirt, oil, or waterfrom getting in the connector portion.
Connecting connectors(1) Check the connector visually.
Check that there is no oil, dirt, or water stuckto the connector pins (mating portion).
Check that there is no deformation, defectivecontact, corrosion, or damage to the conn-ector pins.
a.
b.
C.
*
*
Check that there is no damage or breakageto the outside of the connector.If there is any oil, water, or dirt stuck to theconnector, wipe it off with a dry cloth. If anywater has gotten inside the connector, warmthe inside of the wiring with a dryer, but becareful not to make it too hot as this willcause short circuits.If there is any damage or breakage, replacethe connector.
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
(2) Fix the connector securely.Align the position of the connector correctly, theninsert it securly. For connectors with lock stop-per, push in the connector until the stopper clicksinto position.
CM.5 into position
(3) Correct any protrusion of the boot and any mis-alignment of the wiring harness. For connectorsfitted with boots, correct any protrusion of theboot. In addition, if the wiring harness is mis-aligned, or the clamp is out of postion, adjust itto its correct position.* When blowing with dry air, there is danger
that the oil in the air may cause improper
contact, so clean with air from which all thewater and oil has been removed.
Drying wiring harnessIf there is any oil or dirt on the wiring harness, wipe itoff with a dry cloth. Avoid washing it in water or usingsteam. If the connector must be washed in water, donot use high pressure water or steam directly on thewiring harness. If water gets directly on the conn-ector, do as follows.(1) Disconnect the connector and wipe off the water
with a dry cloth.* If the connector is blown dry with air, there is
the risk that oil in the air may cause defectivecontact, so avoid blowing with air.
(2) Dry the inside of the connector with a dryer.If water gets inside the connector, use a dryer todry the connector.Ir Hot air from the dryer can be used, but be
careful not to make the connector or relatedparts too hot, as this will cause deformationor damage to the connector.
X08DD068
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
(3) Carry out a continuity test on the connector,After drying, leave the wiring harness dis-connected and carry out a continuity testto check for any short circuits between pinscaused by water.* After completely drying the connector, blow
it with contact restorer and reassemble.
3) Handling control box(1) The control box contains a microcomputer
and electronic control circuits.These control all of the electronic circuitson the machine, so be extremely carefulwhen handling the control box.
(2) Do not open the cover of the control boxunless necessary.
(3) Do not place objects on top of the control
box.(4) Cover the control connectors with tape or a
vinyl bag.(5) During rainy weather, do not leave the control
box in a place where it is exposed to rain.(6) Do not place the control box on oil, water, or
soil, or in any hot place, even for a short time.(Place it on a suitable dry stand)
(7) Precautions when carrying out arc weldingWhen carrying out arc welding on the body,disconnect all wiring harness connectorsconnected to the control box. Fit an arcwelding ground close to the welding point.
T-adapter
X08DD070
XOBDDOZI
/I XORDDO72
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
2. POINTS TO REMEMBER WHEN HAN-DLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-drauic equipment, the most common cause of failureis dirt (foreign material) in the hydraulic circuit. Whenadding hydraulic oil, or when disassembling or ass-embling hydraulic equipment, it is necessary to be
particularly careful.
1)
2)
3)
4)
Be careful of the operating environmentAvoid adding hydraulic oil, replacing filters, orrepairing the machine in rain or high winds,or places where there is a lot of dust.
Diassembly and maintenance work in the fieldIf diassembly or maintenance work is carried outon hydraulic equipment in the field, there isdanger of dust entering the equipment. It is alsodifficult to confirm the performance after repairs,so it is desirable to use unit exchange. Diassem-bly and maintenance of hydraulic equipmentshould be carried out in a specially prepareddustproof workshop, and the performance shouldbe confirmed with special test equipment.
Sealing openingsAfter any piping or equipment is removed, theopenings should be sealed with caps, tapes, orvinyl bags to prevent any dirt or dust from enter-ing. If the opening is left open or is blocked witha rag, there is a danger of dirt entering, or of thesurrounding area being made dirty by leaking oil.Do not simply drain oil out on to the ground,collect it and ask the customer to dispose of it, or
take it back with you for disposal.
Do not let any dirt or dust get in duringrefilling operations.Be careful not to let any dirt or dust get in whenrefilling with hydraulic oil. Always keep the oilfiller and the area around it clean, and also useclean pumps and oil containers. If an oil cleaningdevice is used, it is possible to filter out the dirtthat has collected during storage, so this is aneven more effective method.
XlODD061
XlODDOGP
XlODD063
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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature ishigh.When hydraulic oil or other oil is warm, it flowseasily. In addition, the sludge can also be drain-ed out easily from the circuit together with the oil,so it is best to change the oil when it is still warm.When changing the oil, as much as possible ofthe old hydraulic oil must be drained out. (Do notdrain the oil only from the hydraulic tank; alsodrain the oil from the filter and from the drain plugin the circuit.) If any old oil is left, the contam-inants and sludge in it will mix with the new oiland will shorten the life of the hydraulic oil.
6) Flushing operationsAfter disassembling and assembling the equip-ment, or changing the oil, use flushing oil toremove the contaminants, sludge, and old oilfrom the hydraulic circuit.Normally, flushing is carried out twice: primaryflushing is carried out with flushing oil, andsecondary flushing is carried out with the spec-
ified hydraulic oil.
7) Cleaning operationsAfter repairing the hydraulic equipment (pump,control valve, etc.) or when running the machine,carry out oil cleaning to remove the sludge orcontaminants in the hydraulic oil circuit.The oil cleaning equipment is used to remove theultrafine (about 3~) particles that the filter builtinto the hydraulic equipment cannot remove, so itis an extremely effective device.
XlODD064
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CHECKS BEFORE TROUBLESHOOTINGItem Judgement standard
1.
2.
3.
4.
5.
6.
7.
a.
9.
Check fuel level
Check for dirt or water in fuel
Check hydraulic oil level
Check hydraulic oil strainer
Check swing machinery oil level
Check engine oil level (Level of oil in oil pan)
Check cooling water level
Check condition of dust indicator
Check hydraulic oil filter
1. Check for loose or corroded battery terminals Tighten or replace
2. Check for loose or corroded alternator terminals
3. Check for loose or corroded straight motorterminals
Check for abnormal noise or smell
Check for oil leakage
Bleed air from system
1.
2.
3.
4.
5.
6.
7.
a.
Check battery voltage (engine stopped) ZO-30V
_Check level of battery electrolyte
Check for discolored, burnt, or bare wiring-
Check for missing wiring clamps, hanging wires-
Checks for getting wet onto wiring (checkcarefully getting wet at connectors andterminals)
_
_Check for broken or corroded fuses
Check alternator voltage (engine running at overhalf throttle)
Noise when battery relay is operated (swi tchstarting switch from ON to OFF)
27.5 - 29.6 V Replace
_
_
-
-
-
_
_
_
-
-
_
-
_
_
Remedy
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add coolant
Clean or replace
Replace
Tighten or replace
Tighten or replace
Repair
Repair
Bleed air
Replace
Add or replace
Replace
Repair
Disconnect connectorand dry connection
Replace
Replace
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CONNECTOR TYPES AND MOUNTING LOCATIONS
1Co ictor 1 Type 1 o:s 1 Electrical component 1Address:onnector
No. 1ype 12s 1 Electrical component IAddress
co1 (MIC 1 17 1 Pump controller 1 R7
co2 I 040 I 20 I Pump controller 1 R6
MO2 IX I2 I Starting motor 1 J2
MO6 1 M I 3 I Heater switch I 08
co3 I 040 I 16 I Pump controller 1 R7
co4 lx I2 l Rear pump TVC valve I H9
MO7 IM I2 I Light switch 1 08
MO8 I M I 1 1 Right front light 1 D5
co5
CO6 1 sI 10 1 TVC prolix switch
1 05IM 12 1 Tvc prolix resistor I Q6
MO9
Ml0 IM
I 1 1Working lamp (boom)
IF9
1 M 1 1 IIntermediate connector I F5
I co7 1 x 1 3 1 RearP~;;s~- 1 I9 Ml1 IL 12 1 Fusible link I E5
CO8 X 3Front pump pressure
I5sensor
co9 S 8Model selection
connectorR7
Ml2 KESI 3 Heater-
Ml3 KESO 2 Speaker Q9
I Cl0 I x I 2 I ~~;;g I F8 Ml4 1 L 1 2 1 Fusible link E5
Cl3 Ix I l Front pump TVC valve I H9
DO1 IKESI I 2 IWindow washer circuit I J5
Ml6
Ml7
_1 1 I Horn (high sound) 1 G4
_I 1 I Hoorn (low sound) 1 F4
1 DO3 IKESI 1 2 1 Ls se;;;;;enoid 1 - ~18 I M I 4 1Wiper, washer switch I 08
M20 I - ( - I Cigarette lighter I 08
M21
M22
PA 9 Radio Q6
M 2 Intermediate connector_
I I I I
M23 M 2Horn switch, R.H.
knob switchF2
t DO8 IKESI I 2 Heater circuit_
M26 I M I 6 I Air conditioner I R6
Dll
D13
EOI
E04
KESI 2 Alarm buzzer circuit M6
KESI 2Battery relay drive
circuitR8
MIC 21 Engine throttle controller R8
X 3 Governor potentiometer H9
M28 KESO 2
M34 ,:$$,, 1
Window washer motor
Electromagnetic clutchfor air conditioner
compressor
J5
13
M35
M38
X 2Condenser for air
conditioner (PC220)I5
M 2 Liaht switch P8
M40 M 1 Right working light D3
M41 M 1 Left working light D3
M42_
1 Intermediate connector I5
M45 IM I3 I Network bus 1 M5
M46 I M I 3 I For troubleshooting I ~6
FOI Ix I2 Travel alarm 1 G4
HOI I S I 16 I Intermediate connector I ~8
PO1 040 20 Monitor panel N7
PO2 040 16 Monitor panel N7
PO3 M 2 Buzzer cane1 switch 08HO2 i S I 16 I Intermediate connector I R9
HO3 IS 116 1 ntermediate connector 1 Q9
HO4 I S I 16 I Intermediate connector I Q9
PO4 IM I2 I Alarm buzzer 1 N7
PO5 I X I 1 IEngine oil level sensor I J2
PO6 X
PO7 -
1 Fuel level sensor F5
2Coolant temperature
I3sensor
HO5
HO6
M 6 Intermediate connector R8
L 2 Intermediate connector R9
* The Address column in the table above shows the address in the connector arrangement drawing (2-dimensional drawing).
* This table includes connectors that are not in the drawing.
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TROUBLESHOOTING CONNECTOR TYPES
IonnectorNo.
No. IType of Electrical component Address
I pins
PO8 I x 2 Coolant level sensor K8I I I I
’ ‘-.-‘-- llic oil levelG9
I I I ensor
PI 0 ] KEsI 1 I 1 Service meter P9I I ’ n’- ‘--ier clogging
J6ensor
3ging J8
I I IR04 Shinagwa 5 I Light relay P5
R05 Shinagwn15 1 Light relay P5I I ii pressure
witchR2
RAISE oilJre switch I
R3 I
t CURL oilJre switch
R4I
: DUMP oil.rre switch I R3 I)il pressurewitch
zsure 1 - I
vo2
vo3
X 2 LS select solenoid valve Nl
X 2Pump merge-divider
solenoid valveNl
W08 070 18 Wiper motor controller P6
WI0 M 4 Rear limit switch P6
x01 MIC 21 Intermediate connector P9
t x05I I I -----
x07 1MIC 1 17 1 ntermediate car
1 M 1 4 1 Swina lock switch
inector
08
P9
MOUNTING LOCATIONS
j, The Address column in the table above shows the address in the connector arrangement drawing (Z-dimensional drawing).
* This table includes connectors that are not in the drawing.
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A
I
\
u_
I>”
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M46\
M38
M45 \ R04co5
/HO2
Ml3\
LUO ‘ M26
205F06389
/SO8
so4
so5i
so3 :
so1
so2
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
* The terms male and female refer to the pins, while the terms male housing and female housing refer to thematinn nnrtinns of the housino..__... _._. ..- -. _..- ..---...
No. of X type connectorpins Male (female housing) Female (male housing)
X08DDO73 XO8DDO74
XO8DDO75 2XO8DDO76
3 a
XO8DDO77XO8DDO78
4
XO8DD079 4 2 X08DDO80
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins Male (female housing)
M type connector
Female (male housing)
X08DD081 X08DD082
2 %7 E 9
1X08DD083 X08DD084
3 ezl @
X08DD086 1 X08DD086
4 mX08DD087 4 2 X08DD088
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
M type connector
Male (female housing) Female (male housing)
1 4
6
X08DD089
ES
6 3 X08DD090
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 L I
5 10 1X08DD093 X08DD094
No. ofpins
S type connector
Male (female housing) Female (male housing)
I 5 5 1
8
XOSDDOSl X08DD092
16
1 XOBDD095 16 7 X08DD096
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
16
AMP040 type connector
Male (female housing) Female (male housing)
6 16 16 8
X08DD097 X08DD098
20
1 11 X08DD099 11 1 XO8DDlOO
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
AMP070 type connector
Male (female housing) Female (male housing)
14
XOSDDlOl XOSDD102
18
XCr8DD103 XOSDDlO4
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
3
l- AMP250 tv ? connector
Male (female housing)
X08DDlOS
1Female (male housing)
X08DD106
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
14
SWP type connector
Male (female housing) Female (male housing)
1 4 8 11
3 7 10 14X08DD107 X08DD108
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
MIC type connector
Male (female housing) Female (male housing)
1
17
X08DDlOS L_._1 X08Dqllo
l i '
111 0 oao
2121 12
21
XOSDDlll
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
5
Relay connector
2 I
5
3 XOSDD113
No. ofpins Male (male housing)
Simple connector
Female (female housing)
1
XOSDD114 X08DD115
No. ofpins
Ring connector
1
X08DD116
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins Male (female housing)
L type connector
Female (male housing)
ED
1
1
0
20
2
2X08DDll7 XOSDDllB
No. ofpins Male (female housing)
PA type connector
Female (male housing)
g a B ;B H
X08DDllSXOSDD120
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. of Automobile connector (KESO)pins Male (female housing) Female (male housing)
2
:il N1 X08DD121 1XOSDD122
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. ofpins
Automobile connector (KESi)
Female (female housing) Male (male housing)
2
2 I i F?1
FB
X08DD123X08DD124
32 3
3 2X08DD125
X08DD126
4
3 4 4X08DD127 X08DD128
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TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
1. Explanation of machine control functions
2.
The control mechanism for the electrical system consistsj of the monitor panel, pump controller and enginethrottle controller. The monitor panel and each controller all input the signals that are necessary, and to-gether with the signals selected by the monitor panel, the controllers output or input the necessary signalsand control the pump absorption torque and engine outout.
Monitor panel Engine speed sensor
N. WOrt
lock signal
iE”z
m RAISE
IN/OUT
ret CURL
i/l
A
.OWER
>UMP
Explanation of networking functionsWith this system, a networking method has been adopted for the first time for the transmission and receptionof data between the controllers. With the conventional system, the necessary data is transmitted and recievedthrough an independent signal line between each controller. With the new method, this system had been
replaced by two dedicated networking wires; in the new system, all the data that is needed is transmitted andrecieved between the controllers by usiing these networking wires.
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
1.
2.
Display on machine monitorWhen the starting switch is turned ON, all the monitor gauge lamps light up for approx. 3 seconds, and thebuzzer sounds for approx. 1 second. During this time, the monitor itself carries out a self diagnosis, andafter it has finished, it gives the normal display.
Recording of service codes and user code display function
1)
2)
*
3)
All theabnormality date for the engine throttle controller and pump controller is received by the monitorpanel. When the monitor panel receives this data, it records the abnormality date, and at the same time,depending on the nature of the abnormality, it displays the user code on the time display panel to advisethe operator of the action to take.However, in cases of abnormalities which are not urgent and do not require the user code to be displayed,only the content of the abnormality is recorded, and no display is given.
E05 1 G overnor motor system
For details of the service codes includes in the user code, see ACTION TAKEN BY THE CONTROLLERWHEN AN ABNORMALITY OCCURS, THE SYMPTOMS ON THE MACHINE or JUDGEMENT TABLE.Displaying user codeIf it becomes necessary to display the user code, the time displayed panel is automatically switched toadvise the operator to take the necessary action.
Actual display i) Example: Disconnection in the swing brake solenoid system
: m- Blank ’
1 Component code ’ F’ ashes
Blank
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
4) Display of service codeThe monitor panel records both service codes which are included in the user code, and service codeswhich are not included. This data can be displayed on the time display as follows.
* For details of the service codes that are not included in the user code, see ACTION TAKEN BY CON-TROLLER WHEN ABNORMALITY COOURS AND PROBLEMS ON MACHINE.
Time display, 7 Time
Workingmode SW
L.H. tr avelspeed swit
fitch
ch
Front of monitor panel Rear of monitor panel
205FO6376
I, ,“,G’ LI I”” “ I uKJp,ay,,,y a=:1 “IbC b” “ G
Operation Display
1. To set to the service code display 1. Time display goes outmode, keep the time switch + L.H. On the display panel, the service code and numbertravel speed switch pressed for 2.5 of hours (service meter hours) since the occur-seconds. ence of the abnormality are displayed in turn.
* Example of displayNote: It is possible to call it up at thefollowing times.1) In the time display mode (normal
mode)2) In the user code mode
When E2: 12 occurs 12 hours ago (service meter)1) Display of service code 2) Elapsed time
(service meter display)
3) In the machine data monitoringmode
4) In the time adjustment mode.
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
2. To go to the next service code 3) If any abnormality exists at this time, the E mark is
display, displayed.
Press the time switch + R.H. work-ing mode switch. ~I/q7q7Jq-~
- -
?z
-
3. To go back to the previous servicecode display,
If there is an abnormality, or the controller is
Press the time switch + L.H. workingcarrying out self diagnosis, the output is shutoff, and E is displayed.
mode switch.
4. To finish with the service codemode,Use the sam’ e procedure as in Item1.
4) If there is no service code in memory
0 o_) : 1-1-1-1 is displayed.
5. To erase the memory,Keep the time switch pressed, turnthe starting switch from OFF to ON,
and keep the time switch pressedfor 5 seconds.
3. Machine data monitoring mode functionThe input signals from the monitor panel and controller sensors and the output signals to drive the solenoid
can be checked by displaying them on the time display.
Time display, 6 Time
Working III”mode switch \
function switch
Front of monitor panel Rear of monitor panel
7
205FO6378
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I) Method of displaying monitoring mode
Ooeration Display
I. To set to the monitoring mode, do 1. Goes off the time display, and display as follows.as follows. 2. Example of displayKeep the time switch + lever switch 1) When pump controller engine speed is monitoredfunction switch pressed for 2.5 sec-
onds.O~]::ll”1u151
Note: This is possible at the follow-ing times. The 3rd digit is for the tens,
1) During the ti,me display mode---I- so this display means 2050
(normal mode)Blank rpm.
2) During the user code mode ---c3) During the time adjustment
Lonitoring code(Engine speed)
mode4) During the service code mode 2) When front TVC output current is displayed
2. To go to the next monitoring codedisplay,
Press the time switch + R.H. work-0 11 :‘ Wl
ing mode switch.-T
The 3rd digit is for the tens,
3. To go back to the previous moni- Blankso this display means 180 mA(0.18 A)
toring code display,Press the time switch + L.H. workingmode switch.
---I Loniioring code(Front TVC output current)
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
4. Bit pattern display1) Set to the bit pattern display code
m m$jl $jj fi
0 .o 0Monitoring code
206FO6362
5. To finish with the. machine data 3. Example of bit pattern displaymonitoring mode, use the same 1) For code 08 (connection of S-NET components)
procedure as in Item 1. If the display is set to code 08, the applicable bits-light UP.2) For code 20 (input condition of pump controller oil pressure
switch)Set to code 20, and operate the lever of the system to bedisplayed.When the switch is turned ON, the applicable bits light UP.
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
2) Table of machine data monitoring codes
* For details of the B in the Unit column, see the bit pattern chart.
?odeNo. item Unit Name of component
01 Monitor panel model code Monitor panel
02 Pump controller model code Pump controller
03Engine throttle controller model code Engine throttle controller
08 S-NET condition display B Monitor panel
10 Engine speed 1Orpm Pump controller
11 Front pump discharge pressure input kg/cm* Pump controller
12 Rear pump discharge pressure input kg/cm2 Pump controller
13 Front TVC current output IOmA Pump controller
14 Rear TVC current output IOmA Pump controller
15 LS control EPC current output 1OmA Pump controller
16 No. 2 throttle signal value IOrpm Pump controller
20 Oil pressure switch input signal (1) B Pump controller
21 Oil pressure switch input signal (2) B Pump controller
22 Oil pressure switch input signal (3) B Pump controller
23 Pump controller solenoid actuation B Pump controller
30 Fuel control dial input value IOmV Engine throttle controller
31 Governor potentiometer voltage IOmV Engine throttle controller
32 VBB voltage (battery voltage) IOOmV Engine throttle controller
33 Governor motor A phase current IOmA Engine throttle controller
34 Governor motor B phase current IOmA Engine throttle controller
35 Battery relay output voltage IOOmV Engine throttle controller
36 Engine throttle controller input condition B Engine throttle controller
37 Engine throttle controller output condition B Engine throttle controller
38 Engine throttle controller internal condition B Engine throttle controller
40 Engine speed IOrpm Monitor panel
41 Coolant temperature sensor voltage IOmV Monitor panel
42 Fuel level sensor input voltage IOmV Monitor panel
43 Battery charge input voltage IOmV Monitor panel
44 Monitor panel input 1 B Monitor panel
45 Monitor panel input 2 B Monitor panel
46 Monitor panel input 3 B Monitor panel
47 Monitor panel output B Monitor panel
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
3) Bit pattern chartAs shown in the diagram below, the time display has bit numbers which light up to show that the signalis being transmitted. (For details, see method of displaying monitoring code.)
0 0 aMonitoring c ode
205FO6382
:ode 1. . Content 1 Bit 1 Details (condition when liahted UD)No.
a Pump controller connected (ID=2)
0 Engine throttle controller connected (ID=31
08 Connection of S-NET components 0
0
0
8’
0 Swing switch ON
0 Travel switch ON
20 Input condition of pump controller 0 Boom LOWER switch ONPPC oil pressure switches@ Boom RAISE switch ON
0 Arm IN switch ON
8 Arm OUT switch ON
0 Bucket CURL switch ON
0 Bucket DUMP switch ON
21Input condition of pump controller PPCoil pressure switches and other switches 0 Swing lock switch ON
0 Service switch ON
0 TVC prolix switch ON
@ Swing lock prolix switch ON
. 0 Model selection 1 GND connected
0 Model selection 2 GND connected
22Input condition of pump controller model @ Model selection 3 GND connectedselection, etc.
@ Model selection 4 GND connected
0 Kerosene mode input GND connected
69 L.H. knob switch ON
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
CodeNo.
Content Bit Details (condition when lighted up)
23
36
Drive condition of pump controllerON/OFF solenoid valves
a0 LS select solenoid ON
0 Swing brake solenoid Ohi
0 Pump merge-divider solenoid ON
0 2-stage relief solenoid ON I
Input condition of enginethrottle controller
8 Travel speed solenoid ON
0 Model selection 1 GND connected
0 Model selection 2 GND connected
0 Model selection 3, GND connected
0 Model selection 4 GND connected
0 Starting switch ON
8 Auto-deceleration signal ON
0 Battery relay drivedI
37Output condition of engine throttle 0controller
0
38Internal condition of engine throttlecontroller
0
0
I0 I8 Ia Coolant level sensor OPEN
0 Swing lock switch OFF
44 1 Input condition of monitor panel 1. 0 Buzzer cancel switch OFFI
I 0 I
45 Input .condition 2 of monitor panel
00 Starting switch ON
0Swing lock prolix switch OFF
0 Time set switch OFF
0 Hydraulic oil level sensor OPEN
I 0 I
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
46
47
68
69
Content
input condition of monitor panel 3.
Output condition 1 of monitor panel
Input condition of valve controller(HYPER GX)
Input condition of valve controller(HYPER GX)
Bit Details (condition when lighted up)
0 Starting switch HEAT
0 Light switch ON
0 Air cleaner clogging sensor OPEN
0 Engine oil level sensor OPEN
0 Engine oil pressure Lo sensor OPEN
0 Engine oil pressure Hi sensor OPEN
0
0 Alarm buzzer actuated
0
0
0
8
0 .L.H. knob switch signal 1 ON
0 L-H. knob switch signal 2 ON
0 Model selection 1 GND connected
0 Model selection 2 GND connected
0 Model selection 3 GND connected
8 Option selection terminal GND connected
0 Safety relay 1 actuated
0 Safety relay 2 actuated
0
0
0
8
4. Governor motor adjustment modeThis is used when adjusting the linkage between the governor motor and the injection pump. For details ofthe procedure, see TESTING AND ADJUSTING.
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TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
5. lime adjustment modeTo adjust the time, do as follows.
Operation Display
1.
2.
3.
4.
To set to the time adjustmentmode,Keep the time switch depressedfor 2.5 seconds.
Use the L.H. working mode switchto advance the hour..
Use the R.H. working modeswitch to advance the minute.
To return to the time displaymode use the same procedure asin Step 1.
1. The time display flashes
m m : II]]- Blank
L Minute
L L Hour
Flashes
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TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLEThis judgement table is a tool to determine if the problem with the machine is caused by an abnormality in theelectrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used todecide which troubleshooting table (E-00, S-00, F-00, H-00, K-00, M-00) matches the symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code whichtroubleshooting table to go to.t The abnormality display (caution) given by the monitor panel leads directly to troubleshooting of the machine
monitor (M-00). (See troubleshooting of the machine monitor system)1. When using judgement table for engine throttle controller and engine related parts
If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of thejudgement table (E-00).(A mark is put at the places where the failure mode and service code match.)If a problem has appeared but no service code is displayed on the monitor panel, go to the point wherethe failure mode matches the troubleshooting code on the right of the judgement table (E-00 or S-00).
<Example> Failure mode “Engine do& not start”.Procedure: Check if the service code is being displayed on the monitor panel.
[Judgementl1) If a service code is being displayed on the monitor panel:
go to troubleshooting E-00 for the engine throttle controller system.2) If no service code is displayed on the monitor panel, and the engine does not start:
Check that starting motor rotates
cStarting motor rotates . Go to troubleshooting S-2 of mechanical systemStarting motor does not rotate . Go to troubleshooting E-11 of electrical system
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TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
2. When using judgement table for pump controller and hydraulic related partsIf a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of thejudgement table (C-00).(A o-mark is put at the places where the failure mode and service code match.)
0 If a problem has appeared but no service code is displayed on the monitor panel, go to the point wherethe failure mode matches the input signal, and check the display for the input signal (the display at theplace with a o mark).
If it is displayed normally, go to the troubleshooting code on the right of the judgement table (H-00).If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottomof the judgement table (F-00).
<Example> Failure mode “Auto-deceleration does not work”.Procedure: Check if the service code is being displayed on the monitor‘ panel.
[Judgementl1) If a service code is being displayed on the monitor panel:
go to troubleshooting C-00 for the pump controller system.2) If no service code is displayed on the monitor panel, and the auto-deceleration does not work:
Check pump controller input signal
cThere is a signal . Go to troubleshooting H-5 of mechanical systemThere is no signal . Go to troubleshooting F-00 of electrical system
(F mode for applicable system)
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TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS1. Category of troubleshooting code number
TroubleshootingCode No.
Component I Service code____ ._
E-00
s-00
Troubleshooting of electrical system for engine throttle controller
Troubleshootino of engine related parts
E3: 00
c-00 Troubleshooting of electrical system for pump controller
F-00 Troubleshooting of input signal system for pump controller
H-00 Troubleshooting of hydraulic, mechanical system for pump controller
E2: 00
-
K-00
M-00
Troubleshooting of electrical system for valve controller (HYPER GX)
Troubleshooting of machine monitor system
E4: 00
El: 00
2. Method of using troubleshooting table for each troubleshooting mode
I) Troubleshooting code number and problemThe title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode(problem with the machine). (See Example (1))
2) Distinguishing conditionsEven with the same failure mode (problem), the method of troubleshooting may differ according to themodel, component, or problem. In such cases, the failure mode (problem) is further divided into sectionsmarked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting.If the troubleshooting table is not divided into sections, start troubleshooting from the first check item inthe failure mode. (See Example (2))
3) Method of following troubleshooting chartCheck or measure the item inside
iand according to the answer follow either the
YES line or the NO line to go to the next -1. (Note: The number written at the top right cornerof the -1 is an index number; it does not indicate the order to follow.)Following the YES or NO lines according to the results of the check or measurement will lead finallyto the Cause column. Check the cause and take the action given in the Remedy column on theright.(See Example (3))Below the I] there are the methods for inspection or measurement, and the judgementvalues. If the judgement values below the (1 are correct or the answer to the question insidethe 1-1 is YES, follow the YES line; if the judgement value is not correct, or the ans_wer to thequestion is NO, follow the NO line.Below the I] is given the preparatory work needed for inspection and measurement, and thejudgement values. If this preparatory work is neglected, or the method of operation or handling ismistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged.Therefore, before starting inspection or measurement, always read the instructions carefully, aqdstart the work in order from Item 1).
4) General precautionsWhen carrying out troubleshooting for the failure mode (problem), precautions that apply to all items aregiven at the top of the page and marked with Ir. (See Example (4))The precautions marked * are not given in the 1-1 , but must always be followed when carryingout the check inside the -1 .
5) Troubleshooting toolsWhen carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, seeTOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
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TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
6). Installation position, pin numberA diagram or chart is given for the connector type, installation position, and connector pin numberconnection. When carrying out troubleshooting, see this chart for details of the connector pin numberand location for inspection and measurement of the wiring connector number appearing in the trouble-shooting flow chart for each failure mode (problem).
<Example>(1) M-7 When starting switch is turned ON (engine stopped), check item flashes
(4) * Before carrying out troubleshooting, check that all the. related connectors are properly inserted.* Always connect any disconnected connectors before going on the next step.t Check that the coolant is at the specified level before carrying out troubleshooting
(2) al (coolant level) flashes
sl1
Divided into sections a) and b)
b) @ (engine oil level) flashes
(3)
I Cause Remedy
)I Defective coolant level
1Does display goout when shortconnector is con- -netted to PO8(female)?
YES2
Turn startingswitch ON. Is there continuityL between PO8
~0 (female) (2) andchassis ground?
sensor (reservoir tank)system (see M-23)
-
Is continuitv be-31 i” “ ------_l Defective monitor panel
~ $ig;No (gjigzl;connect short connector to PO8 female).
. Turn starting switch OFF.
Replace
Ilean (defective
contact) orreplace
Table
Short connector
ConnectedDisconnected
Continuity
YesNo
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TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTINGPROCEDUREIf any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the
judgement table for that type of failure (engine throttle controller, pump controller, valve controller). For details ofthe troubleshooting and troubleshooting procedure, refer to this flow chart. .When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine, andcheck the following items before starting.
(1) Condition of controller connection (check with monitoring code 02 - 04)
(2) Blown fuses (monitoring code 32)
(3) Battery voltage (monitoring code 32)
(4) Electricity generation (charge input) voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and No. 4 in the flow chart below is given on the followingpages.
Is there a user~n~h~isplay
monitorpanel?
f
E02 (Pump TVC system)
ESE03 (Swing holding brake system) Go to Item No.2
L E05 (Governor motor system)
E2:OO o E2:99 for pump controller system (C mode)Carry out troubleshooting for~;rnn;~;troller system
7
I
Is servicecodedisplayed on
1 monitorpanel?
Operate andcheck servicecode.
LE3:00 to E3:OO or engine throttle controller system (E mode) Carry out troubleshooting forengine throttle controller-systemfE mode, El-El01
.
Are monitorpanel switchsignalsoutputcorrectly?
I*Check
condition ofS-NET inmonitoringcode 08.
*Note (seenext page)
1
Check usingmonitoringmode.Engine thron
(Es
I
1le h
controller30 - 35‘ 37
YE5
Afteradjusting oilpressurejudge fromengine speed.Is all workequipmentslow, doesengine speeddrop under_
Is engineelectricalsystem forwhich there isno service;o;erJ;;pfay
Go o flowchart forsectionwhere is noservice codedisplay onj$,ment
‘ ES Carry out troubleshooting for
r
engine system (S mode)
LCarry out troubleshooting forNOengrne system fE mode, Eli-E15)
Car.ry ?ut troubleshooting for
0nyaraulrc mechanrcal system(H mode)
Carry out troubleshooting forpump controuer rnput srgnarsystem (F mode).
rump controllerlo-23Valve controller50-69
heavy load?
10
*Note-(see next page)
NOIf the display is not given, thecontroller is defective.
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TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
* NOTEIf there is no abnormality display in the networking system transmitted in S-NET, it can be taken that the outputsignal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the oper-ation is defective, use the following procedure when checking directly.If any abnormality occurs in the S-NET system, the system is automatically switched to the following default mode,so be careful when carrying out troubleshooting.
Default mode1
Auto-deceleration
power max. posse
1 8 1 Automatic warming-up-
ON (automatic warming-up mode)
2. When networking cannot be carried out for the monitor and engine throttle controller, only throttle signalis recognized as FULL; normal control is carried out for others.
Procedure for checking monitor panel output signal* For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.1. Connection condition of components
1) Set to the monitoring mode and display monitoring code 08.2) The time display (bits) will light up to display the components that are connected.
* 0 Pump controller, 0 engine throttle controller, 0 valve controller will light up.
2. Checking working mode signal (check No. 2 throttle signal at the same time)1) Set to the monitoring mode and display monitoringcode 40.
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
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TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
3. Checking travel speed selection signal1) Set to the monitoring mode and display monitoring code 23.2) Change the travel speed switch to Mi or Hi, run the engine at 1500 rpm or above, and operate the control
lever. Check that bit 8 lights up when this is done.
4. Checking boom/swing priority selection mode signalj, If the travel oil pressure switch signal is not input to the controller, the flow from the front and rear pumps
will remain divided.1) Turn the boom/swing priority switch to ON.2) Set to the monitoring mode and disply monitoring code 23.3) Check that bit @ lights up when the boom, arm, bucket, and swing are operated independently or together.
* Check the operating condition of the pump merge-divider solenoid valve.
Checking input signal of engine throttle controller, pump controller* Check the input signal for each controller as follows.0 Pump controller1. Checking input signal
1) Check oil pressure switchi) Set to the monitoring mode and display monitoring codes 20 and 21.ii) Operate each work equipment lever, and check how the bit pattern lights up.
* For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIALFUNCTIONS.
2) Check engine speed sensor (check engine speed)i) Set to the monitoring mode and display monitoring code 10.ii) Use the fuel control dial to change the speed, and measure the engine speed when this is done.
3) Check pump pressure sensori) Set to the monitoring mode and display monitoring code 11 and 12.
* Code 11 is for the front pump, and code 12 is for the rear pump.ii) Refer to Table 2 and measure the hydraulic pressure at the front and rear pumps.
Table 2. Pump merge-divided flow logic and pumps actuated by control levers.
Boom/swing priority selection mode OFF Boom/swing priority selection mode ON *I
Basically flow is mergedFlow merged i f there is n el + compound operation
* When the travel is operated independently divided flow, travel + compound operationsbecomes the merged flow.
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4) Check L.H. knob switch input signali) Set to the monitoring mode, and display monitoring code 22.ii) Push the L.H. knob switch ON and check that bit @ lights up.
2. Check output signals
1) Check LS control EPC solenoid output currenti) Set to the monitoring mode, and display monitoring code 15.ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode, and
measure the current.* All levers at neutral: 900 f 80 mA
Engine at high idling, travel speed Hi, travel lever operated: 0 A
2) Check No. 2 throttle signali) Set to the monitoring mode, and display monitoring code 16.ii) Use the procedure in Item 2 for checking the monitor panel output signal, and measure the
engine speed.
3) Check ON * OFF solenoid conditioni) Set to monitoring mode, and display monitoring code 23.ii) Refer to Table 3 and check that the applicable bit lights up.
Table 3. Types of solenoid and conditions for actuation
Name of solenoid Actuation condition Bit that lights up
LS select Swing + travel lever operated 0
Swing brake Swing operated 0
Pump merge-divider L/O mode @
2-stage relief Travel lever operated 0
Travel speed Travel speed switch: HiFuel control dial at midway position or above 8Travel lever operated
4) Check TVC solenoid output currenti) Set to the monitoring mode, and display monitoring codes 13 and 14.
Code 13 is for the front pump, and code 14 is for the rear pump.ii) With the starting switch kept at the ON position and in the G/O mode, measure the current
when the fuel control dial is turned to the MAX position.PC200, PC21 0: 510 f 80 mAPC220, PC250: 410 f 80 mA
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
J
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TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
Engine throttle controller1. Check input signal
1) Check fuel control dial input voltagei) Set to the monitoring mode, and display monitoring code 30.ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.
* Voltage: 0.25 - 4.75 V
2. Check output signal1) Check governor motor drive current
i) Set to the monitoring mode, and display monitoring codes 33 and 34.* Code 33 is the A phase (direction for increasing engine speed), and code 34 is the B phase
(direction for reducing engine speed).ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration
direction and deceleration direction.* Current: 700 f 70mA
2) Measure battery relay drive voltage
0ii)
iii)iv)
Set to the monitoring mode, and display monitoring code 35.Measure the battery relay drive voltage when the starting switch is turned from ON to OFF.orSet to the monitoring mode, and display monitoring code 37.Check that bit 0 lights up when the starting switch is turned from ON to OFF.
(Min. 4 seconds - Max. 7 seconds)
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TROUBLESHOOTING OF ENGINE THROTTLECONTROLLER SYSTEM
(E MODE)
Points to remember when carring out troubleshooting of engine throttle controller systemEngine throttle controller system circuit diagram .................................Action taken by controller when abnormality occurs and problems on machine ........Judgement table for engine throttle controller and engine related parts ..............Troubleshooting flow charts for each failure mode
E- 1 Abnormality in engine throttle controller power source system(engine speed stays at low idling) ......................................E- 2 [E3:08] Abnormality in fuel control dial input value is displayed .......... ....E- 3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayedE- 4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed . .E- 5 [E3:01] Abnormality in network reception system is displayed ...............E- 6 [E3:05] Abnormality in model code is displayed ...........................E- 7 [E3:06] Abnormality in governor potentiometer system is displayed ...........E- 8 [E3:07] Abnormality in pump controller throttle system is displayed ...........E- 9 [E3:15] Abnormality (short circuit) in battery relay output system is displayed ...E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed .........E-l 1 Enginedoesnotstart ................................................E-12 Engine speed is irregular .............................................
a) Idling speed is irregular ............................................b)Thereishunting ..................................................
E-l 3 Lack of output (engine high idling speed is too low) .......................E-l 4 Enginedoesnotstop ................................................E-l 5 Defective operation of battery relay system (engine does not stop) ...........
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. . . 20-I 12
. . . 20-I 13
. . . 20-I 15. . 20-I 16
. . 20-l 17. . . 20-I 18. . . 20-I 19. . . 20-l 20 . . . 20-I 21 . . . 20-I 23 . . . 20-I 24 . . . 20-l 25
. . 20-I 25
. . 20-I 26
. . 20-I 28
. . 20-I 30 . . 20-I 30 . . . 20-I 32 . . . 20-I 34 . . . 20-l 36 . . . 20-I 38
20- I 11
a
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POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-TROUBLESHOOTING SHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTINGOF ENGINE THROTTLE CONTROLLER SYSTEM
1. Points to remember when there is abnormality which is not displayed by codeThe engine is controlled by engine throttle contoller.The problems that may occur with this system include the following.1. Idling speed is too high (too low)2. High idling speed is too low3. Auto-deceleration speed is too high (too low)4. Engine speed for automatic warming-up operation is too high (too low)5. There is hubting6. Engine does not stopIf any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor panel,use the troubleshooting table to determine the appropriate troubleshooting flow chart from El to El 0.However, if there is any abnormality in the machine and no abnormality display is given, it is necessary todetermine whether the problem is in the mechanical system or in the electrical system. If the linkage betweenthe governor motor and the injection pump is not properly adjusted, problems 1 to 6 listed above may occur.Therefore, if there is no abnormality display, but one of problems 1 to 6 above has occured, carry out trouble-shooting as follows.
2 YESIf linkage between
YES q+ynor motor and_ mlechon pump is dis-
1 connected, does opara--
If linkage betweention of governor motorbecome normal?
governor motor andinjection pump s _disconnected and
* With starting switch NO
pump lever is operatedat ON, operate fuel
bv hand or is fixed withcontrol dial and. .__.Lng mode
[ fi;ikd~~i” ‘ ~~ 1 ,0&y;,,.
*If engine does not stop, pushgovernor lever to STOP positionand check if engine stops.
Defective adjustment of governor motor linkageSee TESTING AND ADJUSTING.
Go o troubleshoot ing E-12 - E-15 of electrical system
Go io troubleshooting S-l - S-16 of engine system
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow chartfor the mechanical system or electrical system.* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
2. Points to remember if abnormality returns to normal by itselfIn the following cases, there is a high probability that the same problem will occur again, so it is desirable tofollow up this problem carefully.
1)2)
*
If any abnormality returns to normal by itself,If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and theconnector is returned to its original position when carrying out troubleshooting of the failure, and theservice code is no longer displayed, or if the monitor display returns to normal.After completing troubleshooting, always erase the user code from memory.
3. Service code memory retention functionWhen displaying the service code in memory and carrying out troubleshooting, note down the content of the
display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to theservice code that is displayed.(There are cases where mistaken operation or abnormalities that occur when the connector is disconnectedare recorded by the memory retention function. Erasing the data in this way saves any wasted work.)
20- 112
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ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAMFOLD
Starting switchFuel control dial
I 1
E06 I I(M3) I: $$\
Pump controller 1 0.5WB dCO3(040) 0. 5G
I 10) - - -
X07(M C17)
\ 20 6 a hI I r r
Governor motor7-----
Potentiometer
0. 85RG. ,2 .
0.85BR .l . f
I
-- +5LgRNetwork (Engine -I-)
90.100rrn
E05 X4) Motor
I
120130
v+go._ 16Q_
7
1*0. 85WB
0.85G
50.75G
I I :
-&In cmrn- 0. 5BW AI I I I I
I I I 1 I I I n 5R I I
________________--_- ______-__------ -2
6*7e 0.75R
8 0.75w
i-+
_ H02tM C).
CO9(S8) PC200 PC220
Fusible link
M14(L2)
EO( MC21)‘
Engi ne hrottle controller
3W*a
1 H06(L2)Fuse box LT
3N
33LDLO 5w 5w
2‘
2w 462w 2R
R E 14
H05t M6)
, kO. 58 a
07
0605
0.5RL. ,4
0. 5YG., 3o. 5YB
Monitor panel
1O2(040)
I I 10L -
Model selection COnrWtOr
H05( M6)
3Ml (L2)
I Fusible link
7 k
ti 45(M3)
20
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FOLD
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Jser code Service code Abnormal system Nature of abnormality Condition when normal voltage, current, resistance) Action by controller when abnormality is detected Problem hat appears on machine when there is abnormality
I Short circuit in wiring harness bet weenEOI (5) - (16), (5) - (17), (16) - (17)
2. Short circuit in wiring harness betweenE04 (I) - (2), (I) - (3), (2) - (3) EOI (female) E06 (male) Resistance alue
3. Short circuit in wiring harness be tweenE06 (I) - (2), (1) - (3), (2) - (3) (5) - (7) (I) - (2) 0.25 - 7kR I. Does not become partial speed when set at
4. Short circuit in wiring harness betweenhigh idling position
E3:08Abnormality in fuel
EOI (5) - (7). (7) - (16) (7) - (16) (2) - (3) 0.25 - 7kR Maintains engine speed at position Of fuel COntrOl 2. Does not reach high idling when set at partialcontrol dial input value
5. Disconnection in wiring ha rness betweendial immediately before abnormality occurred
EOI (5) - X07 (6) - E06 (I)(5)-(16) -
speed2-3kQ 3. There are cases of hunting
6. Disconnection in wiring harne ss between (I) - (3) 4-6kQ4. Lacks output (max . spe ed of engine is too low)
-EOI (7) - X07 (5) - E06 (2)
7. Disconnection in wiring harne ss between Betweeneachpin and chassis - Min. 1 MR
EOI (16) -X07 (4) - E06 (3)8. Defective fuel control dial9. Defective contact of EOI, X07, E06 connectors
E : 05 E3:17
E05 (male) EOI (female) Resistance alue
1. Disconnection inside governor motor (l)-(2) (IO) - (20) 2.5 - 7Q2. Disconnection in wiring harn ess between
I. When there is a disconnection in both the A
EOI (10 ) - HO2 (4) - E05 (1 ) (3) - (4) (II)-(21) 2.5 - 7Rphase and 8 phase at the same time, the
Abnormality 3. Disconnection in wiring ha rness betweenproblem is the same as for a short circ uit in the
(disconnection) in EOI ( I 1) - HO2 (7) - E05 (3 )4. Disconnection in wiring harness between
(I) - (3) (IO) - (II) Min. 1 MRgovernor motor system
governor motor driveTakes no particular action 2. When there is a disconnection in only one of A
system EOI (20) - HO2 (5) - E05 (2)phase or B phase
5. Disconnection in wiring ha rness between(I) - (4) (IO) - (21) Min. 1 MQ 1) Engine does not stop
EOI (21) - HO2 (8) - E05 (4) Between pins IO),2) Stops moving at position immedia tely before
6. Defective contact of EOI, H02, E05 connectors ~~~~nn$~~~$i~2) ’ (ll), (20) (21) and Min. 1 MRfailure, so engine speed can not be controlled
chassis 3) There are cases of hunting
Motor drive current : Hold : 0.7 AStart : 0.84 A
E05 (male) EOI (female) Resistance alue
(I) - (2) (IO) - (20) 2.5 - 7R
1. Short circuit inside gover nor motor (3) - (4) (II)-(21) 2.5 - 7R1. If during operation
2. Wiring harness between EOI (IO) - HO2 (4) - E051) Set to low idling
Abnormality (short (I) short circuiting with wiring harness between2) Engine does not stop
E3:18 circuit) in governor EOI (20) - HO2 (5) - E05 (2) (l)-(3) (10) -(II) Min. I MR 3) There are cases of hunting
motor drive system 3. Wiring harness between EOI (I I) - HO2 (7) - E05 Sets motor drive current to 0 2. When sto pped
(3) short circuiting with wiring ha rness between (I) - (4) (IO) - (21) Min. 1 MRI) Engine s tarts, but stays at low idling
EOI (21) - HO2 (8) - E0 5 (4)2) Engine does not stop after starting
4. Wiring harness in Items 2 and 3 short circuiting Between pins I), (2), Between Pins 1%3) There are cases of hunting
with ground (3), (4) and chassis $JJ $?so)’ *I) and Min. 1 MR
Motor drive current : Hold : 0.7 AStart : 0.84 A
E3:Ol
I. When monitor pan el and pump controllerI. When monitor pane l and pump controller
1. %;ntcrcuit, disconnection in network wiringcannot receive signal
Abnormality in network 1) Working mode: H/O cannot receive signal
reception system1) Even when working mode is switched,
2.Abnormality in pump controller2) Automatic warming-up: ON
3.Abnormality in engine throttle controller.3) Overheat signal: OFF engine speed does not change
2. Same as normal when only pump cont rollerp 2. Same as normal when only pump control ler
cannot receive signal cannot receive signal
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JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS Figure in0 shows position of bit pattern
Engine hrott le controller, engine related pans (E3 : 00 system)
L
z
Self-diagnostic displayChecking monitoring, check items
Machinemonitorcheck item
display is given
User code E05 Monitoring code Coolanttemperature
Failure mode Service code E3:08 E3:17 E3:18 E3:Ol E3:05 E3:06 E3:07 E3:15 E3:16 36 35 16 30 31 33 34 41 gauge
1 Engine does not start easily S-l
2 Engine does not start 0 s-2
3Engine speed sta ys at low idling, and does not follow a ccelerator, orengine pickup is poor 0 0 0 0 0 . .x .x .x 0 s-3
4 Engine stops during operation s-4
Engine When idling speed is irregular E-12a), S-55 rotation is
irregular When there is hunting 0 0 0 0 0 % E-12a), S-5
6 Lack of output (engine high idling speed is too low) 0 0 z s 0 S-6
7 Auto-dece leration does not work 0 E-3 , E-4
6 Engine does not stop 0 0 0 0 0 0 0 0 *x E-14
g Automatic warming-up operation is defective 0 0 E-3 , E-4
10 Exhaust gas is black s-7
11 Oil consumption is excessive, or exhaust gas is blue S-8
12 Oil becomes dirty prematurely s-9
13 Fuel consumption is excessive, or exhaust gas is blue S-IO
14 Oil is mixed in coolant s-1 1
15 Oil pressure caution lamp lights up s-12
16 Oil level rises s-13
17 Coolant temperature rises too high 0 0 s-14
16 Abnormal noise is generated s-15
19 There is excessive vibration S-16
20 Engine speed does not change even when working mode is switched 0 % E-3 , E-4
Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-5 E-7 E-9 E-9 E-10 - - - - - - - - - - -
Troubleshooting code when there is abnormality in monitoring mode ormachine monitor check
__ _- - --- -- C-15 E-15 - - - - - M-14 M-13 M-13 E-11
20-1160
0 : This shows applicable item for service code 0 : This shows item to check with monitoring mode or machine mo nitor
+Z This shows item that need.s.only c hecking with monitori ng mode
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TROUBLESHOOTING E-l
E-l Abnormality in engine throttle controller power source system(engine speed stays at low idling)
*
****
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Check that fuses 2 and 14 are not blown .Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l 1.)
I
1
Is voltage betweenEOl (l)(Z) and (12)normal?
IES
:I
:h
NO
0-30V21; starting switc
Isvoltage betweenEOl (6) and (12)
20 - 3ov-Turn starting )
switch ON.
ES
3 YES
pijiij -
*20-30V NOTurn starting switchON.
4 YESI I I
+20-30V NOTurn starting switchON. . ‘
E-l Related electric circuit diagram
X07 (MIC17) Fuse
Starting switch
L IEngine throttle controller . .
E01 (MlC2I I 1
Cause
Defective engine throttle:ontroller
Defective contact, or dis-:onnection in wmng harnesssetween starting switch ACC-X07 (17) - EOl (female) (6)
Defective starting switch[between B and ACC)
Defective contact, or dis-connection in wmng harnessbetween fuse 2 and EOl(female) (1) (2)
Defective contact,, or dis-connection in wmng harnessbetween fuse 2 - HO6 (2) -Ml4 (2) (1) -battery relay M
M14(L2)
Remedy
eplace
:epair oraplace
lepair oreplace
lepair oreplace
20- 117
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TROUBLESHOOTING E-2
*
**
E-2 [E3:08] Abnormality in fuel control dial input value is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly insertedAlways connect any disconnected connectors before going on to the next step.
YE1
tween E06 (male)(1) - (2). (2) - (3) asshown in Table l?
- Turn startingswitch OFF.
* Disconnect E06.
2r II is esistance between I
each pin of EOlIfemale) 15) (7) (16). or _I-etween each pin andchassis as shown inTable l?
*Turn starting NOswitch OFF.
- Disconnect EOl.
YES
Cause
Defective engine throttlecontrolier
Defective wiring harness insystem with defectiveresistance
Defective fuel control dial
Remedy
Replace
Repair orreplace
Replace
Note: If E3:06 also occurs at the same time, check the wiring harness below.Wiring harness between EOI (female) (5) - HO2 (1) - E04 (female) (1) short circuiting with ground, orcontact with other wiring harness.
Table 1
E01 (female)
(5) - (7)
E06 (female) Resistance value
(1) - (2) 0.25 - 7kLI
(7) - (16)
(5) - (16)
(2) - (3)
_
0.25 - 7kfI
2-3kLI
-(1) - (3) 4-6k0
I 1
I Between each _
pin and chassis IMin. 1 MQ
E-2 Related electric circuit diagram
Engine throttle controtterEil6 (M3)
Throttle powersource (c)
Feedback signal
Throttle powersource I-)
E04 (X3)
Fuel controldial
Governor
potentiometer
X08DD130
20- 118
0
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TROUBLESHOOTING E-3
E-3 [E3:17] Abnormality (disconnection) in governor motor drivesystem is displayed
*
*
*
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.During operation, if there is
1) a simultaneous disconnection in A phase and B phase:0 the engine will run at low idling0 the engine will not stop
2) a disconnection in either A phase or B phase:the engine speed will remain the same as before the abnormality occured
If the problem occurs when the engine is stopped,1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) before
checking.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
shown in Table l? 1 1
urn srarung I\”#witch OFF.\:_______. rn.
Defective wiring harness insystem with defectiveresistance
I
* Turn startingswitch OFF. NO Defective governor motor
*Disconnect E05.
Table 1
E05 (male)
(1) - (2)
EOI (female)
(10) - (20)
Resistance value
2.5 - 7k0
(3) - (4)
(1) - (3)
(ll)-(21)
(lD)-(11)
2.5 - 7kfI
Min. 1 MfI
(1) - (4)
Between pins (1)(2) (3) (4) and
chassis
(10) - (21)
Between pins (10)(11) (20) (21) and
chassis
Min. 1 MfI
Min. 1 M0
E-3 Related electric circuit diagram
Replace
Repair orreplace
Replace
X08DD131
20-I 19
0
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TROUBLESHOOTING E-4
E-4 [E3:18] Abnormality (short circuit) in governor motor drive system
*
*
*
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling, or 2) the engine will not stopIf the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) before
checking.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
* Turn starting Iswitch OFF.Disconnect E05.
O
Table 1
E05 (male) EOI (female) Resistance value
2.5 - 7kQ
2.5 - 7kL’
Min. 1 MfI
E-4 Related electric circuit diagram
Defective engine throttlecontroller
Defective wiring harness insystem with defectiveresistance
Defective governor motor
ED (MIC21) E05 (X4) GOVWflOrmcitw
Replace
Repair orreplace
Replace
X08DD131
20- 120
a
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TROUBLESHOOTING E-S
E-5 [E3:01] Abnormality in network reception system is displayed
*
*
**
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitorpanel and the controller, or the positive end (+) of the network wiring harness or the inside of the controllerare short circuited, the controller cannot carry out networking, so the monitor panel does not display any
abnormality.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
When E3:Ol is displayed independently
YES
I1
Disconnect E01connector, then YESconnect it again. -Does service code
display go out? A 2. Turn starting switch
OFF. Is connection of 4 YES*Disconnect connec- - pump controller _
tar, then connect NO displayed?connector again. YES Is voltage between
*Turn starting switch -ON.
S y CO3(7)-W,(8)- -
* Turn starting,~, (15) normal?
switch ON. Does LED of pump - -* W~o;onitor ing _ controller light up - . Turn starting NO
NO or flash? switch ON.* 4-8’ J
* p;,n starting switch Lo
When E2:18 and E3:Ol are displayed simultaneously
YES
1
1Disconnect PO2 1
Ionnector, thenconnect it again. u- YES
lntinuity‘ 02
Iremater \7), (8) and_.*__I
Hi3 YES
Connect connectors I I
switch OFF.* Disconnect P02,
C03, and EOl.. Shake wiring
harness aroundcontroller whenchecking forcontinuity.
u
* Turn starting NOswitch OFF.
- Shake wiringharness aroundwhen checking f
controlleror continuity.
Connect PO2 last.
switch OFF.
* Disconnectconnector, thenconnectconnector again.
* Turn startingswitch ON anddelete servicecode.
Cause
Defective contact or matingof engine throttle controllerconnector EO
Defective engine throttlecontroller
Defective pump controller Replace
Defective contact, ordisconnection in networkwiring harness
See C- l
Remedy
Repair
Replace
Repair orreplace
-
If monitor panel connector‘ 02
Positive (+I end of networkwiring harness in contactwith ground
Controller which has beenconnected is defective
Defective monitor panel
20- I 21
a
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TROUBLESHOOTING E-5
Monitoring display (Time display portion)
5P
(1) “pump controller connected”display
E2
a “Engine throttle controllerconnected” displayc
E-5 Related electric circuit diagram
CO3(04016)
X08DD133
Check for the LED display for the engine throttlecontroller and pump controller from the direction Engine throttle controller
\/Pof the arrow as shown in the diagram on the right.
Note 1: Push the operator’ s seat down to the front,then remove the two rear covers to check.
Note 2: The LED display for the pump controller isdifficult to see, so use a mirror.
X08DD134
20- 122
0
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TROUBLESHOOTING E-6
E-6 [E3:05] Abnormality in model code is displayed
*
**
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
YES1
Is engine throttlecontroller monitor-ing code display as 2 YESshown in Table l?
Is resistance be-
-Turn startingtween EOl (female)
switch ON. - (8).(9).(18).(19) and -
*Set to monitoringNO GND as shown in
code 03 and 36.Table 2?
*Turn starting NOswitch OFF.
- Disconnect EOl.
.:ON
Table 1 Monitoring display (Time display portion) C~ ~FF
Condition of engine Engine throttlethrottle controller input controller model code
PC200_-_, ,‘ - ‘ , , ‘ -‘ ,
PC21 0
I Ic-_ _-_ c-w
PC220
360 ,_,’_/ ,__’
PC250 o c:zr 0 0 u”3:z c12 I
CauseI
Remedy
Defective engine throttlecontroller
Replace
Defective model selectionconnector, or short circuit, Repair orshort circuit with ground, or replacedisconnection in applicablewiring harness
Table 2 Resistance value
r
Between EOI (female)(18) and GND
Min. 1 MQ Min. 1 Mf2
E-6 Related electric circuit diagram
EOl MIC21) CO9tS8) Model selection connector
PC200 PC220X08DD135
20- 123
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TROUBLESHOOTING E-7
*
**
E-7 [E3:06] Abnormality in governor potentiometer system isdisplayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES
Is esistance betweenDefective engine throttle
each pin of EOcontroller
YES (female) k5)(16)(17). or _1 between each pin and
-, chassis as shown in
Is resistanceTable l? Defective wiring harness in
system with defectivebetween E06 (male) _ * Turn starting NO resistance(1) - (21, (2) - (3) as switch OFF.shown in Table l? * Disconnect EOl.
* Turn starting Iswitch OFF. NO Defective governor motor Replace
*Disconnect E04.
Note: If E3:08 also occurs at he same time, check the wiring harness below.Wiring harness between EOI (female) (5) - X07 (6) - E06 (female) (1) short circuiting with ground, orcontact with other wiring harness.
Table 1
EOI (female)
(5) (17)
E04 (male)
( l ) - (2)
Resistance val ue
0.25 - 7 kf 2
I (17) (16) I (2) - (3) I 0.25 - 7 kQ
I - I U)- (3) 4-6kQ
and chassis_ I Min. 1 M I2
E-7 Related electric circuit diagram
X07(MIC17)EO 1 (MI C211
E06 (M3)
333
Fuel control dial
HO2 (S16) E04 (X3)X08DD136
20-I 24
0
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TROUBLESHOOTING
E-8 [E3:07] Abnormality in pump controller throttle system isdisplayed
E-8, E-9
* Start troubleshooting from E-6 [E3:05] or C8 [E2:17].
E-9 [E3:15] Abnormality (short circuit) in battery relay output system
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position).
Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
Note: This only occurs when the engine is stopped and the starting switch is turned OFF.
is displayed
2 YESIs resistance betweenEOl (female) 113) and
YES_ battery relay terminal _1 &and between
- wmng harnessand
Is resistance be-chassis normal?
tween EOl (female) _ * Between E01 NO(13) and chassisnormal?
(female) (13) and battery relay BR: Max 1 R* Between wiring harness and chassis: Min. 1 MQ* Turn starting switch OFF.
* Approx. 100 D * Disconnect E01 and battery relay BR.- Turn starting
switch OFF.NO
Disconnect EOl.
E-9 Related electric circuit diagram
Cause
Defective engine throttlecontroller
Defective battery relay qeplace
1) Contact between otherwiring harness and wiringharness between EOl(female) (13) - HO2 (9) -battery relay BR
2) When light is connected
Remedy
Replace
?epair or,eplace
X07(MIC17) Fuse
Engine throttle controller
XOSDD137
20-I 25
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TROUBLESHOOTING E-l 0
E-IO [E3:16] Abnormality (step-out) in governor motor system is
*
***
**
displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If any other service code [E3:01] - [E3:18] has occured at the same time, start troubleshooting from that code.Check that fuse 2 is normal.Read the precautions given in TESTING AND ADJUSTING, “ Adjusting stroke of governor motor lever” beforecarrying out troubleshooting.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
Are E3:06, E3:17,
* Turn starting switchON.
YES
YES
YESjeflT
n
Is adjustment oflinkage normal?
I
* Turn startingswitch ON.
- Turn auto-deceleration OFF.
*Set to governormotor adjustmentmode.
operation normal?
* 2r.n starting switch
* Turn auto-deceleration OFF.
yz&K&t$toyH
Set to governor motoradjustment mode. Disconnect E05. NO(Only when checking Q isconnectoperation of governor linkage at gover-motor at FULL.) nor motor end.
NO
Cause
30 to applicableroubleshooting code
Defective engine throttle:ontroller
I) Defective linkageI Defective injection pump
Iefective governor motor
Defective adjustment ofinkage
Remedy
-
Replace
Adjust orreplace
Replace
Adjust (Fordetails, see
TESTINGANDADJUSTING)
20- 126
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TROUBLESHOOTING E-l 1
E-11 Engine does not start
* When starting motor does not rotate.* Check that fuse 14 is not blown before starting troubleshooting.j, Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
4 YES
YE
Is voltage andspecific gravity ofbattery normal?
‘ I
* Min. 24V
YI
*Turn startingswitch ON -- OFF.
OFF, is sound heardfrom battery relay?
1NO
. Turn startingswitch START
YE
* Connect 1-1 end oftester to batteryterminal f-j.
.20-29v
. Turn starting NOswitch ON.
- Approx. 24V
5 YESI
Is voltage betweenstarting switchterminal C andchassis normal?
-Turn startingswitch to START.
. Approx. 24V
NO
Is there continuity * Between startingswitch BR and bat- NOtery relay BR: Max. 1 Q
- Between wiring harness and chassis: Min. 1 MQ- Disconnect both starting switch and battery relay
* Turn starting switchON.
ends.
- Remove terminal B. No
NOE-l 1 Related electric circuit diagram
M2 (X2) 26 CTwP14) HO3(516)
HO5 U46) ruse Starting switch
ID13
XOBDD138
20- 128
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TROUBLESHOOTING E-l 1
Cause Remedy
Defective starting motor Replace
Defective contact of wiringharness between batterv (+)
Defective starting switch(between terminals 6 and C)
Defective battery relay
Defective contact of wiringharness between batteryrelay terminal E andrevolving frame groundconnection terminal
(between 5 and BR)
Defective contact, or dis-connection in wrrr ng harnessbetween battery terminal t+j-Mll-H05(6)-X07(1)-starting switch terminal 6(including fusible link)
Repair orreplace
Repair orreolace
Replace
Replace
Repair orreplace
Repair orreplace
Replace
Repair orreplace
1 Lack of battery capacity 1Charge or
20- I 29
0
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TROUBLESHOOTING
E-12 Engine speed is irregular
E-l 2
**
4
Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
Idling speed is irregular
controller modelcode as shown in
*Turn startingswitch ON.
- %;EO;onitoring
Is E3:Ol displayed? 1
- 2d.n starting switct
disconnected andmotor lever is placed
YE
* Turn starting switchON.
N
4
When linkage bet-ween governor motorand injection pump is -adjusted, does condi-tion become normal?
. See TESTING ANDADJUSTING.
Start signal 7 YESI It-
:sE
Fuel control dial 5-1
~ ormal and stable?
. At low idling:4.0 - 4.75V I
NO
. At low idling: IPC200 : 2.8 - 3.2 VPC220 : 2.9 - 3.3 v
NO
Table 1 NO
PC220PC250 332 13
20- 1300
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TROUBLESHOOTING E-l 2
Cause
FISeeE-j Defective adjustment of
linkageidjust
Defective injection pump #ee S mode
7 Defective governor motor
Defective contact of wiringharness between startingswitch ACC - X07 (17) - EOl
(female) (6). or defectivestarting switch
See E-7
See E-2
See E-6
E-12 Related electric circuit diagram
Engine throttle controller
Starting switch X07 (Ml C 17)
Remedy
-
eplace
epair orsplace
EOl(MIC21)I- i 1 x"PK17) I
Starting switchON signal
Throttle signal
Feedback signalThrottle powersource (4
33
H02tS16) E04(X3)
Governor
potentiometer
X08DD139
20- 131
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TROUBLESHOOTING E-l 2
b) There is hunting
controller modelcode as shown in
. Turn s tartingswitch ON.
. &;rg;onitoring
Is E3:Ol displayed?
*Turn startingswitch ON.
YEIS
3I I
When linkage is dis-connected and motorlever is matched with
*Turn startingswitch ON.Turn fuel controldial from MIN toMAX and stopalso at midwayposition.
4When linkage betweengovernor motor andinjection pump isadjusted, doescondition becomenormal?
* See TESTING ANDADJUSTING.
Fuel control dial 5
Is voltage between- EOl (7) and (16)
NO normal and stable?
YES
Deceleration signal 7I sPotentiometer 6
YAt low idling:
2.9 - 3.3v- At high idling: NO
0.5 - 0.9v
*At low idling:4.0 - 4.75v
*At high idling:0.25v - 1 ov NO
0Table 1I I
Engine throttle controllermodel code
PC200PC21 0
PC220PC250
20- 132
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TROUBLESHOOTING E-l 2
Start signal 8 YES
Is voltage between- EOl (6) and (12) -
normal and stable?
. During ope;t:;;” NO
-5 ;ee E-5
-c Defective adjustment of
iinkage
-I: jefective injection pump
-c efective governor motor
cefective contact of wiringh arness between start ing
‘ S witch ACC - X07 (17) - EOl( emale) (6). or defectiveS atting switch
s ice C-15
s ;ee E-7
-S ;ee E-2
-S #ee E-6
Startingswitch X07(MIC171 Fuse
otentiometer
Pump controller
X08DD140
E-12 Related electrical circuit diagram
Cause Remedy
-
rdjust
NeeS mode
eplace
epair oreplace
-
-
-
-
20-I 33
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E-13 Lack of output (engine high idling speed is too low)
* Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
Is engine throttlecontroller modelcode as shown inTable l?
*Turn startingswitch ON.
. .SS;;gTonitoring
Table 1
Is E3:Ol displayed?
* Turn startingswitch ON.
3
Does injectionL pump governor
NO lever contact FULLstopper?
. Start engine.
. Set fuel controldial to MAX.
* H/O mode.
INO
YE
4
Is adjustment oflinkage betweengovernor motorand injection pumpnormal?
YE
Fuel control dial 5
normal and stable?
I-NC
*At low idling:4.0 - 4.75V
- At high idling:0.25v - l.OV
YES
Potentiometer 6 rIs voltage betweenEOl (17) and 116)normal and stable?
H* At low idling:2.9 - 3.3v ‘ L*t high idling: NO0.5 - 0.9v
YES
. See TESTING AND NOADJUSTING.
PC220
PC250
20- 134
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TROUBLESHOOTING E-l 3
Start signal YESI I I
~
. During ope;t?;;V NO
* At deceleration: 1Max. 1V NO
-When cancelled:8-12V
E-13 Related electric circuit diagramStartingswitch X07CMIC17) FlJse
Eng,ne throttle controller
Cause
See E-5
Defective injection pump
Defective governor motor
Defective contact of wiringharness between startingswitch ACC - X07 (17) - EOl(female) (6). or defectivestarting switch
See C-15
See E-7
See E-2
Defective adjustment ofgovernor motor linkage
See S mode
See E-6
Remedy
-
e S mode
place *
-
-
-
-
-
20-I 350
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TROUBLESHOOTING E-l 4
E-14 Engine does not stop
A Stop the engine (push the fuel control lever of the fuel injection pump to the NO INJECTION position) before
***
checking.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Read the precautions given in TESTING AND ADJUSTING, “ Adjusting stroke of governor motor lever” beforecarrying out the troubleshooting.
YE
Is engine throttlecontroller modelcode as shown inTable l?
t
Turn starting switchON.
* ~;&;9~onitoring
Table 1
lever contact STOP
condition becomenormal? and Does
. See TESTING AND
ADJUSTING.
Potentiometer 6 YESWhen starting
YES switch is OFF, is
Relay drive signal 5- voltage between -
_ E01 (17) and (16)When starting normal?
YES switch is OFF, does- voltage between 601 - *When engine is NO
Start signal 4 (13) and (12) changestopped
_ as shown in Table 2? * PC200: 2.9 - 3.3vWhen starting p *PC220: 2.9 - 3.2Vswitch is OFF, is *20 - 3ovvoltage between -EOl (6) and (12)
NO
normal?
.Max.lV
Engine throttle controllermodel code
PC200PC21 0
PC220PC250 u”3:z cf
Table 2When OF
Voltage from starting (APPrOx. 24V)
“ ‘ k ’ - To battery relay (BR)OFF
(Note) -.----When ON
- Voltage output from controller when startin g switch is OFF
Condition of actuation of1 (Approx. 24v)controllercircuit 1 To battery relay (BR)
(EO@)OFFL A Min. 4 sec.
Drive timea Max. 7 sec.
(when it is impossible to set to NO INJECTION because of failure in motor)
Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is alwaysflowing from starting switch BR, so if the voltage is measured at EOI (13), there is a voltage of 20 - 30 V.
20- 136
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TROUBLESHOOTING E-l 5
E-15 Defective operation of battery relay system (engine does not stop)
Note: This only occurs when the engine is stopped and the starting swtich is turned OFF.Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) beforea
**checking.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
1
YES
1 Is E3:15 displayed? [ YESRelay drive signal 2 )
* TurnON.
defective battery relay f
1) Disconnection in wiringharness between E01(female) (13) - HO2 (9) - f
*BetweenEOl NO battery relay BR r
(female) (13) and battery relay BR: Max. 1 R 2) When light is connected* Between wiring harness and chassis: Min. 1 MQ* Turn starting switch OFF.- Disconnect EOl and battery relay BR.
Table 1 When ON
Voltage from starting (APP~O X. 24V)
1 To battew relay (BR)OFF
Cause
Defective engine throttle:ontroller
fSeplace
Ieplace
tepair oreplace
,, y Voltage Output from Controller when starti ng switch is OFF
IWhen ON
Condition of actuation of(Note) (Approx. 24V). I
-To battery relay (BRI77-L 1 Min. 4 sec.
Drive time- Max. 7 sec.
(when it is impossible to set to NO INJECTION because of failure in motor)
See E-9 -
_
Remedy
Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is alwaysflowing from starting switch BR, so if the voltage is measured at EOI (13), there is a voltage of 20 - 30 V.
E-l 5 Related electric circuit diagram
XDi’ (MlC17) Fuse
E01 (MIC21)HOZ(S16)
D13
XOSDDl37
20-I 38
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TROUBLESHOOTING OF ENGINE(S MODE)
Method of using troubleshooting chart . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 40s- 1s- 2
s- 3s- 4s- 5S- 6s- 7S- 8s- 9S-l 0S-l 1S-l 2S-l 3S-l 4S-l 5
S-l 6
Starting performance is poor (Starting always takes time) .................Enginedoesnotstart ............................................0 Enginedoesnotturn ............................................0 Engine turns but no exahaust gas comes out (Fuel is not being injected) .0 Exhaust gas comes out but engine does not start (Fuel is being injected)Engine does not pick up smoothly (Follow-up is poor) ....................Engine stops during operations .......................................Engine does not rotate smoothly. .....................................Engine lacks output (no power) ......................................Exhaust gas is black (incomplete combustion) ..........................Oil consumption is excessive (or exhaust gas is blue) .....................Oil becomes contaminated quickly ....................................Fuel consumption is excessive .......................................Oil is in cooling water, or water spurts back, or water level goes down .......Oil pressure lamp lights up (drop in oil pressure) ........................Oil level rises ..........................................Water temperature becomes too high (overheating) ......................Abnormal noise is made ............................................
Vibration is excessive ............................................
. . .
. . .
. .
. .
. . .
. . .
. . .
. . .
. . .
. . ...
. . .
. . .
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20-I 4420-l 4520-I 4520-l 46 20-I 47
20-I 48 20-I 49 20-I 50 20-I 51 20-I 52 20-I 53 20-l 54 20-I 55 20-I 56 20-I 57 20-I 58 20-I 59 20-I 60
20-I 61
20- I 39
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TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
The basic method of using the troubleshooting chart isas follows.Items listed for [Questions] and [Check items] that havea relationship with the Cause items marked with 0, andof these, causes that have a high probability are mark-ed with @.Check each of the [Questions] and [Check items] inturn, and marked the 0 or @ in the chart for itemswhere the problem appeared. The vertical column
(Causes) that has the highest number of points is themost probable cause, so start troubleshooting for thatitem to make final confirmation of the cause.
rl
%2
For (Confirm recent repair history) in the [Ques-tions] Section, ask the user, and mark the Causecolumn with A to use as reference for locatingthe cause of the failure. However, do not use thiswhen making calculations to narrow down thecauses.Use the A in the Cause column as reference for(Degree of use (Operated for long period)) in the[Questions] section as reference. As a rule, do notuse it when calculating the points for locating thecause, but it can be included if necessary to deter-mine the order for troubleshooting.
, t%l
-----Ionfirm recent repair history
%2 Degree of use Operated for long period A A A
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TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
Example of troubleshooting when exhaust gas is blackLet us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptomshave causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-er], and [Dust indicator is red].If we look from these three symptoms to find the cause, we find that there is a relationship with five causes.Let us explain here the methos of using this causal relationship to pinpoint the most probable cause.
c
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TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
I Five causes I
Clarify the relationship between the three symptomsin the [Questions] and [Check items] section andthe five Cause items in the vertical column.
Three symptoms
i h 1,
I
Step 2
Add up the total of 0 and 0 marks where the hori-zontal lines for the three symptoms and the vertical
columns for the causes intersect.(1)(2)
(3)(4)(5)
Clogged air cleaner element: 908Air leakage between turbocharger andhead: 00Clogged, seized injection nozzle: 0Defective contact of valve, valve seat: 0Worn piston ring, cylinder: 0
Step 3
The calculations in Step 2 show that the deepestrelationship is with [Clogged air cleaner element].Follow this column down to the troubleshootingarea and carry out the troubleshooting item marked0. The Remedy is given as [Clean], so carry outcleaning, and the exhaust gas color should return
, to normal.
20- 143CD
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TROUBLESHOOTINGS-l
S-l Starting performance is poor (Starting always takes time)
* Check that there is no abnormality display for the engine throttle controller on the monitor panel.General causes why starting performance is poor
Defective electrical system0 Insufficient supply of fuel
Insufficient intake of air0 Improper selection of fuel
(At ambient temperature of - ?O” C or below, use ASTM D975 No. 1, and - 10°C or above, use ASTM D975No. 2 diesel fuel.)
* Charging rate of battery.
20x 1.28 1.2 ‘ 6 / 1.24 1.23 1.22
O’C 1.29 1.2. , .._.I 175 1 1.24 1 1.23
-10% 1.30 1.28 1.2L , ..__ , .._-I 176 I 174
. The specific gravity should be for the charging rate of 70% or more in
the above table.
. In cold weather the specific gravity must be for the charging rate of atleast 75% in the above table.
I Confirm recent re*au histow
5 _ Engine oil must be added more frequently-.i: RePlaCement of filters has not been carried ou t according t o2 operation manual
: AKCleanerlogingampightE P IA, / I I I I II I I I I I I /
Non-spectied fuel has been used
/ Battery cha rge lamp is ON
/
Match marks on fuel injection pump we out of ahgnment I ) 1 1 101 1 /I 0
: Mud is stuck to fuel tank cap I I I I I I.s When engine is cranked with starting motor,
% 1I Little fuel comes out even when injection pump sleeve nut 1sI I I I I
When control rack is pushed, it is found 10 be heavy or does not returnI/ (when blind plug at reer of pump IS removed, it can be seen that
plunc,er ~onfrol sleeve does not move,
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TROUBLESHOOTING s-2
S-2 Engine does not start0 Engine does not turn
General causes why engine does not turninternal parts of engine seized* If internal parts of the engine are seized, carry out troubleshooting for “ Engine stops during
operations” .Failure in power train
Defective electrical system I Causes I
Confirm recant repair historyE.g Degree of use Operated for long period
2 Condition of horn when startina 1 Horn does not sound
z 1 switch is turned ON _ Horn sound level is low
When starting switch is
turned to START. pinion
moves out, but
Rotating speed is slow
Makes rattling noise and
does not turn
EC When starting switch is turned to START, pini on does not move out%r”
When starting switch is turned to ON, there is no clicking sound
u Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, volta ge of battery is low
For the following conditions 1) -. 5). turn the starting switch OFF,
connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are connected,
engine starts
-21 When ternimal E and terminal C of starting motor are connected,
z engine starts‘ G8 3) When terminal B and ierminal C of safety relay are connected,52
engine starts
z 4) When terminal of safety switch and terminal B of starting motorg are connected, engine starts
5) There is no 24V voltage between terminal b and terminal E of
I battery relay
When ring gear is inspected directly, tooth surface is found to be
I chipped
Remed)
20- 145a
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TROUBLESHOOTINGs-2
0 Engine turns but no exhaust gas comes out (Fuel is not being injected)
* Check that there is no abnormality display for the engine throttle controller system on the monitor panel.General causes why engine turns but no exhaust gas comes out
Supply of fuel impossible0 Supply of fuel extremely small0 Improper selection of fuel (partucularly in winter)
Standards for use of fuel
When fuel cap is inspected directly, it is found to be clogged 0
0 8 zRemedy 9 a S :
L L @
$ z?5 ‘ I ‘ g p
,odb,g $ 00 a e oz
20- 1460
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TROUBLESHOOTING s-2
COExhaust gas comes out but engine does not start (Fuel is being injected)
General causes why exhaust gas comes out but engine does not startLack of rotating force due to defective electrical system
0 Insufficient supply of fuelInsufficient intake of air
0 Improper selection of fuel
/-
manual
starting motor,
1) Little fuel comes out even when injection pump sleeve nut is
20- 147
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TROUBLESHOOTING S-4
S-4 Engine stops during operations
* Check that the display for the fuel level on the monitor panel indicates that there is still fuel left.General causes why engine stops during operations
Seized parts inside engine0 Insufficient supply of fuel
Overheating* If there is overheating and insufficient output, carry out troubleshooting for overheating.
Failure of power train* If the engine stops because of a failure in the power train,
carry out troubleshooting for the chassis.
Condition when engine
stopped
Try to turn by hand using bar
I Remove oil pan and check directly 1.101 1 1 1 1 1 1 1 1 2Remove head cover and check directlv I.1 I I I I I I I
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TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly* Check that there is no abnormality displayed for engine throttle controller system on the monitor panel.General causes why engine does not rotate smoothly (hunting)
Air in fuel systemDefective governor mechanismDefective electrically controlled throttle mechanism (electrically controlled throttle type)* If there is no hunting when the electrically controlled throttle rod is disconnected, carry out trouble-
shooting for the electrical system.
Condition of hunting
20- 150
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TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)* Check that there is no abnormality displayed for the engine throttle controller system on the monitor panel.General causes why engine lacks output
Insufficient intake of air0 Insufficient supply of fuel
Improper condition of fuel injection0 Use of improper fuel
(if non-specified fuel is used, output drops)
Lack of output due to overheatingjr If there is overheating and insufficient output,
carry out troubleshooting for overheating.
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TROUBLESHOOTING
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is blackInsufficient intake of airImproper condition of fuel injectionExcessive injection of fuel
36
Engine oil must be added more frequently I, I I I ISuddenly C. I IAl I I Ir\l I In
Power was lostGraduallv
I I I I-8 I I
Non-specified fuel has been used I I lol I
E temperature of some cylinders is low I I I IDI Ia.Z Match marks on fuel injection pun.
::2 Seal on injection pump has come off I Iu Clanging sound is heard from around cylinder head I , I I
>o are out of alianmentI 1
0
I ji0
Exhaust noise is abnormal lol I lo1 It Q
Muffler is crushed 0
Leakage of air between trubocharger and head, loose clamp 0
20 I 52
0
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TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)
* Do not run the engine at idling for more that 20 minutes continously. (Both low and high idling).General causes why oil consumption is excessive
Abnormal conbustion of oilExternal leakage of oilWear of lubrication system
I/ I , one IArea around enaine is dirtv with oil
There is oil in engine cooling water
When exhaust oipe is removed, inside is found to be dim, with oil CT3 I lo-G
-0
2Inside of turbocharger intake pipe is dirty with oil 8
Oil level in clutch or TORQFLOW transmission damper chamber rises QClamps for intake system are loose @
When compression pressure is measured, it is found to be low 0 0
When breather element is inspected, it is found to be clogged with0
Pdirty oil
‘ Z There is external leakage of oil from engine 0 0 0
Pressure-tightness test of oil cooler shows there is leakage 0
20-I 53
0
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TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quicklyIntake of exhaust gas due to internal wearClogging of lubrication passageImproper combination
0 Use of improper oilOperation under excessive load
Confirm recent repair history
z Degree of use Operated f or long period A A A.gz
Engine oil must be added more frequently 8Non-soecified fuel has been used 0
IWhen oil filter is inspected, metal particles are found 0 ci,-, , ,
u When exhaust pipe is removed, inside is found to be dirty with oil @Fnrrin,z nil tPmnPllt,,rL liCLI n,,irk,v I IBI I
1L.‘)..‘ - _.. ._... r_._._._ ..___ _I_._ . . . .
I I I I 1-1 , :w
I When compression pressure is measur&d, it is found to be low I.1 I I 1 I I 1
When safety valve is directly inspected, spring is found to bl
20- 154
0
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TROUBLESHOOTING S-l 0
S-IO Fuel consumption is excessive
General causes why fuel consumption is excessiveLeakage of fuelImproper condition of fuel injectionExcessive injection of fuel
IllllllljConfirm recent repair history
Degree of use Operated for long period .4 A A
z More than for other machines
.g 6 0of same model
t Condition of fuel consumption
zGradually increased 0 0
Suddenly increased 0 0
Exhaust gas colorBlack @o 0 0
White 0
( Engine low idling speed is high lOI I I I I I ISI
20- 155
0
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TROUBLESHOOTING S-l 1
S-l 1 Oil is in cooling water, or water spurts back, or water level goesdown
General causes why oil is in cooling waterInternal leakage in lubrication systemInternal leakage in cooling system
20- 156
0
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TROUBLESHOOTING S-l 2
S-12 Oil pressure lamp lights up (drop in oil pressure)j, If engine oil level lamp on monitor panel is not lighted up.* If oil pressure sensor is normal (see item for M mode).General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating systemDefective oil pressure control
0 Use of improper oil (improper viscosity)Deterioration of oil due to overheating
* Standards for engine oil selection
Type of oilSelection of oil SAE number according
to ambient temperature
Condition when oil pressure
20- 157
a
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TROUBLESHOOTING S-l 3
S-13 Oil level rises
* If there is oil in the cooling water, carry out troubleshooting for “ Oil is in cooling water” .Water in oil (cloudy white)Fuel in oil (diluted, and smells of diesel fuel)Entry of oil from other component I Causes
yn engine 1s irst started, drops o
20- 1580
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TROUBLESHOOTING s-14
S-14 Water temperature becomes too high (overheating)
* If coolant level lamp on monitor panel is not lighted up.j, If coolant temperature gauge on monitor panel is normal (see M mode)General causes why water temperature becomes too high
Lack of cooling water (deformation, damage of fan)Drop in heat dissipation efficiencyDefect in cooling circulation system
Rise in oil temperature of power train* Carry out troubleshooting for chassis.
Water temperature gauge
Temperature difference between top and bottom radiator tanks is0
excessive
Temperature difference between top and bottom radiator tanks
1 .; [inspected, the core is found to be clogged
When a function test is carried out on the thermostat, it does not open ( ( ( ( _ ( ( ( ( ( ( I2:
even at the cracking temperature
E0’
When water temperature is measured, it is found to be normal 0
c When oil cooler is inspected directly, it is found to be clogged 0
When measurement is made with radiator cap tester, set pressure is
I I found to be low I I I I I I I 1-1 IWhen compression pressure is measured, it is found to be low 0
Remove oil pan and check directly 0
z .L .b 8 z .= 8 8 ERemedy $ g 0 z $
x“p22SZ_m
ZeaZ$ Caa% $ L+?$-
cc
20- I 59a
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TROUBLESHOOTING S-l 5
S-15 Abnormal noise is madej, Judge if noise is an internal noise or an external noise.General causes why abnormal noise is made
Abnormality due to defective partsAbnormal combustion noiseAir sucked in from intake system
Speed of some cylinders does not change when operating on
20- 1600
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TROUBLESHOOTING S-l 6
S-16 Vibration is excessive
* If there is abnormal noise together with the vibration, carry out troubleshooting for “ Abnormal noise is made” .General causes why vibration is excessive
Defective parts (abnormal wear, breakage)0 Improper &ignn+ent
Abnormal combustion
I outside standard I I I I I I I I IRemove front cover and check directlv
Remove head cover and check directly
/ Injection pump test shows that injection amount is incorrect 0
8 8 g ?j z - .L gRemedy $ $ $ $ $ ‘ $ p z .$
ggg ggaa d 4
20- 161
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TROUBLESHOOTING OFPUMP CONTROLLER SYSTEM
(C MODE)
Points to remember when troubleshooting pump controller system .................Action taken be controller when abnormality occurs and problems on machine ........Judgement table for pump controller and hydraulic related parts ...................Pump controller system circuit diagram ........................................Troubleshooting flow charts for each failure modec- 1c-2
c- 3
Abnormality in pump controller power source system (swing brake is not canceled, etc) . . . . . 20-171
c-4c- 5C-6
c- 7
C- 8c- 9C-l 0C-l 1C-l 2
[E2:32][E2:36][E2:33][E2:37][E2:03][E2:13][E2:02][E2:04][E2:05][E2:06][E2:12][E2:14][E2:15][E2:16][E2:17][E2:18][E2:22][E2:23][E2:24][E2:25]
C-l 3 [E2:26]C-l 4 [E2:27]C-l 5 [E2:28]
. .
. .
. .
. .
. .
. .
. . . 20-I 64 . . 20-I 65
. . 20-169
. . 20-I 70
Short circuit in front pump TVC solenoid system is displayedShort circuit in rear pump TVC solenoid system is displayed .........Disconnection in front pump TVC solenoid system is displayedDisconnection in rear pump TVC solenoid system is displayed .......Short circuit in swing brake solenoid system is displayed ............Disconnection in swing brake solenoid system is displayed ..........Short circuit in LS select solenoid system is displayedShort circuit in pump merge-divider solenoid system is displayedShort circuit in 2-stage relief solenoid system is displayedShort circuit in travel speed solenoid system is displayed ............Disconnection in LS select solenoid system is displayedDisconnection in pump merge-divider solenoid system is displayedDisconnection in 2-stage relief solenoid system is displayedDisconnection in travel speed solenoid system is displayed ..........Model selection input error is displayed ..........................Network response overtime error is displayed .....................Short circuit in LS control EPC solenoid system is displayed ..........Disconnection in LS control EPC soleniod system is displayed ........Abnormality in front pump pressure sensor system is displayedAbnormality in rear pump pressure sensor system is displayed .......Abnormality in pump pressure sensor power source system is displayedAbnormality in engine speed sensor system is displayed ............Abnormality in auto-deceleration output system is displayed .........
. .
. .
. .
.
. .
. .
. .
. .
. . . . . 20-I 80
. ..
. .
.
. .
. .
. . . 20-I 72
. . . 20-I 74
. . . 20-I 76
. . . 20-I 78
. . . 20-I 82
. . . 20-I 84
. . . 20-I 85
. . 20-I 87
. . 20-I 88
. 20-I 90
. . . 20-I 92
. . 20-I 93
. . . 20-I 94
20-I 63
a
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TROUBLESHOOTINGPOINTS TO REMEMNBER WHEN TROUBLE-
SHOOTING PUMP CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itselfIn the following cases, there is a high probability that the same problem will occur again, so it is desirable tofollow uo this oroblem carefully.
1)2)
*
If any abnormality returns to normal by itself,If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and theconnector is returned to its original position when carrying out troubleshooting of the failure, and theservice code is no longer displayed, or if the monitor display returns to normal.After completing troubleshooting, always erase the user code from memory.
2. Service code memory retention functionWhen displaying the service code in memory and carrying out troubleshooting, note down the content of thedisplay, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to theservice code that is displayed.(There are cases where mistaken operation or abnormalities that occur when the connector is disconnectedare recorded by the memory retention function. Erasing the data in this way saves any wasted work.)
20-I 64
a
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User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action b y controller when abnor mality is detected Problem hat appears on machine when there is abnormality
1. Short circuit inside sole noid or betweensolenoid ( ‘I) and (2) (when internal resistance of
1. With swi ng + boom RAISE, the boo m is slow.
- E2:02 Short circuit in LS select solenoid i s extremely low), and excess current Resistance of solenoid: 20 - 60 RMakes power to solenoid 0 2. With s wing + arm OUT, the ar m OUT i s slow.
solenoid system is flowing.Resets power source to restore 3. With swing + travel, there is a big drop in the
2. Abnormality in pump controllertravel speed.
1. Short circuit inside solenoid or between The pump merge-divi der valve continues toShort circuit in pump solenoid ( I ) and (2) (when internal resistance of
E2:04 merge-divider solenoid Solenoid is extremely low), and excess current Makes power to solenoid 0merge the oil flow.
- Resistance of solenoid: 20 - 60 R 1. In the L/O and S/O modes, the work equipment
system is flowing. Resets power source to restore
2. Abnormality in pump controllerand swing speeds become faster .
2. The steering is difficult to turn.
1. Short circui t inside solenoid or between
Short circuit in 2-stagesolenoid (I) and (2) (when internal resistance of When traveling or using the power max. function,
- E2:05 solenoid is extremely low), and excess CUrrefIt Resistance Of Solenoid: 20 - 60 fi Makes power to solenoid 0relief solenoid system the relief pressur e is not raised, so there is lack of
is flowing. Resets power source to restore
2. Abnormality in pump controllerpower.
1. Short circui t inside solenoid or between
Short circuit in travelsolenoid (I ) and (2) (when internal resistance of
E2:06 solenoid i s extremely low), and excess current Resistance of solenoid: 20 - 60 R Makes power to solenoid 0 Even if the travel speed is switched, the travelspeed solenoid system
is flowing.Resets power source to restore speed does not change (remains at Lo)
2. Abnormality in pump controller
1. In the case of 1 and 2, the current stops flowingto the solenoid, so no particular action is taken.Therefore, if the abnormality is restored by thevibration of the machine, the condition wil lreturn to normal.*However, the display does not go out.
2. In the case of 3, the current continues to flow tothe solenoid, bu t the controller takes noparticular action.
1. Short circuit inside solenoid (when inter nal Therefore, if the abnormality is restored by the 1. In the case of 1 and 2, it is the same as E2:02.
resistance of solenoid is extremely high) vibration of the machine, the condition wil l 2. In the case of 3, when the boom/swing priority
E2:12 Disconnecti on in LS2. Disconnection in wiring har ness between
return to normal. selection mode is OFF and the travel is OFF, amselect solenoid system Resistance of solenoid: 20 - 60 R
solenoid (2) and controller*However, the display does not go o.ut. there is combined operation with the swing
3. Solenoid 12) short circuiting with ground*If the controller gives a signal to turn the (except for boom RAISE an d arm OUT),
4. Abnormality in pump controllersolenoid current OFF, the voltage at portion(a) should be 20 - 30V. If there is a
pressure compensation cannot be carried outfor the swing LS pressure.
disconnectio n or short circuit with the ground,the voltage at portion (a) is low (almost OV),so it is judged that there is an abnormality.
I
E-2 IL
- ,,,PFuse
Pump r24”controller
Solenoid +--A
205FO6365
1. Short circuit inside solenoid (when inter nal 1. In the case o f 1 and 2, the current stops flowing
Disconnecti on in pump resistance of solenoid i s extremely high) to the solenoid, so no particular action i s taken.1. In the case of 1 and 2, it is the same as E2:04.
E2:14 merge -divider solenoid 2. Disconnection in Wiring harness betweenTherefore, if the abnormality is restored by
- Resistance of solenoid: 20 - 60 Q 2. In the case of 3, the pump merge-di vider valvesolenoid (2) and controller
the vibration of the machine, the condition willsystem remains divided, so the arm and boom are
3. Solenoid (2) short circuiting with groundreturn to normal.*However, the display does not go out. slow.
4. Abnormality in pump controller 2. In the case of 3, the current continues to flow tothe solenoid, but the controller t akes no
particular action.Therefore, if the abnormality is restored by thevibratio n of the machine, the condition willreturn to normal.*However, the display does not go out.
1. Short circuit inside solenoid (when inter nal *If the controller gives a signal to turn the 1. In the case of 1 and 2, it is the same as E2:05.resistance of solenoid is extremely high)
Disconnecti on in 2-stage 2. Disconnection in wiring harn ess betweensolenoid current OFF, the voltage at portion 2. In the case of 3, it becomes the same condition
E2:15 Resistance of solenoid: 20 - 60 R (a) should be 20 - 30V. If there is a as when the 2-stage relief is used, so the reliefrelief solenoid system solenoid (2) and controller disconnecti on or short circuit with the ground, pressure remains increased
3. Solenoid (2) short circuiting with ground the voltage at portion (a) is low (almost OV), (34.8MPa(355kg/cmz)).
4. Abnormality in pump controller so it is judged that there is an abnormality. (The solenoid stays ON)
20-166a
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FOLD
Jser code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machinewhen there s abnormality
1. In the case o f 1 and 2, the current stops flowingto the solenoid, so no particular action is taken.Therefore, if the abnormality is restored by thevibration of the machine, the condition willreturn to normal.*However, the display does not go out.
2. In the case of 3, the current continues to flow tothe solenoid, but the controller takes no
1. Short circuit inside solenoid (when internalparticular action.Therefore, if the abnormality is restored by the
E2:16 Disconnection in travel resistance of solenoid is extremely high) vibration of the machine, the condition will 1. In the case of 1 or 2, it is the same as the E2:06speed solenoid system 2. Disconnection in wiring harness between Resistance of solenoid: 20 - 60 R return to normal. 2. In the case of 3, the solenoid remains actuated,
solenoid (2) and controller *However, the display does not go out. so the Lo speed is fast.
,3. Solenoid (2) short circuiting with ground *If the controller gives a signal to turn the
4. Abnormality in pump controllersolenoid current OFF, the voltage at portion (a)should be 20 - 30V. If there is a disconnectionor short circuit with the ground, the voltage atportion (a) is low (almost OV), so it is judgedthat there is an abnormality.
PumpcOntrOller
Solenoid205FO6365
E2:17
1. PC210Between CO3 (15) and chassis: M ax. 1 R
Model selection input 1. Disconnection, short circuit in model selection Between CO3 (13), (14), (16) and chassis: Detects abnormality in input1) Retains data when starting switch is ON 1. Travel deviation
error wiring harness Min. 1 MQ2. Abnormality in controller 2. PC240
2) Functions as PC100 when non-set conditions 2. Engine stalls
Between CO3 (13), (15) and chassis: Max. 1 R are input
Between CO3 (14), (16) and chassis: Min. 1 MR
1. When networki ng are impossible with themonitor panel and engine throttle controller(1) Working mode: G/O 1. I) Even when travel is operated, the power(2) Priority mode: OFF does not increase
1. Disconnection, short circuit, short circuit with (3) Travel speed: Lo (2) The swift slow-down function does not work
E2:18 Network response ground in network wiring harness (4) Auto-deceler ation: ON (3) The auto-deceleration cannot be canceled-
overtime error 2. Abnormality in engine throttle controller (5) Power max. : ON (4) The travel speed does not increase
3. Abnormality in pump controller (6) Automatic mode: OFF (HYPER GX) (5) The priority mode has no effect
2. When networki ng are impossible with engine (6) The automatic mode has no effect
throttle controller (HYPER GX)
Control is carried out by recognizing the throttle 2. The engine speed may dropsignal as FULL (others are as usual)
Short circuit in LS1. Short circuit inside solenoid or between
solenoid (1) and (2) (when internal resistance of1. The Lo travel speed is too fast.
- E2:22 control EPC solenoidsystem solenoid is extremely low), and excess current
Resistance of solenoid: 7 - 14 Q Makes power to solenoid 0 2. In L/O and F/O modes, the work equip ment
is flowing. Resets power source to restore speed is too fast.
2. Abnormality in pump controller3. When the engine is running at low idling, the
swing speed is too fast.
1. Disconnection inside solenoid or disconnection1. In the case of 1, the current stops flowing to the
in wiring harness between controller CO1 (15),solenoid, so no particular action is taken.
Disconnect ion in LS (7) and LS control EPC solenoidTherefore, if the abnormality is restored by the 1. In the case of 1, it is the same as E2:22
- E2:23 control EPC solenoid 2. Wiring harness between controller CO1 (7) andCurrent: Approx. 800 mA vibration of the machine, the condition will 2. In the case of 2, electric current continues to
LS control EPC solenoid Cl0 (2) short circuiting(Levers at neutral, low idling) return to normal. flow to the LS control EPC solenoid, so the worl
systemwith ground
*However, the display does not go out. equipment, travel, and swing speeds are slow
3. Abnormality in pump controller2. In the case of 2, the current continues to flow to
the solenoid.
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User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machine when there is abnor
bnormality in front 1. Abnormality in front pump pressure sensor 1. Between CO3 (I) and (9): 0.5 - 4.5 V-
E2:24 pump pressure sensor 2. Disconnection, short circuit in wiring harness 2. Resistance between CO3 (female) (1) and (9), (I) Takes front p ump pres sure as 0 MPa (0 kg/cm’) 1. The travel speed does not automatically shift (ii
system between CO8 and CO3 and chassis : Min. 1 MR when actuating. does not change fr om Hi to Lo).
3. Abnormality in pump controller (Disconnect pressure sensor connector CO8 andIf abnormality is restored, it actuates as normal. *If the button is operated manually, the panel
connector at CO31*However, the display does not go out. display is switched.
Abnormality in rear 1. Abnormality in rear pump pressure sens or1. Between CO3 (2) and (IO): 0.5 - 4.5 V
Takes r ear pump pressure as 0 MPa (0 kg/cm’)- E2:25 pump pressure sensor 2. Disconnection, short circuit in wiring harness
2. Resistance between CO3 (female) (2) and (IO), 1. The travel speed does not automatically shift (it
system between CO7 and CO3(2) and chassis : Min. 1 MR when actuating. does not change fro m Hi to Lo).(Disconnect pressure sensor connector CO7 and If abnormality is restored, it actuates as normal.
3. Abnormality in pump controller connector at CO3) *However, the display does not go out.*If the button is operated manually, the panel
display is switched.
Takes front pump and rear pump pressure as
Abnormality in pressure 1. Defective pressure sensor0 MPa (0 kg/cm’) when actua ting.
1. Voltage between CO3 (3) and (9) and between When abnormality is detected, it switches the1. The travel speed does not automatically shift
- E2:26 sensor power source 2. Wiring har ness between press ure sensor (2) (it does not change from Hi to Lo).
system and controller short circuiting with groundCO3 (3) and (10): 18 - 28 V output OFF, and when all levers are returned to
neutral, it outputs again.*if the button is operated manually, the panel
*This automatic resetting is repeated up to 3display is switched.
times.
E2:27
1. Disconnection, short circuit in speed sensor1. It functions as the equivalent of the G/O mode
Abnormality in engine 2. Disconnection, short circuit in wiring harness(the speed rises)
Resistance: 500 - 7000 0speed sensor system between E7 and CO2 Voltage (AC range) : 0.5 - 3.0 V
*However, the display does not go out. It operates about the same as G/O mode (prol ix)
3. Abnormality in pump contro ler2. When the sensor is lost, such as when ther e i s a (the power is slightly lower)
disconnection inside the speed sensor,monitoring code 10 is not displayed. -
E2:28Abnormality in auto-deceleration outputsystem
1. Disconnection, short circuit in wiring harness 1. Voltage between CO3 (5) and chassis
of CO3 (5) and EOI (4).At deceleration: 8 - 12 V When t here is a short circuit, it stops the output,When canceled: 0 - 1 V
It is controlled as usual
2. Abnormality in engine throttle controllerand restores by resetting the power. (there may be a delay i n response)
3. Abnormality in pump controller2. Resistance between CO3 (5) and chassis
:When there is a disconnection, it continues to
Min 1 MQ move as it is.
20-1680
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MP CONTROLLER SYSTEM CIRCUIT DIAGRAM
Al
Fusible link
Puma controller__--___
I’I IIIII I I III IIIII I I I
II .,,I -I I
IiiI
I
-11I
I
iEO1L _ I
Enqine throttle ContrOller
Model selection connector
Travel 2-stage Swinq Pumb merqe- LSspeed relief brake divider select I.. H. knob
SWtch Rear Front i_S control TVC TVCSolenoid Valve DuniQ DumD E P C valve YIIlYP “RI”0
oressure Dressuresensor sensor
.I.._ ._..”
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TROUBLESHOOTING C-l
C-l Abnormality in pump controller power source system (swingbrake is not canceled, etc.)
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
j, Check that fuses 1 and 14 are not blown.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.j, Always connect any disconnected connectors before going on to the next step.j, When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l 1.)
YES1 Defective pump controller Replace
Is voltage betweenCO1 (10) (11) and -(1) (2) normal? 2yEs
-.20-30V
Is voltage between
- Turn starting- fuse 1and GND -
switch ON.NO normal?
Defective contact: or dis-connection in wmng harnessbetween fuse 1 and CO1(female) (lO)(ll)
Defective contact, or dis-connection in wtnng harness
Repair orreplace
.20-30V NObetween fuse 1 HO6 (2) -
- 2i.n starting switchMl4 (2)(l) - battery relayterminal M
Repair orreplace
C-l Related electric circuit diagram
Pump controller
CO 1 (MlC21)I \ I
Ml4 (L2)
XOY’ (MIC17)
Startingswitch
20- 171
0
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TROUBLESHOOTING c-2
C-2 [E2:32] Short circuit in front pump TVC solenoid system isdisplayed[E2:36] Short circuit in rear pump TVC solenoid system isdisplayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:32or E2:36 are displayed. (If they are not displayed, the problem has been removed.)
* Always turn the TVC prolix switch OFF.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.Jr Always connect any disconnected connectors before going on to the next step.
3 YES
Is resistanceYES between each pin
2 - fortroubleshooting -3 in the table 1Is resistance normal?
ym between each pinr for troubleshooting _ Turn starting switch NO
1 2 in the table 1 OFF.- normal? - Disconnect COl.
Interchange wiringwith other TVCsolenoid. Is
* (Ju;F: tarting switch
applicable service Disconnect CO4 orNO
code displayed? C13, whichever is
Go toA
Cause
Iefective pump controller
* Interchange wiring.applicable.
. Turn starting switch Applicable TVC solenoid isON again. NO defective
A-b
Applicable one of wiring har-ness between CO1 female) (8)
5 YES and CO5 female) (2) (F pump. TX), or wiring harness
Is resistance between CO1 female) (4) andYES between each pin CO5 female) (7) (R pump TVC)4 r fortroubleshooting - in contact with power
5 in the table 1 source wiring harness
Is resistance normal?L Defective TVC prolix switch,etween each pin
I for troubleshooting - -Turn starting switch NO4 in the table 1 OFF.
or applicable one of wiring
normal? - Disconnect CO5harness between NC prolixswitch - CO5 male) (2) (F
T~II starting switch pump TVC solenoid) or CO5
Disconnect C05.NO
(male) (71 R pump TVCsolenoid) in contact withpower source wiringharness
Applicable one of wiringharness between Cl3(female) (2) and CO5 female)(4) tF pump WC solenoid),or wiring harness betweenCO4 female) (2) and CO5(female) (9) (R pump TVCsolenoid) in contact withpower source wiring harness
Remedy
leplace
leplace
lepair oreplace
lepair oreplace
lepair oreplace
20- 172
a
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TROUBLESHOOTING c-2
Service code
Service code Troubleshooting 2
Between Cl3 (male) (1) and
(2)
Measurement location
Troubleshooting 3
Between CO1 (female) (16) and(8)
Troubleshooting 4
Between CO5 (female) (3) and(4)
Resistancevalue
IO-22n
CL. 3L
Between Cl 3 (male) (2) and Between CO1 (female) (8) andchassis chassis
Between CO4 (male) (1) and Between CO1 (female) (17) and(2) (9)
Between CO5 (female) (4) andchassis
Between CO5 (female) (8) and
(9)
Min. 1 MO
IO-22n
CL. 30
Between CO4 (male) (2) andchassis
Between CO1 (female) (9) andchassis
Between CO5 (female) (9) andchassis Min. 1 MO
\Troubleshooting 5: Between CO5 (male) (1) - (3) (2) - (4) (6) - (8) (7) - (9)
IMax. 10 I
I I I
C-2 Related electric circuit diagram
co4
TVC prolix switch
1Prolix resistor
II I II II I I I 1 1
(X2) -
Rear ump c- a
Tvc valve _ G-
X08DD143
20-I 73
0
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TROUBLESHOOTING c-3
C-3 [E2:33] Disconnection in front pump TVC solenoid system isdisplayed[E2:37] Disconnection in rear pump TVC solenoid system isdisplayed
*
*
*
****
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flowto the solenoid.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:33or E2:37 are displayed. (If they are not displayed, the problem has been removed.)Always turn the TVC prolix switch OFF.Before carrying out troubleshooting, check that all the related connectors are properly insertedAlways connect any disconnected connectors before going on to the next step.Check that fuse 1 is normal.
3 YESIs esistance
YES between each pin2 - for troubleshooting -
3 in the table 1Is resistance ’ normal?
YES between each pinP for troubleshooting - T” rn starting
NO-GotoA
1 2 n the table 1 switch OFF.
P normal? * Disconnect CO1interchange wiringwith other NC -Turn startingsolenoid. Is - switch OFF.applicable service Disconnect CO4 or
NOcode displayed? C13, whichever is
applicable.* Turn starting
switch OFF. V* Interchange wiring. NO
*Turn startingswitch ON again.
Y:
A,--p\* Turn starting
switch OFF.*Disconnect 05.
between each pinfor troubleshooting5 in the table 1
Turn startingswitch OFF.
*Disconnect Cg5.r10
IO
Iefective pump controller
4pplicable NC solenoid is defective
disconnection in applicable one of
wiring harness between CO1female) (16) and CO6 (female) (1).301 (female) 16) and CO5 Ifemale (2:F pump NC) or wiring harnesswween CO1 (female) 117) and CO5Ifemale) 16). CO1 Ifemale) (91 andt05 (female) ( 7) (R pump NC). ordisconnection in applicable one ofwiring harness between CO1Ifemale) (3) and CO5 (female) (2) (Fpump). or CO1 (female) (9)and CO5 (female) 17) (R pump)
Defective prolix switch, ordisconnection in applicable one ofwiring harness between NC prolixswitch - CO5 (female). ordisconnection in applicable one ofwiring harness between CO5(female) (2) -NC prolix switch (Fpump) or CO5 (female) (7) -NCprolix switch (Fi pump)
Disconnection in applicable one ofwiring harness between Cl3(female) (1) and CO5 (female) 13).Cl3 (female) (2) - CO5 (female) (21 (pump NC solenoid), ordisconnection in applicable one ofwiring harness between Cl3(female) 12) and CO5 (female) 14) (Fpump solenoidl. or disconnection iapplicable one of wiring harnessbehween CO4 (female) (2) and CO5(female) (9) (R pumpNC solenoid)or applicable one of wiring harriesbehveen Cl3 (female) (2) and CO5(female) I41 IF pump solenoid1wiring harness between CO4(female) (2) and CO5 (female) 19) (Rpump NC solenoid) shortcircuiting with ground
?place
eplace
epair orrplace
lepair oreplace
iepair oreplace
20-I 74
a
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‘ able 1
Service code Measurement location Resistance
Service code Troubleshooting 2 Troubleshooting 3 Troubleshooting 4value
Between Cl 3 (male) (1) and Between CO1 (female) (16) and Between CO5 (female) (3) and
(2) (8) (4)IO-220
E2:33Between Cl 3 (male) (2) and Between CO1 (female) (8) and Between CO5 (female) (4) andchassis chassis chassis
Min. 1 ML?
E2 : 37
Between CO4 (male) (1) and
(2)
Between CO4 (male) (2) andchassis
Between CO1 (female) (17) and
(9)
Between CO1 (female) (9) andchassis
Between CO5 (female) (8) and(9)
Between CO5 (female) (9) andchassis
IO-220
Min. 1 MQ
Troubleshooting 5: Between CO5 (male) (1) - (3) (2) - (4) (6) - (8) (7) - (9) I Max. In
C-3 Related electric circuit diagram
TVC prolix switch
i j ’I Illrrllrl Prolix resistor
0 c c c cF R F I?
1-J (-) (t) f+)
co1
(MICl'?)
X08DD143
20- 175
a
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TROUBLESHOOTING C-4
C-4 [E2:03] Short circuit in swing brake solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing, and checkif E2:03 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
3
_ __. _- .__etwen ~04 ~rna~e\I - Turn startina
111 I .TUTurn star+- SW
solenoid. Is E2:03swi+ak nr
*Dis..,,,,,,
switch OFF.-
1 1z&% in’ T%le l? 1 1 *Disconnect Ol.rn swing lockIitch OFF.,,I ,y
.c, , GF.“ ^“ -ct vo4.
NO
YES
cOGo to A
. Turn startingswitch OFF.
- Interchange wiring. NOTurn startingswitch ON again.
5 YES
A--
Is resistance
Is resistance betweenye X05 (female) (4) and
4- chassis, and between -
V04 (male) (2) andchassis normal?
between X05 _ . Turn starting NO(male) (4) and (3) switch OFF.normal? Disconnect X05 and V04.
* Resistance value: Min. 1 MR*Turn starting I
switch OFF.- Disconnect X05.
NO* Between (4) and
(3): Max. 1 R
V04 (male) CO1 (female) Resistance valueI I
Between (1) and (2) Between (IO) (11)and (13)
20-60C
Cause
lefective pump controller
refective swing brakeolenoid
:ontact of power sourcetiring harness with wi ringarness between X05female) (3) and CO1 female:13)
:ontact of power sourcefiring harness with wiringlarness between X05femaleh4) and V04fmale) (2
Defective swing lock switch
Contact of power sourcewiring harness with wiringharness between X05(male) (4) -swing lockswitch -X05 (male) (3)
;eplace
lepair oreplace
lepair oreplace
leplace
lepair oreplace
Between (2) and Between (13) andchassis chassis
Min. 1 MC
20- 176
a
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TROUBLESHOOTING C-4
C-4 Related electric circuit diagram
Pump controller
Cl
Swing lock prolix switch Swing lock switch
GND
*v4
Swing brake H4
Fuse X08DD144
20-I 77
0
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TROUBLESHOOTING c-5
C-5 Related electric circuit diagram
Pump controller
ClI I
Swing lock prolix switch Swing lock switch
Swing brakesolenoid valve
Hl
I H4
1
Fuse X08DD145
20- I 79a
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TROUBLESHOOTING C-6
C-6 [E2:02] Short circuit in LS select solenoid system is displayed[E2:04] Short circuit in pump merge-divider solenoid system isdisplayed[E2:05] Short circuit in 2-stage relief solenoid system is displayed[E2:06] Short circuit in travel speed solenoid system is displayed
*
*
**
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if anyservice code is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
3 YES
Is resistanceYE between each pin2 - fortroubleshooting -_ 3 in the table 1
Is resistance normal?YES between each pin
for troubleshooting - * Turn starting NO
1 2 in the table 1 switch OFF.normal? *Disconnect COI.
‘ 1Interchange wiringwith other solenoid.Is applicable service
*Turn startingswitch OFF.
*Interchangewiring.
* Turn startingswitch ON again.
.Turn startingswitch OFF.
- Disconnectconnector V02, VO3, V05,or V06, whichever ISapplicable.
NO
Table 1
Cause
Defective pump controller
Contact between wi ringharness for power sourceand applicable wiringharness between solenoid(2) and controller.
One of following solenoids isdefectiveE2:02 . LS select solenoidE2:04 . .Pump merge-divider
solenoidE2:05 . 2-staoe relief
solenoidE2:06 . Travel speed
Service codeTroubleshooting 2
Measurement location
Troubleshooting 3
E2 : 02Between V02 Between CO1 (female) (IO), (11) and (3) 20 - 60 0
(male) (1) and (2)20-60Q
Between CO1 (female) (3) and chassis Min. 1 MQ
E2 : 04Between V03 20-60 J
Between CO1 (female) (IO), (1 I), and (4) 20 - 60 0
(male) (1) and (2) Between CO1 (female) (4) and chassis Min. 1 M J
E2 : 05Between V05 20-600 Between CO1 (female) (IO), (11) and (14) 20 - 60 0
(male) (1) and (2)Between CO1 (female) (14) and chassis Min. 1 MCI
E2 : 06Between V06 20-60fI
Between CO1 (female) (IO), (11) and (6) 20-60L2
(male) (1) and (2)Between CO1 (female) (6) and chassis Min. 1 MfI
lepair oreplace
lepair oreplace
teplace
20- 180
a
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TROUBLESHOOTING C-6
C-6 Related electric circuit diagram
Pump co1controller MIC17)
LS select
Pumpnerge-divider
rravel speed
VB
VB
Z-stage relief
I-El -HO2
,s
@\
-LS select
1
Travel speedsolenoid valve
Fuset- 1
’O4(SlS)
II
VO6(X2)
X08DD146
20- 1810
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TROUBLESHOOTING c-7
C-7 [E2:12] Disconnection in[E2:14] Disconnection indisplayed[E2:15] Disconnection indisplayed[E2:16] Disconnection indisplayed
LS select solenoid system is displayedpump merge-divider solenoid system is
2-stage relief solenoid system is
travel speed solenoid system is
*
*
*
***
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actuated.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, operate accordingto Condition 2 in Table 1, and check if any service code is displayed. (If it is not displayed, the problem hasbeen removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Check that fuse 1 is normal.
3Isvoltage between
ya each pin for2 - troubleshooting 3 F GotoA
in the table 1Is resistance normal?
YJZJ between each pin- for troubleshooting - Turn starting
1 2 in the table 1 switch ON.- normal? . When ON: Max. 3V
When OFF: 20 - 30VInterchange wir ingwith other solenoid.
. Turn starting Operate according to Condition 1.
Is applicable service - switch OFF. NOcode displayed? Disconnect
connector VO2,.VO3, VO5,or V06, whichever is
-Turn startingswitch OFF.
applicable. t* Interchange wi ring. NO-Turn starting
switch ON again.- Operate according
to Condition 2. 5 YES
Is applicable
Is resistance Turn starting NObetween each pin switch ON.
- for troubleshooting -4 in the table 1
. Operate
NO normal?according toCondition 2. )
*Turn starting NO
switch OFF.* Disconnect COl.
Cause
kre of following solenoids islefectivei2:12 . LS select solenoidL2:14 Pump merge-divider
solenoidi2:15 . . 2-stage relief
solenoidi2:16 . Travel speed
solenoid
Iefective pump controller
Disconnection in applicablewiring harness between CO1female) (101, 11) - CO1 31,4), (14) or (6). or applicablewiring harness betweensolenoid (2) - CO1 3). (4).14) or (6) shortcircuitingnrith ground
ieplace
leplace
tepair oreplace
20- 182
0
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TROUBLESHOOTING c-7
able 1
1easurment location
jetvicecode Troubleshooting 2
Troubleshooting 3 Condition 2
Voltage between eachI
Troubleshooting 4 Ipin Condition 1 I
Betweeni2:12 V02 (male)
(1) and (2)
When ON: same as
20 - 60 n Between CO1 (female)(3) and chassis lever slightly to RAISE position
chassis * (Note)
Betweeni2:14 V03 (male)
(1) and (2)20-60f2 Between CO1 (famale)
(4) and chassisWhen OFF: Whencontrol levers are atneutral in modeother than L/O
Set working mode switch toL/O mode
Betweeni2:15 V05 (male)
(1) and (2)20-60f2 Between CO1 (female)
(14) and chassis
When ON: same as (femate) (lo),
~~ Turn wingockwitchN
1Between CO1 I~ I
Betweeni2:16 VO6 (male)
(1) and (2)20 - 60 0
When ON: same asBetween CO1 (female)(6) and chassis
chassis
lote: When the accumulator is charged, it is pos si ble to carry out the same operation with the starting switch ON.
C-7 Related electric circuit diagram
Pump CO1controller (MICl?)
LS select
Pumpmerge-divider
Travel speed
VB
VB
- LS select
solenoid
03(X2)
Z-stage relief
‘ 05(X2)
FuseHO4
(S16)
A07 X08DD146
20- 183
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TROUBLESHOOTING C-8
C-8 [E2:17] Model selection input error is displayed* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:17is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted* Always connect any disconnected connectors before going on to the next step.
YES1
Is monitoringmode display ofpump controller as -shown in Table l? 2 YES
_ Is esistance* Turn starting between CO2
switch ON. - (female) U3), (14). -*Set to monitoring NO (15). (16) -GND as
code 02,22. shown in Table 2?
A
* Turn starting NOswitch OFF.* Disconnect C02.
Table 1 Monitoring display (Time display portion)1 I
.:ONO:OFF
I
Condition of engineI
Engine throttlethrottle controller input controller model code I
C-8 Related electric circuit diagram
Cause
Defective pump controller
Defective model selectionconnector, or disconnection,short circuit with ground, or
short circuit in applicablewiring harness
Remedy
Replace
Repair orreplace
Table 2 Resistance value
Applicable wiringharness
Between CO2 (female)(13) and GND
Between CO2 (female)(14) and GND
Between CO2 (female)(15) and GND
Between CO2 (female)(16) and GND
PC200 PC220PC210 PC250
Min. 1 MQ Max. 1 0
Min. 1 MQ Min. 1 MD
Max. 1 D Max. 1 0
Min. 1 MD Min. 1 MD
CO2( 040-20.) CO9(S8)z:LE8E”2
PC220
X08DD147
20- 184
0
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C-9 [E2:18] Network response overtime error is displayedj, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitorpanel and the controller, or the positive end (+) of the network wiring harness or the inside of the controllerare short circuited, the controller cannot carry out networking, so the monitor panel does not display anyabnormality.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
When E2:18 is displayed independently
YES
Y
1
Disconnectconnector C03, thenconnect it again. -Does service codedisplay go out?
2*Turn startingswitch OFF. Is connection of
* Disconnect engine throttle;,“ ;c;;or, then NO cCJsT;;:;;?
connector again.Turn startingswitch ON.
*Turn startingswitch ON.
- Sz;~o;OnitoringN controller light up
- Turn startingswitch ON.
When E2:18 and E3:Ol are displayed simultaneously
1Disconnectconnector PO2 thenconnect it agam. -Does service codedisplay go out?
YES2
*Turn starting Is there continuity
switch OFF. _ between PO2Disconnect NO 3 YESconnector, then
pNn$;e) (7). (8) and
connectConnect connectors
- removed in Item 2connector again.
* Turn startingTurn startingswitch OFF.
_ one at a time. Is there
switch ON and Disconnect P02,NO continuity betwean
PO2 female) (71, 81delete service C03, and EOl. and GND?code. Shake wiring
harness aroundTurn starting NO
controller whenswitch OFF.
checking for*Shake wiring harness around controller
continuity.when checking for continuity.Connect PO2 last.
Cause
Defective contact or matingof pump controller connect0co3
Defective pump controller Replace
Defective engine throttlecontroller
Defective contact, ordisconnection in networkwiring harness
See E-l
Cause
Defective contact or matingof monitor panel connector
Positive (+) end of networkwiring harness in contactwith ground
Controller which has beenconnected is defective
Iefective monitor panel
Repair orreplace
Replace
Repair orreplace
-
Remedy
Repair orreplace
Repair orreplace
qeplace
?elace
20- 1850
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TROUBLESHOOTING c-9
Monitoring display (Time display portion)
n e ooau ‘ “oom
%
P
C;L) “ pump controbr connected”dwlay
Em “Engine throttle controller‘ - cu connected” display28
f
X08DD132
E-5 Related electric circuit diagram
X08DD133
Check for the LED display for the engine throttlecontroller and pump controller from the direction
Engine throttle controller\/-C
of the arrow as shown in the diagram on the right.Note 1: Push the operator’ s seat down to the front,
then remove the two rear covers to check.Note 2: The LED display for the pump controller is
difficult to see, so use a mirror.
X08DD134
20- 186
0
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TROUBLESHOOTING
C-IO [E2:22] Short circuit in LS control EPC solenoid system is
C-l 0
*
*
**
displayedThis troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E222is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
2 YES,Is resistance
YES between CO1
1- (female) (15) - (7). -
_ (7) -chassis asIs resistance shown in Table l?between Cl0(male) (1) - (2). (2)
Turn starting NO--chassis s shown
switch OFF.
I in Table l? I- . __.Disconnect COl.
Turn startingswitch OFF.
- Disconnect ClO.
Table 1
NO
Cl 0 (male) CO1 (female)
Between (1) and (2) Between (15) and (7)
Resistance value
7-140
Between (2) andchassis
Between (7) andchassis I
Min. 1 MfII
Cause
Defective controller
Contact of power sourcewiring harness with wiringharness between CO1;;rnale) (7) and Cl0 (female)
Defective LS control EPCsolenoid
C-IO Related electric circuit diagram
Pump controller
LS controlEPC valve
X08DD148
leplace
lepair oreplace
leplace
20-I 87
0
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TROUBLESHOOTING C-l 1
C-II [E2:23] Disconnection in LS control EPC solenoid system isdisplayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:23is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
2 YES Defective controller ReplaceIs resistance_ II
YES between CO1
1- (female) (15) - (7), -
(7) -chassis asDisconnection in wiring
I- shown in Table l?harness between CO1
Is resistance(female) (15) and (7). or Repair or
between Cl0 _ Turn starting NO wirin g harness between CO1 replace
(male) (1) - (2) as switch OFF.(female) (7) and Cl0 jfemal e)
shown in Table l? Disconnect COl. ;Jo;Fdti circuiting with
ReplaceI’
. Turn starting Defective LS control EPCswitch OFF.
. Disconnect ClO.NO solenoid
Table 1
Cl 0 (male) CO1 (female) Resistance value
I Between (1) and (2) I Between (15) and (7) I 7-1421 I
C-l 1 Related electric circuit diagram
Pump controller
LS controlEPC valve
X08DD148
CO1 (ME211
LS-EPC +)
20- 188
0
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TROUBLESHOOTING C-l 2
C-12 [E2:24] Abnormality in front pump pressure sensor system isdisplayed[E2:25] Abnormality in rear pump pressure sensor system isdisplayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, start the engine,and check if any service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
Remedyause
3 YES
ml-
Turn startingswitch OFF.
. Disconnect C03.
I
NO
Defective pump controller Replace
Disconnection in wiringharness between CO3(female) (l)- HO1 11) - CO8
(female) (3) (Front), betweenCO3 female) (2) - HO1 13) -CO7 female) (3) (Rear), orshort circuit with ground
Repair orreplace
Applicable pressure sensoris defective
Replace
n
* Run engine at high
switch ON.
1 nterchange wiring*Repeat arm relief. p
Defective pump controller
Disconnection in wiringharness between CO3(female) (3) (9) - HO1 14)(12) -CO8 ( female) (2) (1)(Front), CO3 female) (3) (10)- HO1 (14) (15) - CO7 female)(2) (l), or short circuit withground
Replacewith other pressure
cable service code
* Interchange
Turn startingswitch ON again.
. Run engine at
Repair orreplaceTurn starting
switch OFF.* ;go;;a co3,
NO
1p’ plicable pressure sensor
is defectiveReplaceNO
Table 1 I I
ServiceMeasurement location
code Troubleshootina 2 1 roubleshooting 3 1 roubleshooting 4 Troubleshooting 5
Between CO8(2) and (1)
Between CO3 (female)
Between CO3 (female)Min. 1 MC
I etween CO3 (female)(1) and (9)Between CO8
(3) and (1) Ietween CO3 (female)(I), (9) and chassis
Min. 1 MfI 18-28”
Between CO7(2) and (1)
(3). (10) and chassis’2), (10) and chassis
20- I 900
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TROUBLESHOOTING C-l 2
C-l 2 Related electric circuit diagramPump controller
(RI pressuresensor (4
24vtt
(F) pressuresensor
If% pressuresensor
l(S16) CO8tX3)
F pump pressuresensor
X08DD149
20- 191
a
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TROUBLESHOOTING C-l 3
C-13 [E2:26] Abnormality in pump pressure sensor power sourcesystem is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:26is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
1
* 18-28V
- Turn startingswitch ON. NC
I Cause
Defective rear pump Replace
.-IL
I
I
1
Isvoltage between I 1 I
Replace
1O3 (3) and (9)normal?tl d -1 Defective pump controller
*18-28V-N/#ii~~ H 1Turn startingswitch ON.
*Min. 1 MR*Turn starting
switch OFF.-* Digxyg;ct co3,
C-l 3 Related electrical circuit diagramPump controller
CO3 040-16) HOl S16) CO8 X3)
F pump pressuresensor
R pump pressuresensor
Remedy
Replace
Repair orreplice
X08DD149
20- 192
a
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TROUBLESHOOTING c-14
C-14 [E2:27] Abnormality in engine speed sensor system is displayed* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:26is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES
Is resistanceYES between CO31 (female) (6) - (14)
- normal?Is resistancebetween E07 _ *500- 1OOOR NO(male) (1) - (2)normal?
*Turn startingswitch OFF.
. nicmnnc.r+-n700- 1OOOR I
* Turn startingswitch OFF. NO
- Disconnect E07.
C-14 Related electric circuit diagram
Monitor panel
Defective pump controller Replace
Disconnection in wiringharness between CO3 Repair or(female) (6). (14) -E07 (1). (2) replaceor short circuit with ground
Defective engine speedsensor
Replace
Pump controller I ICO3(04016)
Speed sensorI-1
Speed sensor(+I
H03(S16) E08ISWP14) E07 (X2)
,@ Enginespeed
*@ sensor
X08DD150
20- I 93
0
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TROUBLESHOOTING C-l 5
C-15 [E2:28] Abnormality in auto-deceleration output system isdisplayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When the auto-deceleration switch is ON.If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the control lever(neutral ++ operated) with the auto-deceleration ON, and check if E2:28 is displayed. (If it is not displayed,the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
CO3 5) and chassisas shown in Table
*Turn startingswitch ON.
N
When CO3 s~ isconnected, isvoltage between -EOl (4) and (12) 3 YESnormal? Is resistance etween P Defective engine throttle
P CO3 (female) (5) and controller*8-12V ~ EOl (female) (41, and _- Turn starting
switch ON.NO between CO3 (female)
(5) and chassis as Disconnection in wiringshown in Table Z? harness between CO3
NO(female) (5) and 501 ffemale)t$oo;hort crrcurt wrthTurn starting
switch OFF.Disconnect CO3and EOI.
Cause
t--ES
I7 Defective pump controller ieplace
YES2
teplace
lepair oreplace
Table 1
~1
Auto-deceleration switchOFF, levers at neutral
O-IVI
Remedy
Table 2I I
Connector Resistance value
Between CO3 (female) (5)and CO1 (female) (4)
Max. 1 0I
Between CO3 (female) (5)and chassis
Min. 1 MC
C-15 Related electric circuit diagram
X08DDl51
20- 194
0
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TROUBLESHOOTING OF PUMP CONTROLLERINPUT SIGNAL SYSTEM
(F MODE)
* When the monitoring mode is checked, if the following input signals are not displayed or do not light up, carryout troubleshooting for that item.
Troubleshooting flow charts for each failure mode
F- 1F- 2F- 3F- 4F- 5F- 6F- 7F- 8F- 9F-l 0
F-l 2
Bit pattern 20-(l) Swing oil pressure switch does not light up . . . . . . . .Bit pattern 20-(2) Travel oil pressure switch does not light up _ . . .Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up .Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up . .Bit pattern 20-(5) Arm IN oil pressure switch does not light up . . . . . . .Bit pattern 20-(6) Arm OUT oil pressure switch does not light up . . . . .Bit pattern 21-(l) Bucket CURL oil pressure does not light up . . . . . . .Bit pattern 21-(2) Bucket DUMP oil pressure does not light up . . . . . . .Bit pattern 21-(3) Swing lock switch does not light up . . . . . . . _ . . .Engine speed is not displayed in monitoring code 10
. .
.. . . . .
. .. . .. . .. . .. . .. . .. . .. . .
. . .
. . .
. . .
. . .
. .
. .
. .
(abnormality in engine speed sensor system) . . . . . . . . . . . . . . . . . . . . . . .Bit pattern 22-(6) L.H. knob switch does not light up . . . . . . . . . . . . . . . . . . . .
...... 20-I 96...... 20-l 97
...... 20-I 98
...... 20-I 99
...... 20-200
...... 20-20 1
...... 20-202
...... 20-203
...... 20-204
...... 20-205
...... 20-206
20-I 95
a
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TROUBLESHOOTING F-l
F-l Bit pattern 2041) Swing oil pressure switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.a Turn the swing lock ON before operating the swing lever.
* If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.
1
Is voltage betweenCO2 (1) and chassis
Lever at neutral:
20 - 3ovSwing Levero,p,e:$ I+
Start engine.
3YE-sIs esistance betweenSO8 (female) (2) and
i” _ CO2 (female)Jl)normal, and IS circui t
- insulated fromIs resistance between chassis?SO8 (male) (1) and (2)*normal, and is circuit - Between SO8 and
~- NO1 nsulated from C02: Max. 1 Q
chassis? Between wiring harness and chassis: Min. 1 MC- Disconnect SO8 and C02.
Swing LeveroMpae:aY$ NO
Lever at neutral: Min. 1 MRStart engine.
- Disconnect S08.
tlt is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 1) and the chassis inItem 1 on the flow chart.*If it is 20 - 3OV:
G? o YESlff;; 1;; than 1V:
Iefective pump controller
jefective contact, orlisconnection in wiringlarness between SO8female) (1) and chassis
defective contact, short:ircuit with ground, or
lisconnection in wiringrarness between SO8female) (2) - HO4 7) - CO2female) (I)
M$ive swing oil pressure
t If the condition does notreturn to normal evenwhen the switch isreplaced, go to H-5.
F-l Related electric circuit diagram
Pump controller
CO2(04020) H04(S16) SOEJ(X2) _
Swingswitch
swmg oil pressure switch
L
XOBDD152
Replace
Repair orreplace
Replace
20- I 96
0
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TROUBLESHOOTING F-2
F-2 Bit pattern 2042) Travel oil pressure switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.a Before operating the travel lever, check that the surrounding area is safe.
j, If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective.
Is voltage betweenCO2 3) and chassisnormal?
I
Is resistance betweenSO1 male) (1) and (2)
Lever at neutral:20 - 3ovTravel Leveroperated:Max. 1 V
- Start engine.
3 YES
~
Between SO1 andC02: Max. 1 RBetween wiring harness and chassis: Min. 1 MQDisconnect SO1 and C02.
. Travel lever Ioperated: Max. 1 R NOLever at neutral:Min. 1 MQStart engine.
* Disconnect Sol.
*It is also possible to fit a shot? connector and judge thecondition. In this case, check the voltage between CO2 3)and the chassis in Item 1 on the flow chart.*Ifitis20-30V:
Go to YES* If it is less than 1V:
Go to NO
F-2 Related electric circuit diagram
Pump controller
CO2(04020) HOU(S16) SOl(X2)
-0
_:
bC
-Eia-c
i
Cause Remedy
lefective pump controller
lefective contact, orisconnection in wiringarness between SO1:emale) (1) and chassi s
befective contact, shortircuit with ground, or
,isconnection in wiringarness between SO2female) (3) - HO4 (11) SO1female) (2)
befective ravel oil pressurewitcht If the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
eplace
epair orzplace
:epair or
splace
leplace
Travel oil pressure switch
X08DD153
20-I 97
a
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TROUBLESHOOTING F-3
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not lightUP
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
a When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* When mesuring with the engine stopped, charge the accumulator before starting.
YES
I
Defective pump controller
------+ IIs voltage between;i;;;\Fd chassrs
H_I. Lever at neutral:
20 - 3ov. Boom LOWER I
hy;.apt: NC
Start engine.
Defective contact, or3 YES disconnection in wiring
Is resistance between harness between SO4
SO4 (female) (2) and (female) (1) and chassism_ CO2 female) (2)2 normal, and is circuit
- insulated from Defective contact, short
Is resistance between chassis?_ circuit with ground, or
SO4 (male) (1) and (2) - BeWeen SO4 and Nodisconnection in wiring
normal, and is circuit - ~02: ~~~~ 1 Q harness between SO4
insulated from (female) (2) - HO4 (9) - CO2
chassis?. Between wiring harness and chassis: Min. 1 MR. Disconnect SO4 and C02.
(female) (2)
* Boom LOWER Defective boom LOWER oiloperated: Max. 1 0 NO pressure switchLeverat neutral: * If the condition does notMin. 1 MR. return to normal even
*Start engine. when the switch isDisconnect S04. replaced, go to H-5.
*lt is also possible to fit a short connector and judge the condition .tn this case, check the voltage between CO2 (2) and the chassis in ltem1 on the flow chart.*Ifitis20-30V:
Go TO YESllff;; leg than 1V:
F-3 Related electric circuit diagram
Pump controller
CO2(040201 H04(S16) SOQ(X2) Boom LOWERoil pressure switch
XOSDD154
1I3place
epair orplace
epair ortplace
,eplace
20- 198
0
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F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not lightUP
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
A When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* When mesuring with the engine stopped, charge the accumulator before starting.
IIs voltage between 3 YESCO2 4) and chassis 7s resistance between
SO2 female) (2) andYES_ CO2 female) (4)2 normal, and is circuit
. &veg;neutral: insulated fromIS resistance between -chassis?
Boom RAISE SO2 male) 11 and (2)operated: - normal, and is circuit c
Beve;exSp2Cand No
Max. 1 V NO nsulated romchassis?
Be$een wiring harness and chassis: Min. 1 MD* Start engine. _ . Disconnect SO2 and C02.
. Boom RAISEoperated: Max. 1 R NOLever at neutral:Min. 1 MD
* Start engine.Disconnect S02.
tit is also possible to fit a short connector and judge the condition. .In this case, heck the voltage between CO2 4) and the chassis in hem1 on the flow chart.
If it i s 20 - 8OV:Go to YES
. lf$;; F; than 1V:
F-4 Related electric circuit diagram
Cause
lefective pump controller
lefective contact, orisconnection in wiringarness between SO2Female) 1) and chassis
fefective contact, shortircuit with ground, orIisconnection in wiringlarness between SO2female) (2) - HO4 10) - CO2female) (4)
jefective boom RAISE oilBressure witcht If the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
Pump controller
CO2(04020) H04(S16) SO2(X2) Boom RAISEoil pressure switch
X08DD155
Remedy
,eplace
;epair oreplace
iepair oreplace
teplace
20- 199
a
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TROUBLESHOOTING F-S
F-5 Bit pattern 2045) Arm IN oil pressure switch does not light upj, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
A When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
* When mesuring with the engine stopped, charge the accumulator before starting.
t
YES
3 YESIs esistance betweenSO5 (female) (2) and
YES ~ 2 (female) (5)
7rnormal, and is circuit
. Arm IN operated:Max. 1 V
. Start engine.
SO5 (male) (1) and (2)
S05: Max. 1 <I. Between wiring harness and chassis: Min. 1 ML
Disconnect CO2 and S05.
* Arm IN operated:Max. 1 (1 Nfl
* iever at neutral:Min. 1 M61
* Start engine.*Disconnect S05.
*It is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 (5) and the chassis in Item1 on the flow chart.*Ifitis20-30V:
Go to YES* f it is less than 1V:
Go to NO
F-5 Related electric circuit diagram
F-
.C
CC
:
[CC
i
-I
Cause
fefective pump controller
lefective contact, orlisconnection in wiringrarness between SO5female) (1) and chassis
Iefective contact, short:ircuit with ground, orjisconnection in wiringtarness between SO5female) (2) - HO4 (12) - CO2female) (5)
IDefective Arm IN oiloressure switch* If the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
Pump controller
CO2(040201 H04(Sl6) SO5(X2) Arm IN
Remedy
eplace
epair orzplace
epair orsplace
leplace
XOSDD156
20-200
a
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TROUBLESHOOTlNG F-6
F-6 Bit pattern 209(6) Arm OUT oil pressure switch does not light upSr This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
a When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
* When mesuring with the engine stopped, charge the accumulator before starting.
YES
I1
1s voltage betweenCO2 (6) and chassis -normal? YI
2Lever at neutral:20 - 3ov
* Arm OUToperated:Max. 1 V
* Start engine.
Is esistance betweenSo3 (male) (1) and (2)
- normal, and is circuit 'N3 nsulated from
chassis?
;~,“ ,.~rJ~ operated:
Lever at neutral:Min. 1 MQ
. Start engine.
. Disconnect S03.
@HiBetween ~02 and NOS03: Max. 1 RBetween wiring harness and chassis: Min. 1 MD
- Disconnect CO2 and S03.
*It is also possible o fit a short connector and judge the condition.In this case, heck the voltage between CO2 (6) and the chassis in Item1 on the flow chart.
Ifi& 1,“ ; than 1V:
F-6 Related electric circuit diagram
Cause
jefective p ump controller
Iefective contact, orlisconnection in wiringrarness between SO3female) (1) and chassis
)efective contact, short:ircuit with ground, orjisconnection in wiringiarness between SO3female) (2) - HO4 (8) - CO2female) (8)
Iefective arm OUT oilsressure switch* If the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
Pump controller
CO2(04020) H04(Sl6) SO3(X2) Arm OUToil pressure switch
Remedy
eolace
lepair oreplace
repair oreplace
teplace
XOSDD157
20- 2010
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F-7 Bit pattern 2141) Bucket CURL oil pressure switch does not light
*
a
***
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When mesuring with the engine stopped, charge the accumulator before starting.
Is voltage between;zZ;;I;nd chassis
Lever at neutral:20 - 3ovBucket CURLo,p,e:“ :“ ;: I
- Start engine.
YE
,I3 YE3
Is esistance betweenSO6 female) (2) and
YE_ CO2 female) (7)2 normal, and is circuit
insulated romIs resistance between chassis?SO6 male) (1) and (2)
_ normat, and is circuit _ ’ Between CO2 and No3 insulated rom SO& Max. 1 R
chassis? Between wiring harness and chassis: Min. 1 MRDisconnect CO2 and S06.
*Bucket CURLoperated: Max. 142. NOLever at neutral:Min. 1 MR.Start engine.
*Disconnect S06.
tit is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 7) and the chassis in Item1 on the flow chart.
If it i s 20 - 30V:Go to YESIf it is less than 1V:Go to NO
Cause
lefective pump controller
lefective contact, orisconnection in wiringarness between SO6‘ emale) 1) and chassis
refective contact, shortircuit with ground, orisconnection% wiringarness between SO6female) (2) - HO4 14) -CO2female) (7)
refective bucket CURL oillressure switchI If the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
F-7 Related electric circuit diagram
Pump controller
CO2(04020) H04(S16) SO6(X2) Bucket CURLoil pressure switch
Remedy
eplace
epair orsplace
:epair orsplace
qeplace
XOBDD158
20-202
0
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F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light
*
a
***
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When measuring with the engine running, make sure that the work equipment does not move when the lever
is operated.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When mesuring with the engine stopped, charge the accumulator before starting.
1
Is voltage betweenCO2 8) and chassis
I 2Lever at neutral:20 - 3ov Is resistance betweenBucket DUMP
. ‘ HO7 male) (1) and (2)
zpeeye$ normal, and is circuitNO insulated from
Start engine. chassis?
$$vee;xC;2Dand NO
Bet&aen wiring harness and chassis: Min. 1 MC* Disconnect CO2 and S07.
* Bucket DUMP Iooerated: Max. 1 R NnLever at neutral: AT_Min. 1 MR.
*Start engine.Disconnect S07.
*It is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 8) and the chassis in Item1 on the flow chart.*Ifitis20-30V:
Go to YES
If it i s less than 1V:Go to NO
Iefective pump controller
Defective contact, short:ircuit with ground, orjisconnection in wiringiarness between SO7female) (1) and chassis
Defective contact, short:ircuit with ground, orfisconnection in wiringlarness between SO7female) (2) - HO4 13) - CO2female) (8)
Defective bucket DUMP oilxessure switcht If.the condition does not
return to normal evenwhen the switch isreplaced, go to H-5.
F-8 Related electric circuit diagram
Pump controller
Cl ( BBC171
BucketDUMP @switch
SO7(X2) Bucket DUMPoil pressure switch
XOBDD159
teplace
tepair oreplace
tepair oreplace
Replace
20- 203
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TROUBLESHOOTING F-9
F-9 Bit pattern 2%(3) Swing lock switch does not light up*
***
This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the panel display is normal, go to M-22 when panel swing lock lamp does not light up.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
YYES1 I
Defective pump controller
IReplace
Is voltage betweenDefective swing lock switch
CO2 (9) and CO1 (1) - Disconnection or short
(2) normal? 2 YES circuit with ground in wiring
Is there continuity1 harness between CO1
- between CO2(female) (1) ;2) and swing
. Swing lock switch lock switch (2)ON: Max. 1V - (female)_(g) and ‘ -
OFF: 18 - 28V NO swing lock switch Disconnection in wiring
. Turn starting (112 harness between CO2
switch ON. . Turn starting NO (female) (9) and swing lock
switch OFF.switch (1)
Disconnect C02.
F-9
COl(MIC17)Swung brakesolenoid valve
GNDIND
co2(04020)
\ I
Repair orreplace
Repair orreplace
Related electric circuit diagram
HOl(S16)
solenoid valve
switch
X08DD160
20-204a
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TROUBLESHOOTING F-l 0
F-IO Engine speed is not displayed in monitoring code IO (abnormalityin engine speed sensor system)
* Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
YE
1
between CO3 female)(6) - (14). (81 chassisis normal, is circuit
. 500-1OOOR* Turn starting
switch OFF.Disconnect C03.
Cause
kES2
Defective adjustment ofengine speed sensor
Does condition3s ecome normal
r when engine speed 4 YESsensor is adjusted? P Defective pump COntrOkr
f See TESTING AND _Is voltage between
ADJUSTING. NO $t;;;\;nd ‘ 14)
Defective engine speed
. Measure in AC NO sensor
range.* 0.5-3v
(Reference)Low: 1.9v Defective contact, or
Start engine. Decel: 2.4V disconnection in wiring
3YES High: 2.79V harness between E07(female) (1) (2) - E08 (9) (10)
Is resistance between - HO3 (15) (16) - CO3 (female)E07tmale) (1) - (2). (2)
- -chassis normal, and -(6) (14) or between PO2
JO s circuit insulated(female) (14) (15)
from chassis?Defective engine speed._^
Between (1) andchassis: Min. 1 MR
- Turn startingswitch OFF.
- Disconnect E07.
F-10 Related electric circuit diagram
. Between (1) and NV sensor(2):500-1OOOR
Remedy
4djust
3eplace
Replace
Replace
Pump controller
CO3(04016)
XOSDD161
20-2050
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TROUBLESHOOTING F-12
F-12 Bit pattern 22-(6) L.H. knob switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.
* Set the working mode to G/O or H/O and the power max. /swift slow-down to the power max. position.j, When fuse 5 is not blown.* Before carrying out troubleshooting, check that all related connectors are properly inserted.jl Always connect any disconnected connectors before going on to the next step.
1
Is voltage between 3 YESCO2 181 andchassis normal? Is resistance
YES between terminals _
2L.H. knob switch
cUa,:“ Ob swrtch
ON: 20 - 30VOFF: Max. 1 V Is voltage of L.H. - NO- knobswitch inlet - - .H. knob switch
NO erminal normal? ON: Max. 1 ROFF: Min. 1 MD
Starting switch ION: 20 - 30V NO
F-12 Related electric circuit diagram
Cause
Defective pump controller
Defective contact, ordisconnection in wiringharness between knobswitch - M23 (2) - M22 (2) -HO1 16) - CO2 female) (18)
Defective L.H. knob swi tch
Defective contact, ordisconnection in wiringharness between L.H. knobswitch-M23(1)-M22(1)-HO4 16) -fuse 5
Remedy
eplace
epair wiringarness
replace
lepair wiringlarness
20- 206
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TROUBLESHOOTING OF HYDRAULICAND MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes for hydraulic and mechanical system ....................Pump merge-divider logicTroubleshooting flow charts for each failure modk’ ......................................
All work equipment, travel, swingH- 1 Speeds of all work equipment, swing, travel are slow or lack power .................H-2 There i s excessive drop in engine speed, or engine stall s ..........................H- 3 No work equipment, travel, swing move ........................................H-4 Abnormal noise generated (around pump) .....................................H- 5 Auto-deceleration does not work (when PPC shuttle valve is cause) .................H-6 Fine control ability i s poor or response is poor ...................................
Work Equipment H- 7 Boom is slow or lacks power . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . .H- 8 Arm is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H- 9 Bucket is slow or lacks powerH-IO Work equipment (boom, arm, bucket)‘&& not move (but irave; and’swing are normal) :H-l 1 Excessive hydraulic drift (boom, arm, bucket) . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . .H-l 2 Excessive time lag (engine at low idling) . . . . . . . . _ . . . . . . . . . . . . _ _ . . . . . . . . . . .H-l 3 Lack of power when pressure risesH-14 Other equipment moves when single circuit ~s.relieveb’ : : : : : : : : : : : : : : : : : : : : : : : : : : : :H-l 5 In L/O, F/O modes, work equipment speed is faster that specified speed . . . . . . . . . . .
Compound operationsH-l 6 In compound operations, work equipment with larger load is slow ...................H-17 In swing + boom RAISE, boom RAISE isslow ...................................H-18 Inswing+armOUT,armOUTisslow .........................................H-l 9 In swing + travel, travel speed drops excessively .................................
Travel systemH-20 Travel deviation ..........................................H-21 Travel speed is slow ..........................................H-22 Steering does not turn easily or lacks power ....................................H-23 Travel speed does not switch or is faster than specified speed .....................H-24 Travel does not move (one side only) ..........................................
Swing systemH-25 Does not swingH-26 Swing acceleration is poor or swing speed isslow (both’ left and’r/ght\ bnedirec~dn b&jH-27 Excessive overrun when stopping swing . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . .H-28 Excessive shock when stopping swing (one direction only) . _ . . . . . . . . . . . . . . . . . . . _ .H-29 Excessive abnormal noise when stopping swing . _ . . . . . . . . . . . . . . . . . . . . . . . . . . .H-30 Excessive hydraulic drift of swing . . . _ . . . . . _ . . . . . . _ . . . . . . . . . . . . . . . . . . . . .H-31 Swing speed is faster than specified swing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .20-208 20-211
. . . . 20-I 12
. . . . 20-I 14
. . . . 20-I 15
. . . . 20-I 15
. . . . 20-I 16
. . . . 20-I 16
. . . . 20-218
. . . . 20-220
. . . . 20-222
. . . . 20-223
. . . . 20-223
. . . . 20-224
. . . . 20-224
. . . . 20-224
. . . . 20-225
. . . 20-225
. . . 20-226
. . . 20-226
. . . 20-226
. .
. .
. .
. .
. .
. .
. .
. .
. .. . .
20-227 20-22820-23020-23220-232
20-23320-23420-23620-23720-23720-23820-239
20-207a
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LE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM
Parts causing failure
Piston pump Control valveFront Rear
? re’ief For For $
main front rear Pump merge. Regenerationdivider valve
Tg
unload pump pumpcircuit
valve 2”9
b sE 2
ailure mode
Speeds of all work equipment, swing, travel are slow or lack power A A AAA A0 OOAAAA H-l
There is excess ive drop in engine speed, or engine stalls 000 000 H-2
No work equipment, travel, swing move D a0 0 0 H-3
Abnormal noise generated (around pump) 0 0 0 H-4
Auto-deceleration does not work 0 H-5
Fine control ability is poor or response s poor 0 0 0 H-5
Boom is slow or lacks power 0 000 0 0 00 0 H-7
Arm is slow or l acks power Q 000 0 0 00 0 H-9
Bucket s slow or lacks power 0 0 0 H-9
Boom does not move 0
Arm does not move 0 0 H-1(
Bucket does not move 0 0
Excessive hydraulic drift 0 0 0 H-l ’
Excessive ime lag (engine at low idling) 0 0 H-l:
Lack of power when pre ssure rises 00 0 H-l:
Other equipment moves when single circuit s relieved 0 H-11
In L/O or F/O mode, work equi pment speed is faster han set speed 0 0 00 H-l
H l in compound operations, work equipment with larger load is slow 00 0 . H-l’In swing + boom RAISE, boom is slow
In swing + arm OUT, arm is slow 6 0 H-ll
n swing + travel, travel speed drops excessively _ 10 0 H-l
Travel deviationDeviation is excessive 0 00
H-2(Deviation s excessive hen starting
Travel speed is slow 0 0 0 0 00 H-2’
Steering does not turn or lacks power 0 0 000000 0 H-2
Travel speed does not switch or is faster than set speed H-2:
Does not move (one side only)< 0 H-21
Does not swingBoth left and right H-2One direction only 0 0
Swing acceleration s poor or Both left and right ‘0 0 000 H-2(swing speed is slow One direction only 0 0 00
Excessive overrun.when stopping Both left and rightswrng One direction only 0 0 0
H-2
Excessive shock when stopping swing (one direction only) 0 0 H-21
Excessive abnormal noise when stopping swing H-2
Excessive hydraulic drift of swingWhen br ake is ON
-When brake s OFF
Swing spee d s faster than specified swing speed. _.. . _ .
modes tor compound operatrons are useohe tarlure modes,
20-208a
H-3(0 0
0 0 0, H-3’_. . ..,. _* . .~ . ~_. mI.L __ --I- *-__* __I _-_
operatrons are normal. A : wnen mere Is an aonormarny ror oorn nom ano rear
FOLDO
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TROUBLESHOOTING PUMP MERGE-DIVIDER LOGIC
PUMP MERGE-DIVIDER LOGIC
Categon/ Flow divided Flow merged Flow divided Flow merged
Mode
Boom/swing priority selection mode OFF Boom/swing priorin/ selection mode ON
Pump merge-divider solenoid ON Pump merge-divider solenoid OFF P”mp merge-divider Pump merge-dividersolenoid ON solenoid OFF
L/o - All operations x
With travel ONIndependent operation of travel
* independent operation of swing
With travel ON*Except independent operation of
*Independent Compound operation
travel (compound operation with operation of travel with travel
travel) *Independent*Except independent operation of operation of boom,swing (compound operation withtravel)
arm, bucket,service, swing with
Operations A, B and C with travel Operations except operations A, B travel OFF, and
OFF and swing lock switch OFF and C with travel OFF and swing lock compound Operationswitch OFF of each of these
A Arm IN *Compound operation with
Swing + boom LOWERtravel
*Swing + bucket CURLSwing + arm IN*Swing + arm OUT
Swing + bucket DUMP *Swing + boom RAISE
xF/O *Swing + service
*Independent operation ofu boom
;*Arm IN + bucket CURL ai -Independent operation ofwhen condition is * d arm
P -Arm OUT + bucket DUMPii t *Independent operation of
5B and front or rear pump .o bucket
5 pressure more than 3.92Ii *Arm IN + bucket CURL5
MPa (40 kg/cm’ ) 2with pressure less than
-Arm OUT + service and14.7 MPa (156 kg/cm’ )or
5more than 24.5 MPa
front or rear pump :: (250 kg/cm’ ) (except * )pressure more than “.I *Arm OUT + bucket DUMP
19.6MPa (200 kg/cm’ ) and pressure less than3.92 MPa (40kg/cmz)
*Arm OUT + service andpressure less than
*For HYPER GX : 19.6 MPa (2OOkg/cm’ )C Boom priority 2 mode + boom -AlI others
RAISE + arm OUT
With travel ON
G/O Independent operation of travel
H/O* Independent operation of swing D*Operations B and C with travel
Except operation D
OFF and swing lock switch OFFI
With swing lock OFF: With swing lock OFF:
LS select *Separated for swing + travel, boom RAISE, arm OUT (solenoid ON), not *Separated for swing + travel (solenoid ON),
separated for other operations not separated for other operations (solenoidOFF)
x I ne pressure of tne tront or rear pumps is as tollows:
When pressure rises: 24.5 MPa (250 kg/cm%(For details, see Fig. 1)
When pressure goes down: 14.7 MPa (150 kg/cm?I
ON
OFF
B
------
fII
14.7 (150) 24.5 (250)
Pressure tMPatkg/cm%
Fig. 1 205Po6228_ -21 1
0
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TROUBLESHOOTING H-l
H-l Speeds of all work equipment, swing, travel are slow or lackpower
* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.* Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting.
(If there is any abnormal noise, carry out troubleshooting for H-4.)YES
5
Does conditionm_ become normal
when TVC valve isadjusted?
6 YES
Does condition
4 . See TESTINGbecome normal
AND - when servoNO
Is input pressure of ADJUSTING. assembly is
YE.6 servo pistonreplaced?
approx. 112 of main NO
3
~ Is output pressureof LS control EPC
d
valve normal?
* 0.2 2 0.2 MPa
pressure normal?
Is control pumpcircuit pressurenormal?
* Check andmeasure circuitoil pressure. Fordetails, seeTESTING ANDADJUSTING.
* See below7yEs
Does conditionbecome normal
- when servoNO assembly is
replaced?
* Distribution of NOservo (LS and TVC)and piston pump(servo piston)
(2 2 2 kg/cm’ )* Engine at high
. ZZelief
YES8 I
become normalwhen LS relief *un-load valve assembly
* 31.9 2 1.0 MPa(325 f 10 kg/cm21
* Engine at highidling
* Arm relief* Turn swing lock
switch OFF.
~31.9 + 1.0 MPa become normalwhen sub-unloadvalve is replaced?
idlrng _ I I*Arm relief
Turn swing lock-31.9 t 1.0 MPa kir----
.switch OFF.
(325 210 kg/cmz)* Engine at high idling
Arm relief* Turn swing lock switch OFF.
* Measuring servo piston inlet port pressureMeasure the input pressure to the large diameter end of the servo piston when the pressure rises and the armis relieved. (Approx. 17.64 MPa (Approx 180 kg/cm?)[Basically, the pressure at the large diameter end is approx. % of the small diameter end. For details, seeTESTING AND ADJUSTING.]
20-212
0
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TROUBLESHOOTING H-l
Cause Remedy
Defective adjustment of NC Adjustvalve
Defective servo assembly Repair orreplace
Defective piston pump(servo piston)
Correct orreplace
Defective operation of LScontrol EPC solenoid valve
Replace
Defective operation of sub- Repair orunload valve replace
Defective operation of main Replacerelief valve
Defective hydraulicequipment in control pump
1 circuitAdjust or
(See TESTING ANDreplace
ADJUSTING)
20- 2130
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TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls
* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.* Check that the main relief pressure is normal.
Cause Remedy
YESI Clogged throttle inside servo CleanI 1or &gged filter inside servo
1,I IIs throttle insideservo or filterinside servoclogged?
3YES
Does conditionyEs become normal when
2- Tvc valve kWv0
valve assembly) s- replaced?
_ Is engine speed atNO arm relief normal?
NO
Defective lVC valve orMztive adjustment of TVC
Defective servo piston
I ’ I I- See below.
Adjust orreplace servovalve assembly
Replace (pistonpump assembly)
-
* Replace the servo valve assembly on the defective side with a new part, and if the engine speed is lower thanthe reference value below, carry out troubleshooting for S mode. If it is higher, it can be judged that the TVCvalve (servo valve assembly) is defective, so replace it.
Engine speed (reference) at arm relief when engine and pump are normal
ModelEngine speed at arm
reliefConditions
1 i E ~ 1 : .%~~l~~,“ ~~iti~~?N1: ~~~~ 111Measure the speed at the point where the drop in engine
speed is greatest when the arm cylinder is at the end of strokeand the lever is operated slowly to the full position.
20-214
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H-3 No work equipment, travel, swing move
Y1
Is safety lock valveworking properly?
H-4 Abnormal noise generated
Cause
2mWhen main pump
pressure pickupplug is removed,does oil come out?
Defective control pump,control relief valve, ordefective control circuit
* Crank with NODefective damper
starting motor.
Defective operation of safetylock valve or safety locklinkage
I(around pump)
Cause
Is hydraulic tank oillevel normal?
Are there bubblesinside hydraulictank?
3 YES
\KH-Goto4
NO
Is suction strainer
- External object:Cloth, etc.
Is uction strainerclogged with metal
Defective hydraulic oil
Clogged by external object(cloth, etc.)
Defect inside pump
Operate for a short time andwatch for any change insymptoms
Lack of hydraulic oil
Remedy
leplace
ieplace
\djust
Remedy
teplacerydraulic oil
temove
3epair or,eplace
nspect again’depending on:hanges insymptoms)
Idd hydraulic a il
20-215
0
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TROUBLESHOOTING H-5, H-6
H-5 Auto-deceleration does not work (when PPC shuttle valve iscause)
j, The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied to the oilpressure switch.
*1YES
Does conditionbecome normal _when oil pressureswitch is replaced?
NO
H-6 Fine control ability is poor or response is poor
Defective oil pressure switch
Defective operation of PPCshuttle valve in applicablesystem (swing or travel)
Replace
Repair orreplace
Cause
Clogged throttle in LS circuit
Defective servo valveassembly (LS valve), ordefective servo piston
Remedy
Clean
Replace
20- 216
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TROUBLESHOOTING H-7
H-7 Boom is slow or lacks power* When travel and swing speeds are normalIr Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.
YI
1
switch for boom
. TreeJ;DGEMENT
. Note:If auto-decelerationis canceled whenboom RAISE orboom LOWER soperated, system isnormal.
Yl
2
Is output pressureof PPC (EPC) valve
* Min. 2.74 MPa(Min. 28 kg/cm21Engine at highidling
n
5Is relief pressure offront and rearpumps normalwhen boom RAISEcircuit is relieved?
P
31.9 + 1.0 MPa(325 * 10 kg/cm?Engine at highidling
normal, or does pres-sure compensationvalve piston move
Does control valvespool movesmoothly?
It is also possible tointerchange withother compensationvalve. I
After inspection, do
position.
* 4.9 5 219 MPa(50 + 30 kg/cm2)
. Engine at highidling
YES6
Dois LS shuttle,valve move
Hmoothly?
* Check LS shuttl e:c~R~i. travel and NO
.[ Front is low ]-
yEs [
Cigh ]-
NO C Low ]-
NO
NO
20- 218a
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TROUBLESHOOTING H-7
d YES
Is operatingpressure normal ,when boom RAISEis being operated?
Defective boom cylinderpiston packing
. Pc200: NOW7& 5MPa ( 150+ 15kg/ cm ~
16. 7 + . 5MPa~170~15kg/c m2)- Engine ath$hidi i ng. Atmax.r eac , nol oad
- efective operation of boomholding valve
Defective operation of LSshuttle valve (LS shuttle forR.H. travel or bucket)
9YEs Defective operation of mainmerge-divider valve or LS
Is pump merge- merge-divider valvedivider solenoidvalve outputpressure normal?
Defective operation of pump*When boom is NO merge-divider solenoid valve
raised:0 MPa (0 kg/cm?
Defective boom holdingvalve or suction valve ofcontrol valve
Defective operation of boom Repair orholding valve replace
Defective operation of boomregeneration valve
Repair orreplace
Defective operation ofpressure compensationvalve or pressurecompensation valve piston
Repair orreplace
Defective operation ofcontrol valve spool
Repair orreplace
Defective PPC valve Replace
Defective boom RAISE orboom LOWER oil pressureswitch
Replace
Remedy
Repairorreplace
Repair orreplace
Repair orreplace
Repair orreplace
Repair orreplace
Replace
20-219a
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TROUBLESHOOTINGH-8
H-8 Arm is slow or lacks power* When travel and swing speeds are normal* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.
n
r-----G
- Note:If auto-decelerationis canceled whenarm IN or arm OUTis operated, systemis normal.
Is output pressureof PPC vaii$ ‘ ..normal? -.
1Min. 2.74 MPa(Min 28 kg/cm*)
. Engine at highidling
Yl
Does control valve
Y
A
normal, or does pres-sure compensationvalve piston move
It is also possible tcinterchange withother compensationvalve.Note:After inspection, danot forget to returnto the originalposition.
31.9 f 1.0 MPa(325 t 10 kg/cm*)Engine at highidling
Check LS shuttle
boom, R.H. raveland bucket
1Rearislow ]-
NO
1oth front andrear are low
J
20-2200
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Cause Remedy
7YJ3 Defective operation of armregeneration valve or arm Repair or
counterbalance valve replaceIs leakage from- arm cylinder
normal?
Max. 20 cc/minEngine at highidling
-
NODefective arm cylinder pistonpacking
Defective operation of LSshuttle valve (LS shuttle forL.H. travel, boom, R.H. ravelor bucket)
8YE-S Defective operation of mainmerge-divider valve or LS Repair or
Is pump merge- merge-divider valve replace
_ divider solenoidvalve outputpressure normal?
0 MPa (0 kg/cm’ ) NOArm lever operatedEngine at high idling
Defective operation of pump Repair ormerge-divider solenoid valve replace
Defective PPC valve
Defective arm IN or arm OUT‘ ~I pressure swatch
Replace
20- 221
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TROUBLESHOOTING H-9
H-9 Bucket is slow or lacks power* When travel and swing speeds are normal.* Carry out troubleshooting with the swing priority mode OFF.
Is oil pressureswitch for bucketCURL, DUMPnormal?
. ;ree;fDGEMENT
Note: ’
If auto-decelerationis canceled whenbucket CURL orbucket DUMP isoperated, system isnormal.
*Min. 2.74 MPa(Min. 28 kg/cm*)Engine at highidling
NO
* Max. 20 cc/min* Et&e at high
NO
w&pP~;+; to+other compensationvalve.
- Note:After inspection, donot forget to return tothe original position.
Cause
refeciive operation ofontrol valve spool
refective PPC valve
defective bucket CURL orucket DUMP oil pressurewitch
refective operation ofafety-suction valve
defective bucket cylinder lepair orliston packing eplace
refective operation oflressure compensationalve or pressureompensation valve piston
lepair oreplace
leplace
Leplace
lepair oreplace
lepair oreplace
20-222
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TROUBLESHOOTING H-l 0, H-l 1
H-IO Work equipment (boom, arm, bucket) does not move (but traveland swing are normal)
jr When boom, arm, and bucket are each operated independently.
Is output pressureof PPC’ alvenormal?
Min. 2.14 MPa(Min. 28 kg/cm21Engine at highidling
YESDefective control valve spool
NODefective PPC valve
H-II Excessive hydraulic drift (boom, arm, bucket)
YES1 1
Does speed ofdownwardmovement become -faster when lever is YES
operated? 2
See TESTING AND Does conditionADJUSTING. become normal
- ~oi~~;;$;ssible No when safetv-suction valve is 3YEsinterchanged? Is slipper seal of pree e GotoA
leakage ofcylinder. - sure compensation
* Max. 20 cc/minvalve ree of damage?
At relief N- Or does pressure orn- -- Engine at high idling
O pensatron alve pistonmove smoothly?
* his also possible o NOinterchange withother compensation valve.
- Note: After nspection, o not forget oreturn o the original position.
[ Arm, bucket ]
C Boom
Cause
Iefective hydraulic cylinderciston packing
Defective operation ofsafety-suction valve
Damaged slipper seal ofpressure compensationvalve, or defective operationof pressure compensationvalve piston
Defective control valve spool teplace
Defective operation of boomholding valve
Remedy
Repair orreplace
Remedy
leplace
lepair oreplace
iepair oreplace
20-223
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H-12 Excessive time lag (engine at low idling)
compensation valvenormal, or does pres-sure compensation
1 t Note:See elow. I After inspection, do not forget to return to the original position.
NODefective operation of LScontrol EPC valve
3epair or.eplace
* Output pressure of LS control EPC solenoidAoorox. 2.06 MPa (Approx. 21 kg.cmZ) output from the LS control EPC solenoid when the engine is at low
Cause
Defective safety-suctionvalve, or defective boomregeneration valve
Defective safety-suctionvalve
Defective operation ofpressure compensationvalve or pressurecompensation valve piston
Remedy
TROUBLESHOOTING H-l 2, H-l 3, H-l 4
Replace
3epair or.eplace
. .idling (approx. 1306 rpm or below) regardless of the working mode.
H-13 Lack of power when pressure risesCause
* If condition is normal except when pressure rises.j, Carry out troubleshooting with the swing priority mode OFF. F-
switch normal?
Min. 2.74 MPa(Min 28 kg/en?)
/Omode
/iiEii&HLNO
Defective LS relief valve
Defective main relief valve
Defective operation of 2-stage relief solenoid valve
Operate eachcontrol lever, and ifauto-deceleration is NOcanceled, conditionis normal
1Defective oil pressure switch
h-rote: f PPC shuttle is normal)
Remedy
3eplaca
Xepair orpeplace
3eplace
H-14 Other equipment moves when single circuit is relievedCause Remedy
Defective operation ofI pressure compensation
valve slipper sealReplace
* The slipper seal in the pressure compensation valve of the circuit that moved is defective.
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TROUBLESHOOTING H-15, H-16
H-15 In L/O, F/O modes, work equipment speed is faster than specifiedspeed
2 YE-S
Yl
1
Is oil pressurer-lormal whenpump is relieved?
* At arm reliefFront pump:Approx. 34.6 MPa(Approx. 355 kg/cm’ )Rear pump:Approx. 5.9 MPa N(Approx. 60 kg/cm?)
* At bucket reliefFront pump:
Approx. 5.9 MPa(Approx. 60 kg/cm’ )Raer pump:Approx. 34.6 MPa(Approx. 355 kgfcm*)
* Swing priority mode
Is output pressure
i of LS control EPCsolenoid valvenormal?
See below. NO
. Min. 2.7 MPa(Min. 28 kg/cm?
I* L/O mode
NO
Defective LS valve Repair orreplace
Defective operation of LScontrol EPC solenoid valve
Repair orreplace
Defective operation of LSmerge-divider valve
Repair orreplace
Defective operation of mainmerge-divider valve
?epair or,eplace
Defective operation of pumpmerge-divider solenoid valve
qepair or,eplace
Remedy
* Output pressure of LS control EPC solenoid (travel OFF)Approx. 2.06 MPa (Approx. 21 kg/cm? is output from the LS control EPC solenoid when the engine is at lowidling (approx. 1300 rpm or below) regardless of the working mode.
H-16 In compound operations, work equipment with larger load is slow
Cause RemedyDefective operation of pressure
compensation valveReplace
(replace pressure compensation valve on side where load is lower)
Combination of compound operation Side where load is larger I
I I Boom RAISE + arm IN I Boomerang
2 Boom RAISE + arm OUT Arm OUT
3 Boom RAISE + bucket CURL Boom RAISE
I I Arm OUT + bucket CURL I Arm OUT-1
I I Boom LOWER + arm OUT I Arm OUT I
20-225
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TROUBLESHOOTING H-l 7, H-l 8, H-l 9
H-17 In swing + boom RAISE, boom RAISE is slow* If swing and boom RAISE work normally when operated independently.* Carry out troubleshooting with the swing priority mode OFF.
Cause T
solenoid valve
*Min. 2.74 MPa(Min. 28 kg/cm*) p
- Operate boomRAISE (operatelever slightly)
Defective operation of LSselect valve
2 YES Defective operation of LS
Does LS shuttleselect solenoid valve
- valve move’ smoothly?
Defective operation of LS
NOshuttle valve (LS shuttle forboom RAISE, LS select)
Remedy
Repair orreplace
Repair orreplace
Repair orreplace
H-18 In swing + arm OUT, arm OUT is slow* See H-17
(
If the operation is normal when the swing and arm OUT are operated independently, carry out trouble-shooting with the swing Priority mode OFF. If the Cause column shows that there is defective operation ofthe LS shuttle valve, the cause is in the shuttle valve for the arm OUT and LS selec t.
H-19 In swing + travel, travel speed drops excessively
If the operation is normal when the swing and travel are operated independently. carry outroubleshootingwith the swing priority mode OFF. If the Cause column shows that there iS efective peration of the Ls
shuttle valve,_the cause is in the shuttle valve for the LS select.
>
>
20- 226
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TROUBLESHOOTING H-20
H-20 Travel deviation
j, Carry out troubleshooting in the H/O mode.
a) When there is deviation in normal travel
3 YE3-II
n2
Check as anindividual part
- Output pressure:Min. 2.74MPa(Min. 28 kg/cm2)
- Difference inoutput pressurebetweenFORWARD andREVERSE:Max. 0.4 MPa(Max. 4 kg/cm?
- Engine at highidling
- Travel relief
Note 1:
Note 2:
1 Does control valve 1 1, spool move
smoothly?
NO
IO
5 YES-III Is OUtDUt Dressure I I
(shuttle bjock inletend) of PPCvalve normal?
H. Same conditionsas for Rem 1
NO
Remove PPC shuttle block inlet hose,fi;zzlP:er, and block tip.
NO
Cause
Defective travel motor Repair orassembly (Note 2) replace
Defective operation ofcontrol valve spool
Defective operation of traveljunction valve
Defective PPC shuttle
Defective PPC valve
Defective adjustment oftravel lever linkage
Repair orreplace
Repair orreplace
Repair orreplace
Replace
Adjust
If the adapter for blocking the circuit is not available, interchange swing with one of arm (IN), boom(LOWER), or bucket (CURL, DUMP).When measuring the speed of the travel motor under no load 9 Remove connector of LS control EPCvalve solenoid, and measure travel speed in Lo and Hi.
b) Excessive travel deviation when starting
I Cause Remedy
Defective operation of travelcounterbalance valve
Repair or replace
20-2270
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TROUBLESHOOTING
H-21 Travel speed is slow
H-21
* Check that the spool of the travel PPC valve is moving the full stroke before carrying out troubleshooting.j, Carry out troubleshooting in the H/O mode.
1Is speed slow inboth FORWARD
1
and REVERSE, or isit slow in onedirection only?
Note 1:
Note 2:
I 1
* See JUDGEMENTTABLENote:If auto-decelerationis canceled whentravel is operated,system is normal
Y
4
[Slow in onedirection nly ]jF[
normal?
Is output pressureof LS control EPC l-lsolenoid valvenormal?
- Note 1 NO
- Difference inoutput pressurebetweenFORWARD andREVERSE: WithinMax. 0.4 MPa(Max. 4 kg/cm*)Output pressure:
f
Min. 2.14 MPa(Min. 28 kg/cm*)
* Engine at highidling
* Travel relief
NO
yl
6
compensation valvenormal, or does pres-sure compensationvalve piston move
.- It is also possible ointerchange with othercompensatron valve.
N~
- Note:After inspection, do,notforget to return to theoriginal position.
10 YES
Is output pressurem_ (shuttle block inlet
9 end) of PPC- valve normal?
Is lever of PPC. v&e) contacting
_ Same conditions es NOfor Item 4
stopper? - Remove PPC shuttle block inlethose, fit adapter, and block tip.(NOTF 2)
NO
Output pressure of LS control EPC solenoid (travel OFF) Approx. 2.06 MPa. (Approx. 21 kg/cm? is outputfrom the LS control EPC solenoid when the engine is at low idling (approx. 1300 rpm) regardless of theworking mode.When measuring the speed of the travel motor under no load ti Remove connector of LS control EPCvalve solenoid, and measure travel speed in Lo and Hi.
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TROUBLESHOOTING H-21
Does condition_ become normal
when suction valve_
is replaced?
O
Cause
Defective operation of LSshuttle valve (for boom,bucket)
Defective operation of LScontrol EPC solenoid valve
Defective travel oil pressureswitch
Defective operation ofcontrol valve suction valve
Defective travel motorassembly
Defective pressurecompensation valve, ordefective operation ofpressure compensationvalve piston
Defective operation ofcontrol valve spool
Defective operation of traveljunction valve
Defective PPC shuttle
Defective PPC valve
Defective adjustment oftravel lever linkage
Remedy
iepair orsplace
lepair or,eplace
3eplace
7eez-a
Iepair oreplace
lepair oreplace
iepair oreplace
tepair oreplace
lepair oreplace
leplace
rdjust
20-2290
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TROUBLESHOOTING H-22
H-22 Steering does not turn easily or lacks powerj, Carry out troubleshooting in the H/O mode.
2I I
Is it difficult to turnYES to both left and
- right, or is it difficult 8to turn in onedirection only?
1
Is travel oil pressureswitch normal?
See JUDGEMENTTABLENote:If auto-decelerationis canceled whentravel is operated,system is normal
k
-Difficult toturn to bothleft and right when relieved on
Pressure high only onside not being relieved
4 YES
p$;;pqj~H-
- in. 2.74 MPa NO(Min. 28 kg/cm’ )
- Engine at high idling* Set swing priority mode ON
Pressure high only on side being reli eved(oil pressure is normal)
[Both left and right high]
‘ Neither fron:
nor rearreach reliefpressure
I I
* Interchacye left andright spools.
YE
34.8 :::: MPa(355 ::: kg/cm?
* Engine at highidlingArm IN relief
Does not
c
[urn to left -or right
t -
IO
3
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TROUBLESHOOTING H-77
I Cause
valve
Defective operation of pump iepair ormerge-divider solenoid valve eplace
1Defective operation of traveljunction valve spool
iepair oreplace
Defective operation of LScircuit check valve
lepair oreplace
Defective operation ofcontrol valve main circuitcheck valve (remains open)
iepair oreplace
Defective control valvesuction valve
ieplace
YESDefective travel motor check lepair or
eplace
-I 8 YESDoes conditionbecome normal
Defective travel motor safetyvalve
INO
t
See troubleshooting forH-13 Lack of power whenpressure rises
Defective travel oil pressureswitch
Remedy
Zonnect:orrectly
iepair oreplace
leplace
-
lepair oreplace
leplace
20-231
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TROUBLESHOOTING H-23. H-24
H-23 Travel speed does not switch or is faster than specified speed* Carry out troubleshooting in the H/O mode.
Is travel oil
Is pump pressuresensor normal? NO
Using monitoringcode 11 and 12.
* En?;; at high NOMeasure pumppressure.See JUDGEMENT
TABLENote:If auto-deceleration
NOis canceled whentravel is operated,system is normal.
rable 1 Output pressure of LS control EPC valve
Lo Mi
i-I
i l
Cause
Iefective operation of travelspeed selector servo piston
3efective operation of travelspeed solenoid valve
Defective operation of LScontrol EPC valve
Defective pump pressuresensor
Dek;;;ive travel oil pressure
I
Hi
PC200 2.0 f 0.2 MPaPC21 0 (20 fi 2 kg/cm?
PC220 1.8 f 0.2 MPaPC250 (18 f 2 kg/cm?
2.0 f 0.2 MPa(20 h 2 kg/cm?
1.8 f 0.2 MPa(18 f 2 kg/cm?
0.2 f 0.2 MPa(2 + 2 kg/cm?
0.2 f 0.2 MPa(2 f 2 kg/cm?
RemarksEngine at high idlingTravel lever at fine control position (auto-deceleration canceled)
H-24 Trave #Idoes not move (one side only)
1
1
F Cause
Remedy
?eplace
Repair orreplace
Repair orreplace
Replace
Replace
Es . Defective final drive
3 YESDoes ondition
yEs become normal when- left nd right suction -
2 valves of control valve- are nterchanged?
Is drain amount of NOtrrzaytor
Defective operation ofsuction valve of control valv
Defective counterbalancevalve, or defective operatiorof travel motor safety valve
Max. : 30 IlminEngine at high NO
Defective travel motor
idlingAt travel relief
eReplace
20-232
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TROUBLESHOOTING
H-25 Does not swing
H-25
a) Does not swing to either left or rightCause Remedy
n
See JUDGEMENTTABLE_.- Note: hif autodecelerationis canceled whenswing is operated,
system is normal.
- Min. 2.74 MPa(Min. 28 kg/cm*)
- EI;te swung
. Tz+;F;s lock
IO
n.
Is PPC valveoutput pressurenormal?
NO
b) Does not swing in one direction
Min. 2.74 MPa(Min. 28 kg/cm*)CIcFte swmg
Tu&sw$g lock
Defective swing machinew Repair orreplace
Defective swing holding Repair orbrake or swing motor replace
Defective operation of swingbrake solenoid valve
Repair orreplace
DeIective swing oil pressure Replace
Cause
2YE.s
Does control valvespool movesmoothly?
Defective swing motor safetyvalve
NODefective operation ofcontrol valve spool
yk PPC valve
Remedy
Repair orreplace
Replace
20- 233
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TROUBLESHOOTING H-26
H-26 Swing acceleration is poor or swing speed is slow (both left andright, one direction only)
* Carry out troubleshooting in the H/O mode. YES
a) Swing acceleration is poor4
Does conditionyes become normal
- when servoassembly isreplaced?
5YE-s
3-
Is discharge
Does LS shuttle
YE3 pressure of front - valve move- pump normal
NO smoothly?
when swing isrelieved ?2_ NO
or in one direction
. [ Both left and right ] *Is dischargepressure of rearpump normal whenswing s relieved? H
Front pumpdischargepressure:28.9 f 1.5 MPa(295 * 15 kg/cm*)
NO
. Rear pumpdischargepressure when Iswing is relieved: NO1.8 2 0.2 MPa(80 t 20 kg/cm*)
* Flow chart when speed is slow
gr
Defective LS valve
7 Y
See STANDARD NOGo to Item 5 8,
VALUE TABLE.
n
6
[One direction only]
Min. 2.74 MPa(Min. 28 kg/cm*)Engine at highidlingTurn swing lockswitch ON (lock).
yes Does control valve- spool move
7smoothly?
Is output pressure, fat shuttle block
end) of PPC valve_
normal?
compensation valvenormal, or does pres-sure cwnpensationvalve piston move
* It is also possible ointerchange ith othercompensation valve.
YES
IIO- Note:
After inspection, o notforget o return o theoriginal position.
IO
Same conditionsas for Item 6Remove PPCshuttle block inlet NOhose. fit adapter,and block tip.(Note)
Note: If the adapter for blocking the circuit is not available, interchange PPC hose of swing with one of bucket(CURL, DUMP), boom (LOWER), or arm (IN).
b) When swing speed is slowChange Item 2 marked with * under flow for a) Swing acceleration is poor, and omit Item 4 when carrying outtroubleshooting.
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TROUBLESHOOTING H-26
Cause Remedy
Defective servo assembly Replace
v7i ikfkf~;swing motor 1Replace
1i Defective operation of LS Repair orshuttle valve fall LS shuttles) replace
Defective LS circuit check Repair orvalve replace
Defective main circuit check Repair orvalve replace
10 YESDoes condition become normal when
- left and right safety -valves of motor areinterchanged?
* It is also possible to NOmeasure reliefpressure of motor.
*Relief pressure: 27.4 -23.4 MPa (280 - 310 kg/cm*). Note: After inspection , do not forget to return to the original position.
Defective swing motor safety Replacevalve
Defective swing motor Replacesuction valve
Defective pressurecompensation valve, or Repair ordefective operation of replacecompensation valve piston
7Defective operation ofcontrol valve spool
Defective operat ion of PPCshuttle valve
1 Defective PPC valve
Repair orreplace
Replace
20- 235
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TROUBLESHOOTING H-27
H-27 Excessive overrun when stopping swinga) One direction only
Cause Remedy
3 YES - Defective swing PPC slowIs problem reversed return valve
YES when left and right
2- swmg PPC slow
return valves are
Is problem reversedinterchanged?
_ _YES when left and right
Defective PPC valve
- outout hoses of PPC -
Repair orreplace
Does control valve
smoothly?
Defective swing motor safety Replace
b) Both directions
Cause Remedy
I Defective swing motor Correct or replace
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TROUBLESHOOTING H-28, H-29
H-28 Excessive shock when stopping swing (one direction onCauseF
YE.SDoes conditionbecome normal whenleft and right swingPPC slow returnvalves areinterchanged?
NO
1 Defective swing PPC slowreturn valve (check valve)
Defective PPC valve
H-29 Excessive abnormal noise when stopping swing
become normalwhen safety valve YES
2
Does condition, becomenormal _
when suction valveis cleaned?
3YEs
Is dirt found inNO swing machinery?
NO
-c\I
-tS
-C
-c
Cause
Ie&ztive swing motor safety
pefective swing motor,uction valve
hsfective swing machinery
hafective lift check valve
0Remedy
Repair orreplace
Replace
Remedy
20- 237a
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TROUBLESHOOTING H-30
H-30 Excessive hydraulic drift of swinga) When swing brake is released
Is hydraulic dimexcessive in bothdirections or onedirection only?
-[One direction only]
3yE:Is problem
, eversed when leftand right safety
Hvalves areinterchanged?
NO
NO
{=I=-*[ Both directions ] from motor
20 I/minEngine at highidlingAt swing relief
b) When swing brake is applied
Cause 1
Defective swing motor safetyvalve
Defective swing motorsuction valve
Defective pressurecompensation valve, ordefective operation ofpressure compensationvalve piston
1yEs
Is output pressure- Defective operation of swing
of swing brakeholding brake
solenoid valvenormal? I
L
0.2 + 0.2 MPa(2 + 2 kg/cm*)TG;-rv//;g lock
Remedy
Replace
Repair orreplace
Repair orreplace
Replace
Repair orreplace
Repair orreplace
20-2380
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TROUBLESHOOTING H-31
H-31 Swing speed is faster than specified swing speed* Carry out troubleshooting in the H/O mode.
Yl
* 5.8 - 1.8 MPa(60 - 80 kg/cm*)
- Engine at highidling
p
At bucket relief
2 YES
Is LS control EPCsolenoid valveoutput pressurenormal?
* See Table 1. NO
3YEzi
Is pump merge-divider solenoid _
, valve outputpressure normal?
3.0 + 0.2 MPa NO(31 + 2 kg/cm?
*At swing relief. Turn swing lock
switch ON.
cause
lefective operation of LSalve
qeplace servosssembly
reeztive LS control EPC Repair orreplace
refective operation of mainTerge-divider valve or LSlerge-divider valve
Repair orreplace
tefective operation of pump Repair ornerge-divider solenoid valve replace
Table 1 Output pressure of LS control EPC valveEngine at high idling
H/O mode G/O mode
PC200 0.2 f 0.2 MPa 0.2 f 0.2 MPaPC21 0 (2 f 2 kg/cm? (2 f 2 kg/cm?
PC220 0.2 f 0.2 MPa 0.2 f 0.2 MPaPC250 (2 f 2 kg/cm? (2 + 2 kg/cm?
F/O mode
1.5 f 0.2 MPa(15.5 f 2 kg/cm?
0.2 + 0.2 MPa(2 + 2 kg/cm?
L/O mode
1.5 f 0.2 MPa(15.5 + 2 kg/cm?
1.5 f 0.2 MPa(15.5 + 2 kg/cm?
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TROUBLESHOOTING OFMACHINE MONITOR SYSTEM
(M MODE)Action taken by monitor panel when abnormality occurs and problems on machine . . . . . . . . . . . . . . . 20-242 Machine monitor system cir cuit diagramroubleshooting flow charts for each failure.mobe’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243
M- 1M-2M- 3
M-4
M- 5M- 6
M- 7
M- 8M- 9
M-l 0
M-l 1
[El :Olr Abnormality in error data is displayed ........................................ 20-245
[El :02] Error in clock data is displayed ............................................. 20-245
[El :03] Short circuit in buzzer output or contact of 24V wiring harness with buzzer driveharness is displayed 20-245
When starting switch is turned ON; nbnk’df.the’lampsiigh; upor.3 seconds’ : : : : : : : : : : : : : : : 20-246a) None of the lamps on monitor panel light up. ..................................... 20-246b) Some of the lamps on monitor panel (gauge display, time display) do not light up ....... 20-246When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out . 20-247When starting switch is turned ON, items l ighted up on monitor panel are different frommachinemodel .............................................................. ..20-24 7When starting switch is turned ON, (engine stopped), CHECK items flash (Fl uid levels forCHECK items are at specified level) ................................................ 20-248
a) Coolantlevelflashes ........................................................ 20-248b) Engineoillevelflashes.. ................................................... ..20-24 9c) Hydraulic oil level flashes ..................................................... 20-249Preheating is not being used but preheating display lights up ............................ 20-250
When starting switch is turned ON and engine is started, CHECK items flash............... 20-251
a) Alternator system ........................................................... 20-251b) Engine oil pressure sensor system ............................................. 20-252When starting swit ch is turned ON (engine stopped), CAUTION items flash (but whencharge level, engine oil pressure do not light up) ..................................... 20-253a) Alternator system ........................................................... 20-253b) Engine oil pressure sensor system ............................................. 20-253When starting switch is turned ON and engine is started, CAUTION items flash (but whenthere is no abnormality in engine or CHECK items) .................................... 20-254a) Engine oil pressure flashes ................................................... 20-254b) Coolantlevelflashes ...................................................... ..20-25 5c) Coolant temperature flashes .................................................. 20-255d) Batterychargeflashes ........ . 20-256e) Fuellevelflashes ......................................................... ..20-25 6
M-l 2(a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 secondCAUTION items are flashing but buzzer does not sound ............................ 20-257
M-l 2(b) No abnormality is displayed on monitor but buzzer sounds .......................... 20-257M-13 Liquid crystal night lighting on monitor panel does not light up (Liquid crystal display is normal) 20-258 M-14 Coolant temperature gauge does not rise ........................................... 20-259
M-l 5 Coolant t emperature gauge does not give any display ( none of the gauge lamps li ght upduringoperation) ............................................................. ..20-26 0
M-16 Fuel level gauge always displays FULL ............................................. 20-261M-l 7 Fuel level gauge does not give display .............................................. 20-261M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking display does not light up ... 20-262
M-l 9 Swing lock prolix switch is ON (prolix), but monitor panel parking display does not flash ...... 20-262M-20 Defective fuel level sensor system ................................................. 20-263
M-21 Defective coolant temperature sensor system ........................................ 20-264
M-22 Defective engine oil level sensor system ............................................ 20-265M-23 Defective coolant level sensor system .............................................. 20-266
M-24 Defective hydraulic oil sensor system ............................................... 20-267M-25 Working light, panel lighting do not light up, or switch is not being used but lights light up ..... 20-268
a) Working l ight does not light up ................................................. 20-268b) Panel lighting does not light up ................................................ 20-268c) Light switch is not being used but working light lights up ............................ 20-269
M-26 Wiper motor does not work or switch is not being used but wiper is actuated ............... 20-270a) Wiperdoesnotwork.......... .......... .......... .......... .......... .......20-27 0b) Wiper switch is not being used but wiper is actuated ............................... 20-272
20-241a
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FOLDOUT 22
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY’ OCCURS ND PROBLEMS ON M CHINE
User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machine when there is abnormality
1. Abnormality in internal memory1. Service code cannot be cleared- El:01 Abnormality in error data
2. Excess voltage (more than 36V) has occurred3. Low voltage (less than 12V) has occurred 1. When there is abnormality in engine throttle 2. Time becomes 0O:OO.
4. Connector has separatedWhen starting switch is turned ON, keep time controller, control cannot be carried out.
switch pressed for 5 seconds to actuate clear2. When there is abnormality in pump controller,
function the output is cut off, so control cannot be
1:Abnormality in internal clock function carried out.
El:02 2. Excess voltage (more than 36V) has occurred1. Service code cannot be cleared
- Abnormality in clock data3. Low voltage (less than 12V) has occurred
2. Time becomes 0O:OO.3. Clock does not advance.
4. Connector has separated
El:03
1. Short circuit inside buzzerVoltage between PO1 (13) - (11) (12)
Short circuit in buzzer 2. Power line in contact with wiring harnessBuzzer ON: Max. 1V
between monitor panel POl(13) -buzzerBuzzer OFF: 20 - 30V Buzzer does not sound
output system
3. Abnormality in monitor panel
*When there is disconnection, El:03 is not
displayed and buzzer does not sound
20-242a
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MACt
Mon tor Dane1
C au t i on
buzzer
m
011
p&q%
\ R at te ry re la y
Battery
B uz ze r c an ce
PO(KES12)
w ndow washer
W iD er
contro
P um a c------
Eng ne o
level sensor
c oo a n t t em De ra tu re
ngincontro
Mode se lec t o n c onn ecto r
F ue l l ev el
E ng n e s De ec i se ns or
20
sensor
FOLDOUT 23
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TROUBLESHOOTING M-l, M-2, M-3
M-l [El:Ol] Abnormality in error data is displayed
* This is not a mechanical failure.It is not an abnormality if this occurs when the system has been reset after disconnecting connector PO1 fromthe monitor panel, or after fuse 13 has blown, or after connector HO5 has been disconnected.
Turn the starting switch OFF. Then keep the time switch depressed, switch the starting switch ON again,and keep the time switch depressed for 5 seconds to return the system to normal.
M-2 [El:021 Error in clock data is displayedj, This is not a mechanical failure.
It is not an abnormality if this occurs when the system has been reset after disconnecting connector PO1 fromthe monitor panel, or after fuse 13 has blown, or after connector HO5 has been disconnected.
Turn the starting switch OFF. Then keep the time switch depressed, switch the starting switch ON again,and keep the time switch depressed for 5 seconds to return the system to normal.
M-3 [El:031 Short circuit in buzzer output or contact of 24V wirinharness with buzzer drive harness is displayed
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if El :03is displayed. (If it is not displayed, the system has been reset.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
(male) I) - (21, 2)
Table 1
PO4 (male)
Between (1) and (2)
2 YES Defective monitor panel Replace
Yfi Is voltage between, - PO4 (2) and chassis -_ normal?
_ I startin g switch NO
* B&r ON: Max. 1 V
Contact of 24V wirin gharness with wiring harnessbetween PO1 (female) (13)and PO4 (female) (2). orcontact of wiring harness
betw een PO4 (1) and (2)
Repair orreplace
* Buzzer OFF: 20 - 30 V
NO1Defective buzzer Replace
Resistance value
200 - 300 n
Between (2) andchassis
Min. 1 MO
M-3 Related electric circuit diagram
XOBDOle3
20-245
a
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TROUBLESHOOTING M-4
M-4 When starting switch is turned ON, none of lamps on monitorpanel light up for 3 seconds
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
a) None of the lamps on monitor panel light up
NO
. Voltage: 20 - 30 V* Turn starting
switch ON. NO
M-4 Related electric circuit diagram
Monitor panel
POl(O4020)Power
a Fusesource
1 13a W
6 H05tM6)
GND @.
@--
g
X08DD164
b) Some of lamps on monitor panel (gauge display, time display) do notlight up
Cause
Iefective monitor panel
Iefective contact, orjisconnection in wiringiarness between fuse 13 -‘ 01 (female) (l)(2) or PO1female) (11)(12) - HO5 3)(4)-chassis round, or betweer
‘ use - PO1 6)
3lown fuse
Iefective monitor panel
Remedy
Replace
Repair orreplace
Iheck for cause>f blown fuse,:hen replace
leplace
20- 246
a
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TROUBLESHOOTING M-5, M-6
M-5 When starting switch is turned ON, monitor panel lamps allstay lighted up and do not go out
Cause
Defective monitor panel
Remedy
Replace
lighted up on monitor-6 When starting switch is turned ON, itemspanel are different from machine model
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
YES
1
Is display ofmonitoring code 01as shown in Tablel? 2
. Turn starting Do bits (I),, (‘ 2), 3)switch ON. _ of monitonng code .
*Set to NO 36 light up asmonitoring code shown in Table l?01
Turn starting* switch ON.
Set toh
monitoring code36
1 A
I ES
3 YES
Is voltage between_ PO2 4) (5) (6) -
10 chassis as shownm Table 2?
- Turn startino NOswitch ON.
able 1.:ON
D: OFF_ Table 2
Cause
Defective monitor panel
Defective contact, ordisconnection in wiringharness of PO2 female) (4)
(5) (6)
Remedy
i-
Replace
Repair orreplace
Connector PO2
Between (4) - GND
PC200PC21 0
20-30V
PC220PC250
Max. 1 V
Between (5) - GND
Between (6) - GND
20-30V
Max. 1 V
20-30V
Max. 1 V
20- 247
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TROUBLESHOOTING M-7
M-7 When starting switch is turned ON (engine stopped), CHECK itemsflash (Fluid levels for CHECK items are at specified level)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.Ir Check that the coolant is at the specified level before carrying out troubleshooting.
4 63 coolant level) flashes
1Does display goout when shor t 3 YESconnector isconnected to PO8
Is continuity
(female)?ys between PO1
2 - (female) (17) and -
. Turn starting(3) as shown in the
switch ON. Is there continuitytable?
_ between PO8 . Connect ct disconnect NONO (female) (2) and short connector to PO8
chassis ground?(female).
* Turn starting switch OFF.
Turn starting* Disconnect POl.
switch OFF.- Disconnect P08.
NO
Table
Short connector Continuity
Connected I Yes
Disconnected I No
M-7 a) Related electric circuit diagram
POl(O4020)\ I
H03( 516
Monitor
1 POS(X
Cause
Defective coolant levelsensor (reservoir tank)system (see M-23)
Defective monitor panel Replace
Defective contact, ordisconnection in wiringharness between PO8(female) (1) - HO3 (11) - PO1(female) (10)
Defective contact, ordisconnection in wiringharness between PO8(female) (2) -chassis ground
2)Coolant level sensor
panel
Remedy
-
Repair orreplace
fW;reor
XOSDD165
20- 248
0
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b) 0 (engine oil level) flashes
* Use the level gauge to check that the engine oil level is correct before carrying out troubleshooting.
Cause Remedy
3efective engine oil level
sensor system (see M-22)
-
When PO5 (female)(1) is connected to
2YEsIscontinuitybetween PO1(female) (18) and -fllLf12) as shown
. Connect PO5(female) (1) and 1chassis ground.Turn starting
in table? IIswitch ON. NODisconnect POl,
Connect tfdisconnect PO5
PO5 (female) (1) andchassis ground.Disconnect POl,PO5.Turn startingswitch OFF.
Table
teplace
Defective contact, ordisconnection i n wiringharness between W5(female) (1) - E08 (5) - (18)
lepair oreplace
M-7 b) Related electric circuit diagram
EOB(SWP14)orConnection with ground Continuity
Connected Yes
Disconnected
X08DD166
cl cl (hydraulic oil level) flashesRemedyause
Y1
5
When PO9 female)(1) is connected ochassif ground,cllte,s isplay go
Defective hydraulic oil levelsensor system lsee M-24)
. T~;x&tt$g
Disconnect w9.f
2YEsIs continuitybetween PO1
- (female) 13)) Ulh3) as shown in
the table?
Turn startingswitch OFF.Disconnect F’ Ol.
NO
Defective monitor panel
Defective contact, ordisconnection in wiring
’ harness between PO9(female) (1) - HO2 15) PO1(female) 13)
M-7 c) Related electric circuit diagram
-
repair oreplace
Table
Hydraulic oillevel sensorOl(O4020) H02(516) PO9fXl)
Monitpanel
X08DD167
Between PO9 (female)and chassis
Continuity
Connected I Yes
Disconnected I No
20-249
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TROUBLESHOOTING M-8
M-8 Preheating is not being used but preheating display lights up* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
2YEs Defective monitor panel
yEs Is voltage between
1 - PO1 8) and chassis -_ ground normal? Contact of 24V wiring
Is voltage betweenharness with wiring harness
wiring of startings between starting switch
switch terminal Rl - Ov NO terminal Rl - HO3 21, or
and chassis ground TurTurctaarti.“ g between PO1 8) - HO3 2) -
normal?El1 (male) (1)
ov Defective starting switch* Turn starting NO (contact between terminal 8
switch ON. and terminal Rl)Disconnectterminal Rl.
M-8 Related electric circuit diagramHO3
Starting switch M 1 ( M4 ) Ell(X2) t24v
f
Monitor panel r relay
:-i
Electrical intakeair heater
Remedy
Replace
Repair orreplace
Replace
rfT XOSDD188
20-250
a
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TROUBLESHOOTING M-9
M-9 When starting switch is turned ON and engine started, CHECKitems flash
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.Ir Always connect any disconnected connectors before going on to the next step.j, Check both the alternator system and the engine oil pressure system.
a) Alternator systemCause
I I or above.26-30V
* Start engine andrun at half throttle
NO
or above.
Iefective monitor panel
Iefective contact, orkzonnection in wiringiarness between alternator:erminal R - E08 (2k- HO3 7)- PO2 female) (13). ordefective alternator
Defective alternator
Remedy
Replace
Repair orreplace
20-25 1
a
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TROUBLESHOOTING M-9
b) Engine oil pressure system
* When engine oil pressure is normal
I Cause
When angina isrunning at low idlingand wiring harness of
.
oil pressure sensor sremoved, doesdis la o out?
. Engine at lowidling
2YESIs here continuitybetween PO1 16)
j (female) (17) and -chassis ground?
I I I
* Turn starting NOswitch OFF.Disconnect wiringharness PO1 of oilpressure sensor.
M-9 Related electric circuit diagram
Defective oil pressure sensor Replace
Contact of chassis groundwith wiring harnessbetween PO1 (female) (17)- HO3 (13) - E08 (8) - o ilpressure sensorPO1 (female) (16) - HO3(12) - E08 (7)
Defective monitor panel
PO2(04016) H03tS16) EOEterminal D
3(SWPl4) Altematc
Monitorpanet PO1 (04020)
Id-4 - I Pll
) i-y HOi) ,
I_
-nh
Engine oilpressure Sensor
Remedy
X08DD169
Repair orreplace
Replace
20-252
a
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TROUBLESHOOTING M-l 0
M-IO When starting switch is turned ON (engine stopped), CAUTIONitems flash (but when charge level, engine oil pressure do notlight up)
**
4
Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.
Alternator system
-i.yIrIs voltage between
YES PO2 fema e) (13)1 ~MJSIS ground
_Contact of 24V wiringharness with wiring harness
Is voltage betweenalternator terminalR and chassisground normal?
. When engine isstopped: Max. 3 V
m urn startingswitch ON.
. .
NObetween alternator terminal
_ . When engineis R - E08 (2) - HO3 7) - PO2stopped: Max. 3 V (female) (13)Turn startingswitch ON.Disconnect P02. Defective alternator
NO
Remove wmngharness fromterminal R.
b) Engine oil pressure sensor system* When engine oil pressure is normal
7 YES_-- Defective monitor panelIs here cont$rity
yEs between wmng_ harness f Wl 17)Defective contact, or
_
1 (female) 16) and disconnection in Wiringe terminal of oil harness between oil
Is there continuity Pressure ensor? pressure sensor terminalbetween oil * - I38 (8) - HO3 (13) - i’ Of
- NOpressure sensor - Turn starting
terminal and switch OFF.(female) (17) PI1 ( 1138(7) - HO3 (12) - PO1
chassis ground? Disconnect POl. (female) (16)
Turn startingswitch OFF.Remove wiringharness from oilpressure sensorterminal.
Id/x__ oil pressure sense
Remedy
eplace
epair orIplace
leplace
?eplace
qepair or,eplace
Replace
20- 253
a
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M-II When starting switch is turned ON and engine is started,CAUTION items flash (but when there is no abnormalityengine or CHECK items)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.
in
4
0(engine oil pressure) flashes
kl1
harness at terminal
sensor is removed,
. Engine at lowidling. B
B
I0Is there continuitybetween PO1(female) (17) - (11)(12)?
. Turn startingswitch OFF.
* Disconnect POl.
*NO
Cause
Defective engine oil pressuresensor
Contact of chassis groundwith wiring harnessbetween EO6 (male)(l) -HO3 (13) - PO1 (female) (171EO6(7) - HO3 (12) - FOI (16)
Defective monitor panel
M-l 1 a) Related electric circuit diagram
HO3(S16) E08( SWP14 1\A “ A/ w\
:zor PO1 (04>20 1 /MC\ -2
Remedy
Replace
20- 254
0
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TROUBLESHOOTING M-l 1
b) r63coolant level) flashes
Cause Remedy
See Item M-7 a). -
cl 09 coolant temperature) flashes
Cause Remedy
2 YESWhen short Defective coolant -
ym connector is temperature sensor, F connected to PO7 - system (see M-21)
_ (female) does
Is coolantdisplay go out?
temperature _ -Start engine. NO Defective monitor panel Replacegauge in redrange?
. Start engineand run at half * Defective monitor panel Replacethrottle orabove.
M-l 1 c) Related electric circuit diagramPO2 HO3 E08(04016) (516) (SWP14 1 PO7(X2)
Coolant temperature sensor
Monitorpanel
X08DD171
20-2550
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TROUBLESHOOTING M-l 1
d) I_ (battery charge) flashes
2YF3
Isvoltage betweenF_ PO2 fema e) (13)
a+%~lc~;ss~s round_
Isvoltage between p _alternator terminal _ .20-30V NORand chassisground normal?
Start engine.
. 20-30VStart engine andrun at half throttle
~0
or above.
M-l 1 d) Related electric circuit diagram
PO2 HO3(04016) (516)
E08(SWP14)
Monitorpanel
0 Alternator terminal R
e) EBfuel level) flashes
* Check that there is fuel before carrying out troubleshooting.
Yl1
. Start engine andrrn,;;;;lf throttle
2 YES
When PO6 s’ emoved, does
display go out?-
. Disconnect P06.Start engine.
NO
Wait for approx. 2 minutes.t The fuel level may vary, so the display s given a time delay.
M-l 1 e) Related electric circuit diagram
PO2(04016)
lonitoranel
Cause
Defective monitor panel
Defective contact, ordisconnection n wiring
harness between alternatorterminal R and PO2(femaleNl3)
Defective alternator
Cause
HO3(516) PO6(X1)
Fuel level sensor
Defective uel level sensorsystem (see M-20) orinterference with sensorinside uel tank
Defective monitor panel
Defective monitor panel
Remedy
Replace
Replace
Replace
X08DD173
20- 256
a
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TROUBLESHOOTING M-12
M-12 (a) When starting switch is turned ON (engine stopped), buzzerdoes not sound for 1 second, CAUTION items are flashing butbuzzer does not sound
***
Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Of the CAUTION items, the buzzer will not sound even if there is an abnormality in the battery charge or fuellevel.
1YES
When PO1 female)(13) and chassi sare connected,fioe; zer
Tz;c;;arng NO
Defective monitor panel
Disconnection in wiringharness between PO1(female) (13) - PO4 2) -buzzer, or between t24V -PO4 1) -buzzer t, ordefective buzzer
Replace
Repair orreplace
M-12 (b) No abnormality is displayed on monitor but buzzer sounds
1YEZ.S
When PO1 sremoved, doesbuzzer sound?
Remove POl.TJ-yct$g
NO
M-12 Related electric circuit diagram
Cause I Remedy
Contact of chassis groundwith wiring harness betweenPO1 female) (13) and buzzer
Defective monitor panel
PO1 POU(M2)
X08DD174
Repair orreplace
Replace
20-257
0
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TROUBLESHOOTING M-l 3
M-13 Liquid crystal night lighting on monitor panel does not light up(Liquid crystal display is normal)
* When the working light lights up normally.
Cause
wES
1Blown bulb or’ defectivecontact of bulb
Is bulb blown, or isthere defectivecontact? 2 yEsm Defective monitor panel
ARemove bulb.
Does bit (2) of
Check bulb- monitoring code 46 -
visually.NO light up? Defective contact, or
disconnection in wiring
NO harness between MO7 (male)(1)-X01 Ill-POl(female) (7)
M-l 3 Related electric circuit diagram
Monitor panel
POl(O4020)
X08DD175
R
R
Remedy
lepair oreplace
leplace
lepair oreplace
20- 258a
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TROUBLESHOOTING M-14
M-14 Coolant temperature gauge does not rise* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* If the coolant temperature actually does not rise, check the engine system.
1
nector is connectedto P07, do all gauge 2YF S
1 s here continuitv i 1
Ietween PO2 ’(female) and chassiswhen short l-l
. Turn startina NOswitch OFF.-
. Disconnect P02.
Defective coolanttemperature sensor system(see M-21)
Defective monitor panel Replace
Defective contact, ordiiconnection in wiringharness between PO2,(female) (12) - HO3 (6) - EOf(6) - PO7 (female) (A) or POi(female) (B) - E08 (11) - HO:fg3/o;;35 (4)(3) - chassis
Repair orreplace
M-14 Related electric circuit diagramPO2 HO3 E08(04016) (S16) (SWP14 1 PO7(X2)
Coolant temperature sensor
Monitorpanel
-
X08DD171
20-259
0
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TROUBLESHOOTING M-l 5
M-15 Coolant temperature gauge does not give any display (none ofgauge lamps light up during operation)
When PO7 sremoved, doescoolanttemperature gauge ,_ 2 YESdisplay appear?
- Is there continuityTurn startingswitch ON.
_ betweenP02f12) _NO ;;gducnhF
- urn starting NOswitch OFF.
- k7connect P02,
M-l 5 Related electric circuit diagramPO2 HO3 E08(04016) (516) (SWP14 ) PO7(X2)
Monitorpanel
Cause Remedy
Defective coolanttemperature sensor system(see M-21)
Contact of chassis groundwith wiring harness betweenPO7 female)(A) - E08 (6) -HO3 6) - PO2 female) (6)
Defective monitor panel
Coolant temperature sensor
PO1(04020)
I I
a.
H05tM6)
X08DD171
-
Iepair oreplace
Ieplace
20- 260
0
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TROUBLESHOOTING M-l 6, M-l 7
M-16 Fuel level gauge always displays FULL* Check if the tank is actually full before carrying out troubleshooting.
Cause Remedy
YES1
Defective fuel level sensor -system (see M-20)
When PO6 sremoved, does fuel _gauge displaydisappear?
2YE.sContact of chassis groundwith wiring harness betweenPO6 female) 11) HO3 5) -
Repair orreplace
^* Turn starting
Is there continuity PO2 female) (11)
switch-ON._ between PO2 11) _
- Wait for approx.NJ and-chassis
2 minutes.ground?
- The fuel level Turn starting NO Defective monitor panel Replacemay vary, so thedisplay is given a
switch OFF.
time delay.Disconnect P02,P06.
M-17 Fuel level gauge does not give display* Check that there is actually no fuel before carrying out troubleshooting.
Does displayappear when PO6(female)(l) and -chassis ground are 2connected? Is here continuity
- between m2 (female)
Turn starting_ (11)andchassisground
switch ON. NO when w6 (female) 1)and chassisgrwnd areccnnsctsd?
Turn starting NOswitch OFF.Disconnect P02,P06.
M-16, M-17 Related electric circuit diagram
Cause
PO2(04016)
Monitorpanel
HO3(516) PO6(XlI
Fuel level sensor
Defective fuel level sensorsystem (see M-20)
Defective monitor panel
Defective contact, ordisconnection in wiringharness between PO6Ifemale) (1) - HO3 (5) - PO2(female) (11)
Remedy
-
qepair or.eplace
XOSDD173
20- 2610
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TROUBLESHOOTING M-18, M-19
M-18 Swing lock switch is turned ON (LOCK) but monitor panelparking display does not light up
* Carry out this troubleshooting only if the swing lock is actually being actuated.
Cause Remedy
1YESIs voltage betweenPO2 9) and (16) as -shown in Table 11
. Turn startingswitch ON.
flE,
Defective monitor panel Replace
Disconnection in wiringharness between swing lock Repair orswitch 1) -X05 (1) - X01 (4) replace- PO2 female) (9)
M-18 Related electric circuit diagram
P2 x01 Swing lock switch(040161 (MIC21) X05(M4)
11
2Monitor panel 3-b
4”w6, 205CAO6540
M-19 Swing lock prolix switch is ON (prolix), but monitor panel
parking display does not flash* Carry out this troubleshooting only if the swing prolix is actually being actuated.
Cause Remedy
1 YES
is voltage betweenPO2 3) and (16) as -shown in Table l?
Turn starting NOswitch ON.
Defective monitor panel Replace
Disconnection in wiringharness between swing lock Repair orprolix switch (4) and PO2 replace(female) (3)
Table 1 VoltageM-19 Related electric circuit diagram
Swing lock prolix switch ON Max. 1 V
Swing lock prolix switch OFF 20 - 30 v
205CA06541
20- 262a
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TROUBLESHOOTING M-20
M-20 Defective fuel level sensor system
Note 1: Difference between fuel level and gauge displayFor gauge display position 10 (F), the amount of fuel is 78 - 100%; and for display position 1 (E) it is below14.5%. If the chassis is at an angle, the displayed amount of fuel will be different from the actual amount.Therefore, when checking, stop the machine at a horizontal place and wait for at least 2 minutes beforechecking the gauge. (The display is given a time delay so that the gauge can deal with sudden changes inthe fuel level.)
* Remove the fuel level sensor when carrying out the troubleshooting.
YE
resistance betweenconnector (1) and
3 YESinterference with sensor Replace (Note 2)
m Is there any large’
2- crack, chip, or
damage to float?
inside tank
Does arm movesmoothly?
_P Defective contact ofNO connector
Clean connectoror replace
’ W/afl*sensor
Table 1
Top (FULL) stopper posit ion Max.lZRI
I I
Iottom (EMPTY) stopperposition
Approx. 85 - 110 RI
Replace
Replace sensor
Replace
Top (FULL)
Bottom (EMPTY)
F20205053
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be carefulwhen installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
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TROUBLESHOOTING M-21
M-21 Defective coolant tern perature sensor system
YES1
Is esistance betweentemperature sensorconnector (male) (1) _and (2) as shown inTable l?
2yEs
- Check wiring- harness visually. -
NO IS it broken?
NO
Table 1
Sensor
Connector
Cause
Iefective contact ofzonnector (Note 1)
Iisconnection in wiringlarness (Note 2) (defective:lamp) (external forceapplied)
3efective sensor
Remedy
:lean connectorir replace
ensor
leplace sensor
leplace
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.
Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
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TROUBLESHOOTING M-22
M-22 Defective engine oil level sensor system
Note 1: Variations in oil levelThe oil level may change according to the angle of the machine, the engine speed, or the temperature ofthe oil, so if there is any display, check the oil level again with the machine at a horizontal place.
* Remove the engine oil level sensor when carrying out troubleshooting.
‘ I
resistance betweenconnector 11 andflange as shown in
Es
IOI I I
NO
Check wiringharness visually.Is t broken? H
I IINO
Cause
Defective movement of floatdue to dirt
Resonance of mount
Defective contact ofconnector (Note 2)
Disconnection in wiringharness (Note 3) (defectiveclamp) (external forceapplied)
Defective sensor
UP
lean
eplace sensorJote 4)
lean connectorr replace
,eplace sensor
leplace
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check
for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
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TROUBLESHOOTING M-23
M-23 Defective coolant level sensor system
Note 1: Variations in coolant levelThe coolant level may change according to the angle of the machine, or the swaying of the machine, so ifthere is any display, check the coolant level again with the machine at a horizontal place.
* Remove the coolant level sensor when carrying out troubleshooting.
YE
1
When float i s movedup and down, is
Etesistance between
connector (1) and (2)as shown in Table l?
P
Note 2:
Note 3:Note 4:
r1
Is any dirt stuck tomoving part offloat?
I ,piijiGJNO
I II
NO
Table 1
I Float UP Max. 1 Q
I Float DOWN Min.1 MD
ri==lloat
-II
I
,
Cause
Iefective movement of floatdue to dirt
Resonance of mount (Note 2
Defective contact ofconnector (Note 2)
Disconnection in wiringharness (Note 3) (defectiveclamp) (external forceapplied)
Defective sensor
F20205056
Iean
Clean connectoror replace
Replace sensor
If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Defective installation is a possible cause, so be careful when installing. If the problem occurs again, checkfor any vibration of the mount, and if there is excessive vibration, take the appropriate action.
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TROUBLESHOOTING M 24
M-24 Defective hydraulic oil level sensor system
Note 1: Variations in hydraulic oil levelThe hydraulic oil level may change according to the angle of the machine, or the swaying of the machine,so if there is any display, check the hydraulic oil level again with the machine at a horizontal place.
j, Remove the hydraulic oil level sensor when carrying out troubleshooting.
YI
resistance betweenconnector (1) and
K
-r----G
IIINO
4YES
Check wiringaharnessvisually. -
Is it broken?
NO
befective movement of floatlue to dirt
-G lesonance of mount
C befective contact ofC nnector (Note 2)
_:Ca
hsconnection in wiringlarness (Note 3) (defectivelamp) (external forcepplied)
tefective sensor
Cause Remedy
Clean
Replace sensor(Note 4)
Clean connectoror replace
Replace sensor
Replace
Table 1
)I,
F20205055
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check
for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
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TROUBLESHOOTING M-25
M-25 Working light, panel lighting do not light up, or switch is notbeing used but lights light up
a) Working light does not light up* Check that fuse 4 is normal.
Is resistancebetween MO7(fmrnl$ (1) and (2)
I
Connect 24V to pin(1). and connectpin (2) to ground.Max. ID
I t Disconnect R04.Ivrn light switch I
@IL. Checkvisually. NO
_. .Max. 1 R NODisconnect M07.
Cause
Iefective contact,lisconnection in lamp
lepair oreplace
kfective contact, or disconnection1 iring harness between MO7male) (2) -X01 (3) -fuse (4).etween MO7 (male) (1) -X01 (1) -IO4 11, RO4 (2) - HO5 (1) -chassi sIround, between RO4 (3) and fuse0). betw een RO4 (5) - HO2 (10) -flWfemale)ll) or between RO4(5) -102110) M Ot11 - MOS(female)1)
defective light relay leplace
defective light switch
b) Panel lighting does not light upj, When the lamp light up normally.
Cause
IYES
Is resistancebetween MO7(male) (1) -X01 (1) ---o~-;~maleH7)
Turn starting NOswitch OFF.
- F)slconnect M07,
Max. 1 R
Defective contact,disconnection in lamp forlighting inside monitor panel
Defective contact, ordisconnection in wiringharness between MO7 (male1(11 X01 (1) - PO1 female) (7
Remedy
leplace
Remedy
Repair orreplace
Repair or
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c) Light switch is not being used but working light lights up
YE
1
~When MO7 sdisconnected, doesworking light lightup?
2I I
When R04 is IContact of 24V wiringharness or power sourcewith wir ing harness betweenMO7 (male) (1) -X01 (1) -R04 (1)
Defective light relay. Disconnect R04. NO* Min. 1 MR
0
M-25 Related electric circuit diagram
Light switch
Defective light switch
LH decklamp
Rear lamp
Boom lamp,
RH decklamp
HO6
Floor
205CA06542
Remedy
3epair or.eplace
3epair orpeplace
Replace
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TROUBLESHOOTING M-26
M-26 Wiper does not work or switch is not being used but wiper isactuated
a) Wiper does not work* Check that fuse 7 is normal.
Wo8 (I) and (5)
Is resistancebetween Ml8Hfemale) (1) - (2).(1) - (4) as shownin Table l?
Turn startingswitch OFF.
NC,
Is resistancem between WlO
1 1 * Disconnect M18.
20-30V
- (male) (3) (4) - W08 - ' urn tartingswitch ON.NO
1 (4) (18) normal?
Is resistance . Max. 1 Qbetween WlO _ - Turn starting(ferr;lej (3) and (4) switch OFF. NO
Disconnect WIO,W08.Front windowclosed position:Min. 1 MR
- Turn starting NOswitch OFF.
* Disconnect WlO.
A-c-
Table 1
n
5Is resistance betweeneach pin of Ml8
1
(female) 1) (2) (4) and
W08 (female) l2lI14)‘ 1;“) s shown In Table
b Turn startingswitch OFF.
*~,inect M18,
6
Is voltage of eachpin of W04 asshown in Table 3?
I
Turn starting 1switch ON. NC
7YEsIs resistancebetween each pin
H
of W04 (male) -W08 (female) asshown in Table 2?
..^
)
1T$;c;t;rrng NW
zinect W04,
I3
0
, fActuation mode Ml8 (female) W08 (female) Resistance
Between (1) - (4) Between (12) - (15) Max. 1 QINT mode Between (1) - (2) Between (12) - (14)
.Between (2) - (4) Between (14) - (15)Min , MR
Between (1) - (2) Between (12) - (14)OFF mode Between (I) - (4) Between (12) - (15) Min 1 MQ
Between (2) - (4) Between (14) - (15)
Between (1) - (2) Between (12) - (14) Max. 1 R
ON mode Between (1) - (4) Between (12) - (15)Between (2) - (4) Between (14) - (15)
Min , MR
Table.2
Cause Remedy
- GotoA
Defective wiper washerswitch
Defective contact, ordisconnection in wiringharness between fuse (7) -W08 (female) (51, betweenFtl8 pNyle) (1). (8) - HO6
Defective contact, ordisconnection in wiringharness between Ml0 (male)
(3) (4) - W08 (female) (4) (18)
p Defective rear limit switchI Front window is open
Defective wiper motor
Defective wiper motorcontroller
Contact between wiringharnesses of system withdefective resistance
Contact of wiring harnessbetween Ml8 (male) (1) (2);;;,,:I; (y(l$E~l- WO8
leplace
lepair oreplace
tepair oraplace
Replace%S~;~~ow in
comsctly.
leplace
leplace
lepair oreplace
Iepair oreplace
Between W04 (female) (1) - W08 (female) (7)Between W04 (female) (3) - W08 (female) (6)Between W04 (female) (4) - W08 (female) (11)Beb,veen W04 (female) (5) - W08 (female) (9)Between W04 (female) (6) - W08 (female) (10)
Between W04 (female) (l )(3)(4)(5)(6) - GND
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TROUBLESHOOTING M-26
Table 3
Timing chart (when wiper switch is ON)
Timing chart (when wiper switch is HUTI
I
M-26 Related electric circuit diagram
item Symbol Set time
Length of pause untilnext actuation Tla 0.13 set
Safety circuit duringoperation of wiper Tsa 10 set
[safety function (111
Set time
10 set
Item Symbol
Length of pause untilnext actuation Tla 4 set
Safety circuit duringoperation of wiper. Tsa[safety function (111
Length of pause whenstowing wiper blade TIPSafety circuit duringoperation of wiper Tsp 10 set[safety function ( 211
1.5 set
gyver wiperswitch (OPT)
PCZIO-A018
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TROUBLESHOOTING M-26
b) Wiper switch is not being used but wiper is actuated
M
Is resistancebetween WlO
. Front windowclosed position:Min. 1 MDTurn startingswitch OFF.
- Disconnect WlO.
YESGotoA
NO
Is resistanceyEs between Ml8
2 - (female) (1) - (21,(1) - (41, 2) - (4) asshown in Table l?
Is resistancebetween WlO(male) (3) and (8)normal?
Max. 1 MR* Turn starting
switch OFF.Disconnect WlO,W08.
NO
IO
5v
i
Is voltage of eachpin of W04 asshown in Table 3?
Max. 1 MRTurn startingswitch OFF.
* Disconnect W04,
b
Table .l
Between (14) - (15)
Dek;;ive wiper washer Ieplace
Defective contact, ordisconnection in wiringharness between Ml0 (male1(3) (4) - W08 (female) (4) (18)
b Defective rear limit switch1Front window is open
Defective wiper motor
Defective wiper motorcontroller
Contact between wiringharnesses of system withdefective resistance
Contact of wiring harnessbetween Ml8 (male) (1) (2)(4)-X01 t21)tl1)(2o)-wO8(female) (12) (14) (15)
Remedy
Iepair or,eplace
ReplaceSet window inpositioncorrectly.
qeplace
?eplace
qepair orreplace
Repair orreplace
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TROUBLESHOOTING M-26
Table 3
Timing chart (when wiper switch is ON)
Timing chart (when wiper switch is INTI
F
Item
Length of pause untilnext actuation
Safety circuit duringoperation of wiper[safety function (l)]
Length of pause whenstowing wiper blade
Safety circuit duringoperation of wiper[safety function WI
Symbol’ Set time
Tla 0.13 set
Tsa 10 set
TIP 1.5set
Tsp 10 set
Item 1 ymbol 1 Set time 1
Length of pause untilnext actuation /Tla / 4sec /
Safety circuit duringoperation of wiper[safety function (l)]
Tsa 10 set
Length of pause whenstowing wiper blade TIP 1.5 set
Safety circuit duringoperation of wiper Tsp 10 set[safety function (2)l
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30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . . . . . . . 30-4
PRECAUTIONS WHEN CARRYING OUT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
SPECIAL TOOL LIST ...................... 30-7REMOVAL ....................... 30-I 1
AIR CONDITIONER COMPRESSOR ........ 30-I 1INSTALLATION ......... .......... 30-I 1REMOVAL ....................... 30-I 2
CONDENSER ASSEMBLY ................ 30-12INSTALLATION ................... 30-12REMOVAL ....................... 30-I 3
GOVERNOR MOTOR .................... 30-I 3INSTALLATION ......... .......... 30-I 3REMOVAL ....................... 30-14
HYDRAULIC OIL COOLER ................ 30-14INSTALLATION ................... 30-14REMOVAL ....................... 30-I 5
RADIATOR. HYDRAULIC OIL COOLER. . . . 30-15INSTALLATION . . . . . . . . . . . . . . . . 30-16REMOVAL . . . . . . . . . . . . . . . . . . . 30-I 7
....... HYDRAULIC ................. 30-17INSTALLATION ................... 30-20.............................. 30-21
DAMPER .............................. 30-21INSTALLATION ................... 30-21REMOVAL ....................... 30-22
FUEL TANK ............................ 30-22INSTALLATION ................... 30-22REMOVAL ....................... 30-23
CENTER SWIVEL JOINT. ................. 30-23INSTALLATION ................... 30-23DISASSEMBLY ................... 30-24ASSEMBLY ...................... 30-24REMOVAL ....................... 30-25
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . 30-25INSTALLATION . . . . . . . . . . . . . . 30-25DISASSEMBLY OF FINAL DRIVE ASSEMBLY
PC200-6, PC2OOLC-6, PC21OLC-6,
PC22OLC-630-26
ASSEMBLY & hi’ &‘ dl%k&tibLYPC200-6, PC2OOLC-6, PC21OLC-6,PC22OLC-6
30-29~is~ss~ki_v & F~NAL’ ~R~VEASSEMBLY
PC25OLC-630-33
ASSEMBLY & hk.‘ dl$k’ f%&ti~LYPC25OLC-6
30-36DlSASSEhi_V : : : : : : : : : : : : : : : : : : : 30-41
TRAVEL MOTOR ........................ 30-41ASSEMBLY ...................... 30-46 REMOVAL ....................... 30-54
SPROCKET ............................ 30-54INSTALLATION ................... 30-54REMOVAL ....................... 30-55
SWlNG MOTOR ......................... 30-55INSTALLATION ................... 30-55REMOVAL ....................... 30-56
SWING MACHINERY ..................... 30-56INSTALLATION ................... 30-56DISASSEMBLY ................... 30-57 ASSEMBLY ...................... 30-60 REMOVAL ....................... 30-64
REVOLVING FRAME ..................... 30-64INSTALLATION ................... 30-65 REMOVAL ....................... 30-66
SWING CIRCLE ......................... 30-66 INSTALLATION ................... 30-67 REMOVAL ....................... 30-68
...... RECOIL SPRING .. _ ............. 30-68INSTALLATION ..... _ ............. 30-68DISASSEMBLY ................... 30-69
RECOIL SPRING ........................ 30-69ASSEMBLY ...................... 30-70 DISASSEMBLY ................... 30-71
IDLER.. ............................... 30-71 ASSEMBLY ...................... 30-72 REMOVAL ....................... 30-74
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TRACK ROLLER ........................ 30-74INSTALLATION ................... 30-74DISASSEMBLY ................... 30-76 ASSEMBLY ...................... 30-77 REMOVAL ....................... 30-79
CARRIER ROLLER ...................... 30-79INSTALLATION ................... 30-79DISASSEMBLY ................... 30-80
ASSEMBLY ...................... 30-81 REMOVAL ....................... 30-83
TRACK SHOE .......................... 30-83INSTALLATION ................... 30-83REMOVAL ....................... 30-84
HYDRAULIC TANK ...................... 30-84 INSTALLATION ................... 30-85 REMOVAL ....................... 30-86
CONTROL PUMP ....................... 30-86INSTALLATION ................... 30-86
REMOVAL ....................... 30-87
MAIN PUMP ............................ 30-87INSTALLATION ................... 30-88 DISASSEMBLY ................... 30-89 ASSEMBLY ...................... 30-95 REMOVAL ...................... 30-I 11
MAIN PUMP INPUT SHAFT OIL SEAL ...... 30-I 11INSTALLATION .................. 30-I 11REMOVAL ...................... 30-I 12
CONTROL VALVE ...................... 30-I 12
INSTALLATION .................. 30-I 13 REMOVAL ...................... 30-I 14
CONTROL VALVE ASSEMBLY * -/-spool control valve(1 service valve) ................. 30-I 14INSTALLATION .................. 30-I 15 DISASSEMBLY .................. 30-I 16 ASSEMBLY ..................... 30-I 18 DISASSEMBLY .................. 30-120
TVC . LS VALVE ASSEMBLY FOR FRONT PUMP30-124
IN&hTb~ : : : : : : : : : : : : : : : : : : 30-124REMOVAL . . . . . . . . . . . . . . . . . . 30-125
TVC LS VALVE ASSEMBLY FOR REAR PUMP30-I 25
lN&kk& : : : : : : : : : : : : : : : : : : 30-125REMOVAL . . . . . . . . . . . . . . . . . . . . . 30-126
LS CONTROL EPC VALVE ............... 30-126INSTALLATION .................. 30-126REMOVAL ...................... 30-127
SOLENOID VALVE ..................... 30-127INSTALLATION .................. 30-127REMOVAL ...................... 30-128
WORK EQUIPMENT. SWING PPC VALVE . 30-128INSTALLATION .................. 30-128DISASSEMBLY .................. 30-129 ............................ _ 30-I .. ............................. 30-I ..
TRAVEL PPC VALVE. ................... 30-131INSTALLATION .................. 30-131DISASSEMBLY .................. 30-132ASSEMBLY ..................... 30-132REMOVAL ...................... 30-I 34
BOOM LOCK VALVE .................... 30-I 34INSTALLATION .................. 30-134REMOVAL ...................... 30-135
BOOM CYLINDER ...................... 30-135INSTALLATION .................. 30-136
REMOVAL ...................... 30-137
ARM CYLINDER ....................... 30-137 INSTALLATION .................. 30-138 REMOVAL ...................... 30-I 39
BUCKET CYLINDER .................... 30-139 INSTALLATION .................. 30-140 DISASSEMBLY .................. 30-141
PUMP MERGE-DIVIDER VALVE. .......... 30-120 HYDRAULIC CYLINDER ................. 30-141 ASSEMBLY ..................... 30-120 ASSEMBLY ..................... 30-143DISASSEMBLY .................. 30-121 REMOVAL ...................... 30-146
PRESSURE COMPENSATION VALVE ...... 30-121 WORK EQUIPMENT .................... 30-146ASSEMBLY ..................... 30-121 INSTALLATION .................. 30-147 DISASSEMBLY .................. 30-122 REMOVAL ...................... 30-148
MAIN RELIEF VALVE ................... 30-122 BUCKET .............................. 30-148 ASSEMBLY ..................... 30-I 23 INSTALLATION .................. 30-149 REMOVAL ...................... 30-I 24 REMOVAL ...................... 30-I 50
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ARM ................................. 30-150INSTALLATION .................. 30-151REMOVAL ...................... 30-I 52
BUCKET ARM ....................... 30-152INSTALLATION .................. 30-153REMOVAL ...................... 30-I 54
BOOM ............................... 30-154INSTALLATION .................. 30-155
REMOVAL ...................... 30-I 56
OPERATOR’ S CAB ..................... 30-I 56INSTALLATION .......... ........ 30-I 58 REMOVAL ...................... 30-I 59
COUNTERWEIGHT ............ : ........ 30-159INSTALLATION .................. 30-159REMOVAL ...................... 30-I 60
ENGINE THROTTLE CONTROLLER ....... 30-160INSTALLATION .................. 30-160REMOVAL ...................... 30-I 61
PUMP CONTROLLER ................... 30-161INSTALLATION .................. 30-161REMOVAL ...................... 30-162
MONITOR ............................ 30-162INSTALLATION .................. 30-162
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DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautionsgiven below when carrying out the operation.]
Precautions when carrying out removal workIf the coolant contains antifreeze, dispose of it correctly.After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.When draining oil, prepare a container of adequate size to catch the oil.Confirm the match marks showing the installation position, and make match marks in the necessary placesbefore removal to prevent any mistake when assembling.To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnectingthe connectors.Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.Check the number and thickness of the shims, and keep in a safe place.When raising components, be sure to use lifting equipment of ample strength.When using forcing screws to remove any components, tighten the forcing screws alternately.Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering afterremoval.Precautions when handling piping during disassemblingFit the following blind plugs into the piping after disconnecting it during disassembly operations.1) Hoses and tubes using sleeve nuts
Nomnalnumber
02
03
Pl ug (nut end)
07376-50210
07376-50315
Sl eeve nut (elbow end)Use the two i t ems below as a set
07221-20210(Nut) , 07222-00210(Pl ug)
07221-20315(Nut) , 07222-00312(Pl ug)
04 I 07376-50422 I ' 07221-20422(Nut) , 07222-00414(Pl ug)
05 07376-50522 07221-20522(Nut) , 07222-00515(Pl ug)
06 07376-50628 07221-20628(Nut) , 07222-00616(Pl ug)
10 07376-51034 07221-21034(Nut) , 07222-01018(Pl ug)
12 07376-51234 07221-21234(Nut) , 07222-01219(Pl ug)
2) Split flanae tvoe hoses and tubesNomnalnumber
04
Fl ange( hose end)
07379- 00400
Sl eevehead( tubeend)
07378-10400
Split flange
07371-30400
05 07379- 00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nomnalnumber
Part number1 D Drnsdi ons, L
06 07049- 00608 6 5 8
08 07049- 00811 8 6. 5 11
10 1 07049-01012 1 10 1 8. 5 1 12
I I I I
22 1 07049-02228 1 22 1 18. 5 1 28
24 1 07049-02430 1 24 1 20 1 30
27 1 07049-02734 1 27 1 22. 5 1 34
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DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.Install the hoses without twisting or interference.Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.Bend the cotter pin or lock plate securely.When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with
2-3 drops of adhesive.When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirtor damage, then coat uniformly with gasket sealant.Clean all parts, and correct any damage, dents, burrs, or rust.Coat rotating parts and sliding parts with engine oil.When press fitting parts, coat the surface with antifriction compound (LM-P).After fitting snap rings, check that the snap ring is fitted securely in the ring groove.When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the directionof the hook.When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulicequipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from
end of its stroke.3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.4. After doing this, run the engine at normal speed.
+ When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engineto circulate the coolant through the system. Then check the coolant level again.If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run theengine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed forrepair, always bleed air from the system after reassembling the parts.* For details, see TESTING AND ADJUSTING, Bleeding air.Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Iymbol Part No. Part Name I Q’ @ I Remarksature of work
Engine hydraulic pumpRadiator hydraulic oil cooler
Control pump Hydraulic pumpRemoval, installation of TVC LSvalve assembly
B 796- 460- 1210 Oil stopper I
Push-puller Iisassembly of center swivel joint
assemblyD
790- 101- 2501
790-331- l 1 O Wrench I 1 I Tightening of circle boltemoval, installation of swing circle
Disassembly, assembly of swingmachinery assembly
G
E
F
1-
2
-
3-
4
-
I
H
-
2
-
796-426-I 120 Push tool 1 Press fitting of bearing
796427-l 120 Wrench I
796-427-I 130 Push tool I
790-l 01-2510
792- I 04-3940
01580-11631Press
fitting ofbearing
inner race
01643-31645Disassembly, assembly of finaldrive assembly 790-I 05-2100 Jack 1 I 1
790- 101- 1102 Pump I I796-570- l O Plate I PC25OLC
790-331- I 110
791- 545- 1510
791- 580- 1510
791-600-2001
794-6:;-8005
Installer
Compressor (A)
Compressor (B)
Extension
Cylinder (70 ton)
I PC250LC
I
I PC200PCZOOLC
I PC21 OLC
I PC22OLC
791-935-3160
790-101-1600Removal,
pressfitting of
master pin
790- 101- 1102 Pump I i - 1791- 600- 2001
791-6: ; - 8003
791-935-3160
Removal, installation ofrecoil spring assembly
790- 101- 1600 Cylinder (70 ton) I I I
790- 101- 1102 Pump I 1 I790-201 -I 500 Push tool kit
. 790-201 -I 620 0 Plate790-l 01-5021 Grip
.OIOIO-50816 Bolt
I Installation of recoil springI piston dust sealI
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work Symbol 1 Part No. I Part Name 1 Q’ ty 1 Remarks
Removal, installation of track shoeassembly
Assembly of idler assembly J
Disassembly, assembly of trackroller assembly
Disassembly, assembly of carrierroller assembly
Installation of track roller M 790- 331- 1110 I Wrench I 1 l Tightening of track roller bolt
Replacement of pump shaft oil seal N
790- 630- 3000790-101-1300
790-101-1102
Remover & installerCylinder (70 ton)
Pump
PC200PC200LCPC210LCPC22OLC
I 791-630-3000 I Remover & installer I 1 I790- 101- 1300
790-101-1102790-434-I 630
Cylinder (100 ton) 1 PC25OLC
Pump 1Installer 1 Installation (
Iff
Removepress fitting
of master pin
Toating seal
791- 601- 1000 Oil pump 1Charging with oil, checking
for air leakage
790434- l 640 I Installer I 1 l Installation of floating seal
791- 601- 1000 I Oil pumpI I
1Charging with oil, checking
for air leakage
790- 331- 1110 I WrenchI I
1Tightening of track roller
mounting bolt
797- 101- 1121 I Wrench I 1 I Removal, installation of nut
796-430-I 110 1 Push tool I 1 1 Press fitting of bearing
791-434-I 650 Installer
791-601-1000 Oil pump
1 Installation of floating seal
1Charging with oil, checking
for air leakage
791-463-1141 Push tool 1
790-201-2740 Spacer 1
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
r: Tature of work Symbol Part No. Part Name Q’ty Remarks-
1
-
2
-
3-
4
-
790-502-I 003Cylinder repair
stand
790- 101- 1102 Pump
ARMPC200
PC2OOLCPC21 OLCPC22OLCPC25OLC
BOOMPC200
PC2OOLCPC21 OLCPC22OLCPC250LC
BUCKET
PC220LCPC25OLC
Socket (widthacross flats: 95 mm)
90- 302- 1450
BUCKETPC200
PC2OOLCPC21 OLC
Hydraulic cylinder 0 Socket (widthacross flats: 85 mm)
90-302-I 350 1
790- 720- I 00 Expander 1Expansion of piston
ring
ARM &BOOMPC22OLCPC25OLC
BOOMPC200
PC2OOLCPC21OLC
BUCKETPC22OLCPC25OLC
BUCKETPC200PC200LCPC21 OLC
796-720-I 68007281-01589
RingClamp
11
796-720-I 670 Ring07281-01279 Clamp
796-720-I 660 Ring07281-01159 Clamp
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work
Hydraulic cylinder
Removal, installation ofwork equipment
Boom assembly
Symbol-
0
-
P
-
5
-
6
-
Part No. Part Name
790-201-I 702 Push tool kit790-201-I 831 . Push tool
.790-101-5021 Grip0 01010-50816 . Bolt
790-201-I 702. 790-201-I 8410 790-101-5021. OlOlO-50816
Push tool kit. Push tool
Grip. Bolt
790-201-1702790-201-I 851790-101-502101010-50816
Push tool kit. Push tool
GripBolt
790-201-I 702. 790-201-I 930
. 790-101-502101010-50816
Push tool kit. Push tool
GripBolt
790-201-I 500. 790-201-I 640
790-101-502101010-50816
Push tool kit. Push tool
GripBolt
790-201-1500790-201-I 650790-I 01-5021
.OlOlO-50816
Push tool kit. Push tool
GripBolt
790-201-I 5000 790-201-I 6600 790-I 01-5021
01010-50816
Push tool kit. Push tool
GripBolt
790-201-I 990790-I 01-502101010-50816
PlateGripBolt
796-900-I 200790-101-4000790-101-1102
RemoverPuller (50 ton long)
Pump (30 ton)
Remarks
BUCKETPC200
PC200LCPC21 OLC
BOOMPC200
PC2OOLCPC21OLC
BUCKETPC22OLCPC25OLC
ARM &BOOM
PC22OLCPC25OLC
ARMPC200
PC2OOLCPC21OLC
BUCKETPC200
PC200LCPC21 OLC
BOOMPC200
PC2OOLCPC21 OLC
BUCKET
PC22OLCPC25OLC
ARMPC22OLCPC25OLC
BOOMPC220LCPC250LC
ARMPC200
PC2OOLC
PC21 OLC
Removal of boom footpin
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DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR CONDITIONERCOMPRESSOR ASSEMBLY
A
1.
2.
3.
4.
5.
Under pressure, precautions must be taken toprotect eyes and skin. Never loosen any part of therefrigerant circuit while charged with gas. The airconditioner system should only be serviced by
qualified personnel.
Remove refrigerant gas (R134a) using dischargeports (1). Don’ t release gas into the atmosphere.
Remove fan guard (2).
Disconnect hoses (3) and (4) and disconnectelectrical connector.
Loosen bolts (5) and (6) and rotate compressorabout bolt (5) towards the engine and remove drivebelt (7).
Remove bolts (8) then remove air conditionercompressor (9).
INSTALLATION OF AIRI
CONDITIONER COMPRESSORASSEMBLY
Carry out installation in reverse order of removal.* Check O-rings of hoses are not damaged or
deteriorated.* Adjust the belt tension (see TESTING AND
ADJUSTING).
Fill with refrigerant (R-134a).
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DISASSEMBLY AND ASSEMBLY CONDENSER
REMOVAL OF CONDENSERASSEMBLY
1. Open forward left side cover and remove top cover.
2. Remove overfill tank bracket (2) by removing bolts
and washers (1).
3. Disconnect electrical connector and hoses (3) and(4).j, Loosen the sleeve nut slightly and release the
refrigerant (RI 34a) completely beforedisconnecting hoses and tubes.
* Fit plugs to hoses and tubes to prevent ingressof moisture, dust or dirt.
4. Remove condenser assembly (5) by removing boltsand washers (6).
INSTALLATION OF CONDENSERASSEMBLY
0 Carry out installation in the reverse order toremoval.* Check that the O-ring is not damaged or
deteriorated.0 Fill with refrigerant (RI 34a).
_ -
X13ED017
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DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
REMOVAL OF GOVERNORMOTOR ASSEMBLY
A1.
2.
3.
4.
Disconnect the cable from the negative (-) terminalof the battery.
Open engine hood and disconnect governor motor
connector (1).
Remove motor cover (4).
Remove motor rod (2).
Remove governor motor assembly (3).Sr
mRotate the shaft of the governor motor and donot stop it suddenly.
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY0 Carry out installation in the reverse order to
removal.
/-%q* Adjust the rod. For details, see TESTING AND
ADJUSTING, Testing and adjusting of governormotor lever stroke.
X12BV120
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DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OILCOOLER ASSEMBLY
1. Remove tool box and under cover, and set oilcontainer under chassis.
2. Disconnect hoses (4) and (5).
* Disconnect hose (4) at the cooler end, andhose (5) at the chassis end.
* Put blind plugs in the places that have beendisconnected.
3. Remove mounting bolts (6) at side of hydraulic oilcooler assembly.
4. Sling hydraulic oil cooler assembly (7 ), remove 2mounting bolts each on left and right, then lift offhydraulic oil cooler assembly (7).
6Hydraulic oil cooler assembly: 55 kg
kg
INSTALLATION OF HYDRAULICOIL COOLER ASSEMBLY
Carry out installation in the reverse order toremoval.
0 Refill with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
6
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DISASSEMBLY AND ASSEMBLY RADIATOR HYDRAULIC OIL COOLER
REMOVAL OF RADIATOR.HYDRAULIC OIL COOLERASSEMBLY
A
0
0
1.
2.
3.
4.
5.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil fillercap slowly to release the pressure inside thehydraulic tank.Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Hydraulic tank: Approx. 170 P
Drain engine coolant.
Remove undercover under radiator.
Disconnect small diameter from radiator (near cap)to reservoir tank.
Disconnect cooler hoses (4) and (5).
Disconnect radiator upper hose (9) and removeclamps of heater hose (10) from right side ofradiator assembly.
Remove fan guard (11).
I
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DISASSEMBLY AND ASSEMBLY RADIATOR. HYDRAULIC OIL COOLER
6. Disconnect radiator support rods (12) and (13).* Loosen the mounting bolts, then remove the
top mounting bolts and move the rods towardthe rear of the engine.
7. Disconnect radiator lower hose (14) and heaterhose (15).* The radiator lower hose is fixed by a clamp to
the radiator, so always disconnect the clamp.
8. Sling radiator and hydraulic oil cooler assembly(16) remove 4 bottom mounting bolts, then lift offradiator and hydraulic oil cooler assembly.* When raising the radiator and hydraulic oil
cooler assembly, check the position carefullyand do not let it hit the fan when removing it.
Radiator hydraulic oil coolerassembly: 125 kg
INSTALLATION OF RADIATOR.HYDRAULIC OIL COOLERASSEMBLY
Carry out installation in the reverse order toremoval.
Refilling with coolant.* Add coolant through the water filler to the
specified level. Run the engine to circulate thecoolant through the system. Then check thecoolant level again.
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
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DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
REMOVAL OF ENGINE.HYDRAULIC PUMP ASSEMBLY
AA
0
1.
2.
3.
Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside thehydraulic tank.Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Hydraulic tank: Approx. 170 P
Mark all the piping with tags to prevent mistakes inthe mounting position when installing.
Drain engine coolant.
Remove cotter pin (1) of stopper, then removeengine hood (2).
Remove side cover and mounting frame (3).
Remove engine hood mounting bracket (4), cover(5) and engine room partition plate (6).
XiOARO14
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DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
4. Disconnect hoses (7) (8) and (9) from NC LSvalve.
5. Pull out connectors (10) and (11) from holder anddisconnect.* Remove the connector wiring clamps
completely.
6. Disconnect hoses (12) and (13) from control pump.
7. Remove suction tubes (14) and (15).
8. Disconnect hoses (16) and (17) installed to top ofmain pump assembly.
9. Remove cover (18) and disconnect hose bracket(19) from pump.
10. Remove bracket (20) at counterweight end.
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DISASSEMBLY AND ASSEMBLY ENGINE HYDRAULIC PUMP
11. Disconnect connector (21).
12.
13.
14.
15.
16.
Disconnect governor motor connectors (22) andremove wiring clamp (23).
Disconnect starting motor wiring (24). Disconnectintake heat wiring (24A) and engine earth (24B).
Disconnect air conditioner compressor hoses (25)and (26). (If fitted)* Loosen the sleeve nut slightly and release the
refrigerant (gas) completely beforedisconnecting the hoses.
* Fit blind plugs to prevent the entry of moisture,dust or dirt into the hoses.
Disconnect fuel hoses (27) and ground connection(26).
Remove radiator upper hose (29), heater hose (30)air cleaner connector (31) and fan guard (32).
XlOAR022
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DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP
17. Remove fan (33), and disconnect radiator lowerhose (34).
18. Remove mount bolt, and raise engine and hydraulicpump assembly (36) slowly, then move to right sideof chassis and lift off.j, When removing the engine and hydraulic pump
assembly, check that all the wiring and piping
has been disconnected.
Engine hydraulic pump assembly:750 kg
INSTALLATION OF ENGINE.HYDRAULIC PUMP ASSEMBLY
0 Carry out installation in the reverse order toremoval.
\
Engine mount bolt: 276.9 f 31.9 NmI r ,J XlOARO25
m (28.3 f 3.3 kgm)
Refilling with coolant.* Add coolant through the water filler to specified
level. Run the engine to circulate the coolantthrough the system. Then check the coolantlevel again.
Refilling with oil (hydraulic tank)
j, Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed air from the hydraulic pump. For details,
see TESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPERASSEMBLY
1. Remove main pump assembly. For details, seeREMOVAL OF MAIN PUMP ASSEMBLY.
2. Remove damper assembly (1).
INSTALLATION OF DAMPERASSEMBLY
0 Carry out installation in the reverse order toremoval.
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DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANKASSEMBLY
1.
2.
3.
4.
5.
6.
Disconnect the cable from the negative (-) terminalof the battery.
Loosen drain valve (1) of fuel tank and drain fuel.
tFuel tank: Approx. 315 0 (when tank is
u full)
Disconnect fuel supply hose (2) and return hose(3).
Remove handrail (4) battery case (5) and cover(6).
Remove connector (7) from holder, and disconnectit.* Remove the wiring from the clamp, then
disconnect from the fuel tank.
If refueling pump is fitted, disconnect hose (9) fromtank tube.
Remove mounting bolts and lift off fuel tankassembly (8). j-%q
el Fuel tank assembly: 120 kgkg
INSTALLATION OF FUEL TANKASSEMBLY
a Carry out installation in the reverse order toremoval.
Fuel tank mounting bolt: 276.9 + 31.9Nm (28.25 f 3.25 kgm)
0 Refilling with oil (fuel tank)
Add fuel.
X12BD009
XlZBDOH
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DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVELJOINT ASSEMBLY
A
*1.
2.
3.4.
5.
6.7.8.
Release the remaining pressure in the hydrauliccircuit. For details, see TESTING ANDADJUSTING, Releasing remaining pressure fromhydraulic circuit.
Mark all the piping with tags to prevent mistakes inthe mounting position when installing.Disconnect hoses (I), (2) (3) and (4) and tubes (5)and (6), and remove filter and bracket assembly.* Machines equipped with additional attachment
circuit.
&Filter, bracket assembly: 95 kg
kgDisconnect hoses (7) (8) (9) and (10) betweentravel motor and swivel joint.Remove elbow (11).Disconnect drain hose (12).
Disconnect hoses (13) and (14) between controlvalve and swivel joint.Disconnect travel speed selector hose (15).Disconnect plate (16).Remove center swivel joint assembly (17).
Center swivel joint assembly: 45 kg
INSTALLATION OF CENTERSWIVEL JOINT ASSEMBLY
0 Carry out installation in the reverse order to
removal.
* Assemble the center swivel as shown in thediagram below.
Center swivel ’
+ s-6
2Pprocket
@@ X09DDO23
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding airJr Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY OF CENTERSWIVEL JOINT ASSEMBLY
1. Remove cover (1).2. Remove snap ring (2).3. Using tool D, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from swivelrotor.
ASSEMBLY OF CENTER SWIVELJOINT ASSEMBLY
1. Assembly slipper seal (7) and O-ring (6) to swivel
rotor.2. Set swivel shaft (5) to block, then using push tool,tap swivel rotor (4) with a plastic hammer to install.
Contact surface of rotor, shaft: Grease- (G2-LI)
XOSDDO28
* When installing the rotor, be extremely carefulnot to damage the slipper seal and the O-ring.
3. Install ring (3) and secure with snap ring (2).4. Fit O-ring and install cover (1).
Mounting bolt: 31.4 + 2.9 Nm (3.2 + 0.3kgm)
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVEASSEMBLY
1.
a
2.3.
Remove sprocket. For details, see REMOVAL OFSPROCKET.Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside thehydraulic tank.
Remove cover (1).Disconnect 4 travel motor hoses (2) and lift off finaldrive assembly (3).j r Be extremely careful not to damage the
tool surface of the hose mount.Final drive assembly: 425 kg
INSTALLATION OF FINAL DRIVEASSEMBLY
0 Carry out installation in the reverse order toremoval.
m
Final drive mounting bolt: 276.9 f31.9 Nm (28.25 f 3.25 kgm)
Bleeding air* Bleed the air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level.Run the engine to circulate the oil through thesystem. Then check the oil level again.
.---I
X07HH034
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVEASSEMBLYPC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6
1.
2.
3.
4.
Draining oilRemove drain plug and drain oil from final drivecase.
Final drive case: Approx. 5.5 I?
CoverRemove mounting bolts, then remove cover (1)using eyebolts 0.
X07HH037
SpacerRemove spacer (2).
No. 1 sun gear shaftRemove No. 1 sun gear shaft (3).
5. No. 1 carrier assembly1) Remove No. 1 carrier assembly (4).
X07HH039
2) Disassembly No. 1 carrier assembly as follows.i) Push in pin (5) and pull out shaft (6) from
carrier (7).9
j, After removing the shaft, remove pin
(5).ii) Remove thrust washer (8) gear (9),
bearing (IO), and thrust washer (11). 6XO7HHO40
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Ring gearUsing eyebolts 0, remove ring gear (12).
7. No. 2 sun gearRemove No. 2 sun gear (13).
8. Thrust washerRemove thrust washer (14).
9. No. 2 carrier assembly1) Remove No. 2 carrier assembly (15).
2) Disassemble No. 2 carrier assembly as follows.i) Push in pin (16) and pull out shaft (17) from
carrier (18).* After removing the shaft, remove pin
(16).
ii) Remove thrust washer (19) gear (20)bearing (21), and thrust washer (22).
10. Nut1) Remove lock plate (23).2) Using tool G,, remove nut (24).
12
XO7HHO41
19 17 21 18
20
---_---22
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
11. Hub assembly1) Using eyebolts 0, remove hub assembly (25)
from travel motor.
2) Disassemble hub assembly as follows.i) Remove floating seal (26).ii) Remove bearings (27) and (28) from hub
(2%
3) Remove floating seal (30) from travel motor(31).
X07HH045
26 XO7HHO46
X07HH047
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ASSEMBLY OF FINAL DRIVEASSEMBLYPC200-6, PC2OOLC6, PC21OLC-6, PC22OLC-6*
1.
2.
Clean all parts, and check for dirt or damage. Coatthe sliding surfaces of all parts with engine oilbefore installing.
Hub assembly1) Using push tool, press fit bearings (27) and (28)
to hub (29).2) Using tool Gq, install floating seal (26).
G4.
*
*
*
X07HH049
Remove all oil and grease from the O-ringand O-ring contact surface, and dry theparts before installing the floating seal.After installing the floating seal, check thatthe angle of the floating seal is within 1 mm.After installing the floating seal, coat thesliding surface thinly with engine oil.
3)
4)
Using tool G,, install floating seal (30) to travelmotor (31).* The procedure for installation is the same
as in Step 2) above.
Using eyebolts 0, set hub assembly (25) totravel motor, then using push tool, tap to pressfit bearing portion.
Nut1) Install nut as follows.
i) Using tool G,, push bearing inner raceportion.* Pushing force: 8.82 - 12.74 kN (0.9 -
1.3 ton)
j, Rotate the hub 2 - 3 times beforeapplying the pushing force to thebearing inner race.
ii) Measure dimension “a” in the condition inStep i) above.
&IIX07HH047
I
25
X07HH045
a
-.-.. --__- _ XO7HHO45
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
iii) Measure thickness “b” of nut itself.iv) Calculate a - b = c.v) Using tool G,, tighten nut (24) to a point
where dimension “d” is cj,,
vi) Using push-pull scale 8, measuretangential force in direction of rotation ofhub in relation to motor case.* Tangential force: Max. 294.2 N (30 kg)* The tangential force is the maximum
force when starting rotation.vii) Install lock plate (23).
* Install the lock plate as shown in thediagram below.
\Casting notch
X07HHOSO
Thread of mounting bolt: Thread- tightener (LT-2)
* Do not coat the tap portion of the nutwith thread tightener (LT-2).
3. No. 2 carrier assembly1) Assemble No. 2 carrier assembly as follows.
* There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove the
caulked metal from the inside diameter ofthe hole before starting to assemble.i) Assemble bearing (21) to gear (20) fit top
and bottom thrust washers (19) and (20)and set gear assembly in carrier (18).
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ii) Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (17).* When installing the shaft, rotate the
planetary gear. Be careful not todamage the thrust washer.
iii) Insert pin (16).* After inserting the pin, caulk the pin
portion of the carrier.* After assembling the carrier assembly,
check that gear (20) rotates smoothly.
2) Install No. 2 carrier assembly (15).
4. Thrust washerInstall thrust washer (14).
5. No. 2 sun gearInstall No. 2 sun gear (13).
6. No. 1 carrier assembly1) Assemble No. 1 carrier assembly as follows.
* There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove the
caulked metal from the inside diameter ofthe hole before starting to assemble.
i) Assemble bearing (10) to gear (9) fit topand bottom thrust washers (8) and (11) andset gear assembly to carrier (7).
Ii -X07HH056
h9
XO7HHOS
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ii) Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (6).* When installing the shaft, rotate the
planetary gear. Be careful not todamage the thrust washer.
iii) Insert pin (5).* After inserting the pin, caulk the pin
portion of the carrier.* After assembling the carrier assembly,
check that gear (9) rotates smoothly.2) Install No. 1 carrier assembly (14).
7. No. 1 sun gear shaftInstall No. 1 sun gear shaft (3).
8. SpacerInstall spacer (2).
9. Ring gearFit O-ring to hub end, then using eyebolts Q, align
position of bolt holes of hub and ring gear (12) andinstall.j, Remove all grease and oil from the mating
surface of the ring gear and hub.* Do not put any gasket sealant on the mating
surface of the ring gear and hub under anycircumstances.
IO. CoverUsing eyebolts 0, fit cover (I), then tightenmounting bolts with angle tightening wrench G,.
Mounting surface of cover: GasketJ=E& sealant (LG-6)
Mounting bolt: 1st pass98 Nm (10 kgm) 2nd pass Turn 70 - 80”
II. Refilling with oilTighten drain plug and add engine oil through oilfiller.
Q 1Final drive case: Approx. 5.5 4
* Carry out a final check of the oil level at thedetermined position after installing the finaldrive assembly to the chassis.
6’
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVEASSEMBLYPC25OLC-6
1. Draining oilRemove drain plug and drain oil from final drivecase.
Final drive case: Approx. 8.0 Q
2. CoverUsing forcing screws and eyebolts 0, remove cover(1).
3. Thrust washerRemove thrust washer (2).
4. No. 1 sun gear shaftRemove No. 1 sun gear shaft (3).
5. No. 1 carrier assembly1) Remove carrier assembly (4).2) Disassemble carrier assembly as follows.
i) Remove mounting bolts (5), then removeholder.
ii) Set carrier assembly (4) in press, thenusing push tool Q, pull out pin (6) andremove gear assembly (7).
iii) Remove bearing (9) and spacer (10) fromgear (8).
iv) Remove outer race (11).
I X07HH066
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6.
7.
8.
9.
10.
11.
12.
Ring gear1) Remove ring gear (12).2) Remove ring (13).
No. 2 sun gearRemove sun gear (14).
Thrust washer
Remove thrust washer (15).No. 1 carrier assembly1) Remove carrier assembly (16).
2) Disassemble carrier assembly as follows. I - 10
ii)
iii)
iv)
Remove mounting bolts (i7), then removeholder.Set carrier assembly (16) in press, thenusing push tool 0, pull out pin (18) andremove gear assembly (19).
Remove bearing (21) and spacer(22) fromgear (20).Remove outer race (23).
No. 2 ring gearRemove ring gear (24).
Gear couplingRemove mounting bolts, then remove gear coupling
(25).
SpacerRemove spacer (26).
7
XO7HHO64
I 2425-/
I
X07HH071
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
13. Hub assembly1) Using eyebolts a,, remove hub assembly (27)
from travel motor.
2) Remove floating seal (28).3) Remove cage (29), then remove floating seal
(30).4) Remove bearing (31) and (32).
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
ASSEMBLY OF FINAL DRIVEASSEMBLYPC250LC-6
*
1.
*
*
*
*
2.
Clean all parts, and check for dirt or damage. Coatthe sliding surfaces of all parts with engine oilbefore installing.
Hub assembly1) Using push tool, press fit bearings (32) and
(31).2) Using tool G,, install floating seal (30) to cage,
then install cage (29).Cage mounting surface: Gasket
- sealant (LG-6)
Mount bolt: 11.2 + 7.4 Nm (6.75 f.75 kgm)
Remove all oil and grease from the O-ring and O-
ring contact surface, and dry the parts beforeinstalling the floating seal.
After installing the floating seal, check that the angleof the floating seal is within 1 mm.
After installing the floating seal, coat the slidingsurface thinly with engine oil.
3) Using tool G,, install floating seal (28).
The procedure for installation is the same as in step2) above.
4) Using eyebolts @,, set hub assembly (27) ontravel motor, then using push tool, tap to pressfit bearing.
Adjusting bearing clearance1) Using tool G2, hold bearing and temporarily
tighten 2 bolts.2) Rotate hub 2 - 3 turns to settle bearing.3) Loosen bolts of tool G, and then tighten again.
Bearing clearance bolts: 24.5 + 4.9Nm (2.5 f 0.5 kgm)
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4) Using a depth micrometer, measure steppeddifference “ a” between end face of shaft andinner race.j, Measure two places and take the average
value.5) Select a spacer to give a value of “ a” between
0.15 - 0.1 mm.* Select the suitable thickness of spacer
from the 7 types of spacers.6) Install the selected spacer (26).
3. Gear coupling1) Fit gear coupling (25), and tighten with the
mount bolts.Mount bolt: Thread tightener (LT-2)
Mount bolt: 720.3 f 44 Nm (73.5 f4.5 kgm)
2) Check adjustment of bearing clearance again.
Hook spring balance 0 in the tap hole for thesprocket mount bolt, pull to rotate the hub onthe shaft and measure the starting force.j, Starting force: See Tightening Torques and
Standard Values Table.* If the starting force is higher than the
standard value, there is a preload on thebearing, so adjust again.
4. No. 2 ring gearFit ring gear (24).
Ring gear mounting surface: Gasket- sealant (LG-6)
*
*
*
Coat thread tightener only on ring gear uppersurface.
Remove all grease and oil from the matingsurface on the ring gear and hub.
Do not put any gasket sealant on the matingsurface of the ring gear and hub under anycircumstances.
X07HH019
24
X07HH070 I
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
5. No. 2 carrier assembly1) Assemble carrier assembly as follows.
* The inner race, outer race and spacer fromone set are similar to the other set, soassemble the sets with the same marks.
i) Using push tool, press fit outer race (23) ingear (20).
ii) Assemble spacer (22) and bearing (21).
iii) Set carrier assembly (16) in press,assemble gear assembly (19) then usingpush tool 0, press fit pin (18).* When press fitting the pin, be ex
tremely careful of the angle of the pin,and rotate the gear while press fitting.
* After assembling the carrier assembly,check that gear (19) rotates smoothly.
iv) Fit holder and tighten with mount bolts (17).Mount bolt: Thread tightener (LT-2)
Mount bolt: 382.2 + 39.2 Nm (39 f
4 kgm)
2) Install carrier assembly (16).
6. Thrust washerAssembly thrust washer (15).
7. No. 2 sun gearAssemble sun gear (14).
8. No. 1 ring gear1)
2)
Install ring (13).Mounting surface of ring: Gasket
0C& sealant (LG-6)
Align with teeth surface of carrier, and installring gear (12).
-Ring gear mounting surface:Gasket sealant (LG-6)
X07HH068
15 16
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
9.
10.
11.
12.
No. 1 carrier assembly1) Assemble carrier assembly as follows.
* The inner race, outer race and spacer fromone set are similar to the other set, soassemble the sets with the same marks.
i) Using push tool, press fit outer race (11) ingear (8).
ii) Assemble spacer (10) and bearing (9).
iii) Set carrier assembly (4) in press, assemblegear assembly (7), then using push tool 0,press fit pin (6).* When press fitting the pin, be ex
tremely careful of the angle of the pin,and rotate the gear while press fitting.
* After assembling the carrier assembly,
check that gear (19) rotates smoothly.iv) Fit holder and tighten with the mount bolts
(6).
A&i Mount bolt: Thread tightener (LT-2)
Mount bolt: 60.8 f 7.4 Nm (6.75 +0.75 kgm)
2) Align with teeth surface of ring gear, and installcarrier assembly (4).
.
No. 1 sun gear shaft
Assemble sun gear shaft (3).
Thrust washerAssembly thrust washer (2).
Cover1) Using eyebolts 0, install cover (1).
Cover mountingA sealant (LG-6)
surface: Gasket
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
13.
2) Tighten bolts to specified initial torque.Mount bolt: 98 Nm (10 kgm) Stan mark
on cover
3)
4)
5)
Set angle of hexagonal head of bolt tostandard, then make start marks on cover andsocket.Make end mark at specified angle from start
mark.* Make the end mark only on the cover.A Bolt tightening angle: 120” - 130”Tighten until start mark on socket is alignedwith end mark on cover.
Mounting boll Stan mark00 ocket
X07HH076
j, When disassembling or assembling thefinal drive, replace cover mounting bolt @with bolt @, and tighten according to theabove procedure.
Refilling with oilTighten drain plug and add engine oil through oilfiller to the specified level.
Final drive case: 8.0 I
* Carry out the final check of the oil level afterinstalling the final drive assembly to themachine. Check the level again at the specifiedposition.
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY OF TRAVELMOTOR ASSEMBLY
1. Travel motor assemblySet travel motor assembly (1) on tool A.
Tool A: Unit repair stand (790-501-5000)Bracket (790-901-2110)
Plate (790-901-I 350)
*
2.
A
Piston plugLoosen plug (2) slowly and remove, then removespring (3) and piston (4).There is a force of approx. 294 N (30 kg) applied tothe plug, so push the removal tool at a right anglewhen loosening the plug.
3. End cover assembly and valve plate
Xl OAV14t
1)
2)3)
4)
5)
Turn over tool A and remove safety valveassembly (5).Loosen plug (6) slowly.Lift off end cover (7).* The valve plate may be stuck to the end
cover, so be careful not to drop it.
Remove valve plate (8).* When reusing, keep in a safe place and be
careful not to scratch or damage thecylinder block contact surface.
Remove outer race (9) then remove spacer
(10).
8 9 IO 7
6
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
6) Disassembly of end cover assembly
0
A
ii)
iii)
iv)
v)
Loosen plug (6) slowly and remove, thenremove spring (1 I), piston (12) and spool(13).There is a force of approx. 441 N (45 kg)applied to the plug, so push the removaltool at a right angle when loosening theplug.Remove plug (14) then remove spring (15)and valve (16).Remove ring (17) then remove seat (18)spring (19), and spool (20).Remove plug (21) then remove ball (22).Remove plug (23) then remove valve (24).
4. SpringRemove parking brake spring (25).
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5. Brake pistonBlow in compressed air with tool C, and removebrake piston (26).* Tool C: Oil leak tester (799-301-1600)* Air pressure: 0.2 MPa (2 kg/cm2)* Be careful that the air pressure is not too high.
The brake piston will fly out.
6. BearingUsing bearing race puller 0 and gear puller Q,remove bearing (27).* Be careful not to apply force to the bearing
holder.* When reusing the cylinder block, put gasket
paper on the valve plate contact surface to
protect the surface.* Never allow the puller to scratch or damage the
cylinder block sliding surface.
7. Cylinder block and piston assembly1) Rotate tool A 90” , and remove cylinder block
and piston assembly (28) from motor case (29).Sr The cylinder block and piston assembly
may come off separately, so be careful notto drop them.
2) Disassemble piston assembly as follows.i) Remove plate (30) and disc (31).ii) Pull out piston assembly (33) from cylinder
block (32) and remove retainer guide (34)and preload pin (35).
* When removing the piston assemblyfrom the cylinder block, the preload pinmay come out, so be careful not tolose it.
28
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
8.
iii) Pull out piston (37) from retainer shoe (36).
I36
3) Disassemble cylinder block as follows. I 40 320
ii)
iii)
iv)
Set tool Q to cylinder block (32).-k Tool Q: Bolt (790-201-3610)
Washer (796-465-l 110)Washer (01643-32460)Washer (01643-32060) x 2Nut (01582-02016)
Hold bolt of tool Q with wrench, tighten nutto compress spring, then remove snap ring(36).
38
39Loosen nut slowly to relieve tension ofspring (39) then remove tool Q.Remove spacer (40), spring (39), andspacer (40) from cylinder block (32).
Xl QAVI 5I
Rocker cam and shaft assembly1) Remove rocker cam (41) together with shaft
assembly (42) from motor case (29).
2) Using push tool 0, remove bearing (44) fromshaft (43).
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
9. Disassembly of motor case1)2)
3)4)
Remove ball (45).Rotate tool A 90”, then remove snap ring (46)from motor case (29), then remove spacer (47).Remove oil seal (48).Remove outer race (49).
10. If above disassembly operation is not neededand only the oil seal is replaced, replace the oilseal as follows.1) Remove snap ring (46) and spacer (47).2) Using bar 8 (hit end face with hammer), hit
through to core of oil seal (48) then twist toremove.
* Hit at a point midway between the insideand outside circumference of the oil seal,and twist at two places on opposite sides(A and B in diagram) to remove.
* Be careful not to damage the shaft case.
46
47
48
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
ASSEMBLY OF TRAVEL MOTORASSEMBLY
Clean all parts, remove all burrs, and check for dirt ordamage. Coat the rotating and sliding surfaces of allparts with engine oil before installing.
Always check the following parts before assembling.
*
0
1.
2.
This check is unnecessary if both the cylinder blockand valve plate are replacement parts (new parts).
Check contact between cylinder block and valveplate (For details, see procedure for checkingcontact.)
Motor case1) Using push tool a,, press fit outer race (49).2) Set motor case (29) to tool A.3) Install ball (45).
Rocker cam and shaft assembly1)
**
*
2)*
*
Using tool R, press fit bearing (44) to shaft (43)to make shaft assembly (42).Tool R: Push tool (709-465-I 120)When press fitting the bearing, push the endface of the bearing inner race with tool R andpress fit until it is in tight contact with the endface of the shaft.Press fitting load: 2.39 - 9.69 kN (224 - 988 kg)
QPress-fitting surface of bearing:Lubricating oil (EO-IOCD)
Install rocker cam (41) together with shaftassembly (42) to motor case (29).When installing three rocker cam, check thecontact with the ball, and check that the rockercam moves smoothly without interfering withthe motor case or shaft.Coat the ball hole in the rocker cam with grease (G2-LI). (To prevent it from coming outwhen the cylinder block and piston assemblyare assembled.)
49XlOAV164
44
42
43
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3. Cylinder block and piston assembly1) Assembly of cylinder block. 40 32 1
0
ii)iii)
iv)
Assembly spacer (40) spring (39), andspacer (40) to cylinder block (32).Set tool Q to cylinder block (32).Hold bolt of tool Q with wrench, tighten nutto compress spring (39), then install snapring (38).
* Check that the snap ring is fittingsecurely in the groove.
Remove tool Q.
2) Assembly of piston assembly.Assemble piston (37) to retainer shoe (36).
3) Assembly of cylinder block and pistonassembly.i) Assemble 3 preloaded pins (35) to cylinder
block (32).j, Coat the preload pins with grease (G2-
Ll) to prevent them from coming out.
ii) Assemble retainer guide (34) to cylinderblock (32) then assemble piston assembly(33) to make cylinder block and pistonassembly (28).* Align the cylinder block and the soline
38
36XlOAVl5j
35
34 33Xl OAVI 6E
of the retainer guide.
iii) Install cylinder block and(38) to motor case (29).
28
piston assembly
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
4. Plate, disc and piston1) Assemble plate (30) and disc (31) in order.
* Do not wash the discs in trichlene or drizol,or blow strongly with air.
Front face of disc: Lubricating oilA (EOIO-CD)
Method of placing plates and discs on
top of each other.i) Align cutout arc teeth areas G, H and I
of the discs.ii) Protrusions A, B, C, D, E, and F on the
outside of the plates can be set at anyposition in relation to discs G, H, and I.
A G A G A G A
b ’ b ’ d b
XlOAV172
2) Fit O-ring and backup ring, and install brakepiston (26).* Assemble so that the grove in the brake
piston is aligned with the dowel pin in theend cover.
* Assemble the backup ring in the directionshown in the diagram.
5. Adjusting end play of shaft1)
2)
3)
Using tool S and puller 8, press fit bearing (27)to shaft (43).
* Tool S: Push tool (796-460-I 120)* When press fitting the bearing, push the
end face of the bearing inner race with toolS and press fit until it is in tight contact withthe end face of the shaft.
* Press fitting load: 2.67 - 10.96 kN (272 -1118 kg)
-Press fitting surface of bearing:Lubricating oil (EOIO-CD)
Assemble spacer (10) to end cover (7), andinstall outer race (9).Align with dowel pin and install valve plate (8)
to end cover (7).*
*
Check that there is no interference with thebearing and pin.Do not hit the valve plate or apply anyimpact when assembling. (There is dangerthat this will damage the sliding surface orcause distortion.)
26
Backup ring
O-ring
4
Backup ring
8 9 10 7
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
4) Install end cover (7) to motor case (29).j, Do not install the O-ring and spring of the
parking brake.-Mounting bolt: 460.9 + 29.4 Nm (47+ 3 kgm)
5) Fit dial gauge @ o motor case (29) move shaftin axial direction, and measure end play
between shaft and bearing.* End play: 0.05 - 0.25 mm
6) If dimension is not within standard value, adjustagain as follows.i) Remove end cover.ii) Remove valve plate and outer race.iii) Set outer race (9) to bearing, then measure
dimension a between end face of outerrace and case, and calculate spacer b from
the following formula.b = 12.95 -a
iv) Select spacer from table below.
XlOAV17:
al
b(mm) 1 1.70- 1.79 1 1.80- 1.89 1 1.90- 1.99 1 2.00-2.09
Spacer to 708-8H- 708-8H- 708-8H- 708-8H-select 32220 32230 32240 32250
v) Assemble selected spacer, then assembleagain according to assembly Steps 5-2 thru5-5, and measure end play.
vi) After completion of adjustment, removeend cover, then remove valve plate.
6. End cover assembly1) Assembly of end cover assembly.* Precautions when installing plug.
Remove all oil and grease from the plugand male thread (end cover), and drycompletely.When coating with adhesive, coat with two
drops (approx. 0.04 g) at a point 2-3 mmfrom the tip of the thread of the plug.Plug: Thread tightener (loctite
a 638/648)
XlOAV175
Do not apply any pressure to the plug for30 minutes after tightening.
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
i) Assemble valve (24), then fit O-ring andinstall plug (23).
Plug: 23.5 f 3.9 Nm (2.4 ~tr 0.4kgm)
ii) Assemble ball (22) then fit O-ring andinstall plug (21).
Plug: 23.5 f 3.9 Nm (2.4 f 0.4
kgm)
iii)
iv)
Assemble spool (20) spring (19) and seat(18) in order, then fit O-ring and install ring(17).Assemble valve (16) and spring (15) inorder, then fit backup ring and O-ring andinstall plug (14).
Plug: 137.3 f 14.7 Nm (14 + 1.5kgm)
v) Assemble spool (13) piston (12) andspring (11) in order, then fit O-ring and
tighten plug (6) temporarily.
2) Align with dowel pin, and install valve plate (8)to end cover (7).j, Check that there is no interference with the
bearing and pin.j, Do not hit the valve plate or apply any
impact when assembling. (There is danger
that this will damage the sliding surface orcause distortion.)
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3) Install parking brake spring (25).4) Fit O-ring, align dowel pin with groove portion of
brake piston, and install end cover (7).* Be extremely careful that the O-ring does
not come out or get caught.Mating surface of motor case:
- Gasket sealant (LG-7 or LG-5)(Loctite 572/575)
Mounting bolt: 460.9 f 29.4 Nm (47f 3 kgm)
5) Tighten plug (6).Plug: 419.2 f 46.6 Nm (42.75 f4.75 kgm)
6) Fit backup ring and O-ring, and install safetyvalve assembly (5).
Safety valve assembly: 318.7 f24.5 Nm (32.5 f 2.5 kgm)
7. Piston plugAssemble piston (4) and spring (3) then fit O-ringand install plug (2).* Precautions when installing plug.
1) Remove all oil and grease from the plugand male thread (motor case), and drycompletely.
2) When coating with adhesive, coat with twodrops (approx. 0.04 g) at a point 2-3 mmfrom the tip of the thread of the plug.
Plug: Thread tightener (LoctiteA 638/648)
3) Do not apply any pressure to plug for 30minutes after tightening.
Plug: 362.8 + 39.2 Nm (37 f 4 kgm)
8. Installation of oil seal1) Check that there are no burrs or flashes at the
corners of the shaft.2) Using tool T, press fit oil seal (48).
j, Tool T: Push tool (796-465-l 130)Grip (790-101-5221)Bolt (01010-51225)
* Clean the oil seal lip.
- Tip of oil seal (wholecircumference) Grease (G2-Ll-S)
25
6
6
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3) Assemble spacer (47), and install snap ring(46). 46 47
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
CHECKING CONTACT BETWEENCYLINDER BLOCK AND VALVEPLATE
* This check is unnecessary if both the cylinder blockand valve plate are replacement parts (new parts).
* This check applies if one of the parts is areplacement part or a restored part.
* If the contact is defective, use a surface plate andcorrect by lapping.
1. Make a centering tool for the cylinder block andvalve plate.* The tool can be made from plastic, bakelite or
any other soft material.2. Remove all oil and grease from the parts to be
checked.* Do not wipe with a cloth.
3. Set the tool in position, then paint the cylinder blockwith inspection paint.* Coat thinly with paint.
4. Push the valve plate with a force of 39.2 - 49.0 N (4- 5 kg) against the cylinder block, turn the valveplate 90” , then turn it back to the original position.Repeat this process two or three times.
5. Remove the valve plate, transfer the contactsurface to a tape, and check the contact surface.* The contact of the plane surface of the valve
plate and cylinder block must fulfill the conditionbelow and cover the whole circumferencewithout any break.1) The contact at the seal portion (range of 0
84.4 - 0 116.5 from the inside) must be atleast 80%.
2) The contact at the land portion (range of 0128 - 0 142) must be at lease 60%.
*
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DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Remove track shoe assembly. For details, seeREMOVAL OF TRACK SHOE ASSEMBLY.
2. Swing work equipment 90” , then push up chassiswith work equipment and set block 0 between track
frame and track shoe.
3. Lift off sprocket (1).
INSTALLATION OF SPROCKET
0 Carry out installation in the reverse order toremoval.
AThread of sprocket mounting bolt:Thread tightener (LT-2)
Sprocket mounting bolt:
PC200-6, PC2OOLC-6, 465.8 f 24.5 Nm (47.5 fPC21 OLC-6, PC220LC-6 2.5 kgm)
PC25OLC-6 637 f 49 Nm (65 + 5kgm)
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DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTORASSEMBLY
A Lower the work equipment completely to the groundand stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then set the safety lock lever to the LOCK position.
I. Disconnect hoses (I), (2), (3), and (4), and tubes(5) and (6) then remove filter and bracket assembly0.* 0 For machines equipped with additional
attachment circuit.
&
Filter, bracket assembly: 95 kgkg
2.
3.
Remove hose clamps (7) and (8).
Disconnect swing motor inlet and outlet hoses (9)(IO), and (11).
4. Remove bracket (12).
5. Disconnect drain hoses (13) and (14).
6. Disconnect pilot hose (15).
7. Remove swing motor assembly (16).Swing motor assembly: 65 kg
INSTALLATION OF SWINGMOTOR ASSEMBLY
0 Carry out installation in the reverse order toremoval.
0 Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
k Bleeding air* Bleed the air from the swing motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWINGMACHINERY ASSEMBLY
1. Remove swing motor assembly. For details, seeREMOVAL OF SWING MOTOR ASSEMBLY.
2. Using eyebolts 0, remove swing machinery
assembly (1). Jx 1* When removing the swing mach;nkry
assembly, lift off slowly and be careful not todamage the hoses.
Swing machinery assembly: 215 kg
INSTALLATION OF SWINGMACHINERY ASSEMBLY
0 Carry out installation in the reverse order toremoval.
Swing machinery mounting bolt: 548.8?r49 Nm (56 f 5 kgm)
Refilling with oil (hydraulic tank)j, Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. There check the oil level again.
Bleeding air* Bleed the air from swing motor. For details, seeTESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY OF SWINGMACHINERY ASSEMBLY
1. Draining oilRemove drain plug and drain oil from swingmachinery.
Swing machinery case: Approx. 6.8 e
2. CoverRemove mounting bolts, then remove cover (1).
3. No. 1 ring gearRemove No. 1 ring gear (2).
2) Disassemble No. 1 carrier assembly as followsi) Remove snap ring (5) then remove thrust
washer (6) gear (7) bearing (8), and thrustwasher (9).
XO9DH042
4. No. 1 sun gearRemove No. 1 sun gear (3).
5. No. 1 carrier assembly1) Remove No. 1 carrier assembly (4).
I
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
6.
7.
ii) Remove holder (10).iii) Remove shaft (11) from carrier (12).iv) Remove snap ring (13) from shaft.
CouplingRemove coupling (14).
CoverRemove mounting bolts, then using eyebolts 0,remove cover (15) .
8. No. 2 ring gearRemove No. 2 ring gear (16).
9. No. 2 sun gearRemove No. 2 sun gear (17).
10. BoltRemove holder mounting bolt (18).
11. No. 2 carrier assembly1) Remove No. 2 carrier assembly (19).
12 10 11
13
XOSDHO4j
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
2) Disassemble No. 2 carrier as follows.
9
*ii)
iii)
Push in pin (20), and knock out shaft (21)from carrier (22).After removing the shaft, remove pin (20).Remove thrust washer (23) gear (24)bearing (25) and thrust washer (26).Remove plate (27).
12. Shaft assembly1) Remove mounting bolts (28).2) Set shaft and case assembly to press, then
using push tool 0, remove shaft assembly (29)from case assembly (30).
21
23
24
25
262j
\ 20XOSDH050
3) Disassemble shaft assembly as follows. I0
ii)
Using push tool 0, remove cover assembly(31) and bearing (32) from shaft (33).Remove oil seal (34) from cover (35).
13. BearingUsing push tool, remove bearing (36) from case(37).
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLY OF SWINGMACHINERY ASSEMBLY
* Clean all parts, and check for dirt or damage.Coat the sliding surfaces of all parts withengine oil before installing.
1.
2.
BearingUsing push tool @), press fit bearing (32) to case(37).
Cover assembly1) Using push tool 0, press fit oil seal (334) to
cover (35).
aOutside circumference of oil seal:Gasket sealant (LG-6)
* Be careful not to let the gasket sealant(LG-6) get on the oil seal lip when pressfitting.
2) Fit cover assembly (31) to case (37), andtighten mounting bolts (28).
Cover mounting surface: Gasketa sealant (LG-6)
Mounting bolt: 66.2 f 7.4 Nm (6.75+ 0.75 kgm)
Lip of oil seal: Grease (G2-Ll)
Case assemblySet case assembly (30) to shaft (33), then usingpush tool @, press fit bearing inner race portion.
* When setting the case assembly to the shaft,be extremely careful not to damage the oil seal.
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
4. BearingUsing tool F, press fit bearing (36).* Press the bearing inner race and outer race at
the same time when press fitting. Do not pressonly the inner race when press fitting.
* After press fitting the bearing, check that thecase rotates smoothly.
5. No. 2 carrier assembly1) Assemble No. 2 carrier assemblv as follows
0ii)
iii)
There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove thecaulked metal from the inside diameter ofthe hole before starting to assemble.
Assemble plate (27) to carrier (22).Assemble bearing (25) to gear (24) fit topand bottom thrust washers (23) and (26)and set gear assembly to carrier (22).Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (21).
iv)
* When installing the shaft, rotate theplanetary gear. Be careful not todamage the thrust washer.
Insert pin (20).* After inserting the pin, caulk the pin
portion of the carrier.
2) Install No. 2 carrier assembly (19).
6. BoltTighten bolt (18).
Thread of mounting bolt: Thread- tightener (LT-2)
Mounting bolt: 176.4 + 19.6 Nm (18 +
2.0 kgm)
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
7. No. sun gearInstall No. sun gear (17).
8. No. 2 ring gearInstall No. 2 ring gear (16).
ARing gear mounting surface:Gasket sealant (LG-6)
9. CoverUsing eyebolts 0, sling cover (15) align position ofholes for oil filler port as shown in diagram, theninstall.
Cover mounting- sealant (LG-6)
surface: Gasket
Mounting bolt: 276 ?s 31.9 Nm (28.25 +3.25 kgm)
10. CouplingInstall coupling (14).
11. No. 1 carrier assembly1) Assemble No. 1 carrier assembly as follows.
i) Fit snap ring (13) to shaft (1 I), and tap witha plastic hammer to install shaft to carrier(12).
ii) Assemble holder (10).
Position ofoil filler port
XO9DHOl
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DISASSEMBLY AND ASSEMBLY SWING MACHINERY
iii) Assemble thrust washer (9), bearing (8),gear (7), and thrust washer (6), and installsnap ring (5).* After assembling the carrier assembly,
check that gear (7) rotates smoothly.Sr Replace thrust washer (6) with a new
part.
iv) Install No. 1 carrier assembly (4).
12. No. 1 sun gearInstall No. 1 sun gear (3).
13.
14.
15.
No. 1 ring gearAlign position of holes for oil filler port of No. 1 ringgear (2) with cover (15) then install.
Ring gear mounting surface: GasketA sealant (LG-6)
CoverInstall cover (1).
Cover mountingA sealant (LG-6)
surface: Gasket
Mounting bolt: 110.3 f 12.3 Nm (11.25+ 1.25 kgm)
Refilling with oilTighten drain plug and add engine oil through oilfiller.
Swing machinery case: Approx 6.8 e
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DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVINGFRAME ASSEMBLY
1.
2.
3.
4.
5.
6.
Remove 2 boom cylinder assemblies. For details,see REMOVAL OF BOOM CYLINDER ASSEMBLY.
Remove work equipment assembly. For details, see
REMOVAL OF WORK EQUIPMENT ASSEMBLY.
Remove counterweight assembly. For details, seeREMOVAL OF COUNTERWEIGHT ASSEMBLY.
Disconnect top mounting hoses (I), (2) and (3) ofswivel joint assembly at swivel joint assembly end.
Remove stopper link (4).
Remove mounting bolts, then lift off revolving frameassembly (5). 1*
A
Leave 2 bolts 0 each at the front and rear, use
a lever block to adjust the balance of therevolving frame assembly to the front and rear,and left and right, then remove the remainingbolts, and lift off.When removing the revolving frame assembly,be careful not to hit the center swivel jointassembly.
Revolving frame assembly: 5,200kg
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DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVINGFRAME ASSEMBLY
a Carry out installation in the reverse order toremoval.
Mating surface of swing circle: GasketA sealant (LG-1)
AThread of revolving frame mountingbolt: Thread tightener (LT-2)
Revolving frame mounting bolt:
ItemMounting bolt
Mounting bolttightening torque
Model
PC200-6PC21 O-6
PC220-6PC250-6
Size
22-l 10
24-l 50
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLEASSEMBLY
1. Remove revolving frame assembly. For details, seeREMOVAL OF REVOLVING FRAME ASSEMBLY.
2. Remove swing circle mounting bolts (I), leaving 1
bolt each in front and rear direction m* Swing circle assembly mounting bolts: 36
3. Sling swing circle assembly (2) at three points, thenremove remaining mounting bolts.
4. Lift off swing circle assembly (2).Swing circle assembly:
m
PC200-6, PC2OOLC-6 280 kgPC21 OLC-6, PC220LC-6
PC25OLC-6 I 716 ka
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DISASSEMBLY AND ASSEMBLY SWING CIRCLE
INSTALLATION OF SWINGCIRCLE ASSEMBLY
0 Carry out installation in the reverse order toremoval.
m/
1st pass:
2nd pass:
Thread of swing circle mounting bolt:Thread tightener (LT-2)
Swing circle mounting bolt: PC200-6,PC2OOLC-6, PC21 OLC-6, PC22OLC-6
Tighten to 191.3 f 19.6 Nm (19.5 f 2kgm)1)
2)i)
ii)
iii)
When using tool E.Set tool E to bolt (I), install clip toother bolt, then tighten bolt 48 f5” .
When not using tool E.Using the angle of the bolt head asthe base, make start marks on theswing circle and socket.Make an end mark at a point (onswing circle) 48 + 5” from the startmark.Tighten so that the start mark onthe socket is aligned with the endmark on the swing circle at the 48f 5” position.
Swing circle mounting bolt: PC250LC-6926.7 f 103.0 Nm (94.5 + 10.5 kgm)
G2et the soft zone S mark on the inside ring of
the inner race facing the right side as shown inthe diagram, then install to the track frame.
aSwing circle: Grease (G2-Ll)PC200-6, PC2OOLC-6, PC21 OLC-6,PC22OLC-6 = 21 QPC25OLC-6 = 34 P
lip
Swing circle start mark
Socketstart mark
socket&;zz2z$eerk
Socket start mark
Outer raoe soft zone
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DISASSEMBLY AND ASSEMBLY IDLER. RECOIL SPRING
REMOVAL OF IDLER. RECOILSPRING ASSEMBLY
1. Remove track shoe assembly. For details, seeREMOVAL OF TRACK SHOE ASSEMBLY.
2. Sling idler and recoil spring assembly (I), and pull
out to the front to remove.Idler recoil spring assembly:
*
3. Disconnect recoil spring assembly (3) from idlerassembly (2). m
Idler Recoil spring
PC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6 I I
140 kg 135 kg
PC25OLC-6 166 kg 257 kg
INSTALLATION OF IDLER.RECOIL SPRING ASSEMBLY
Carry out installation in the reverse order toremoval.
PC200-6, PC200LC-6, PC21OLC-6, and PC220LC-6* When installing the idler assembly and recoil spring
assembly, assemble so that the position of thegreasing plug on the idler is on the outside for theright side of the machine and on the inside for theleft side of the machine.
PC25OLC-6* Install recoil spring assembly (3) to idler assembly
(2) so that the mud removal hole in the yoke is atthe bottom.
0
6ii?\ s
0
0
\Mud removal ole
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DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOILSPRING ASSEMBLY
1
--_ .- - - .--. I
[
II’L
1. Remove piston assembly (2) from recoil springassembly (1).
2. Disassembly of recoil spring assembly1) Set recoil spring assembly (1) to tool H,.a The recoil spring is under large installed load,
so be sure to set the tool properly. Failure to dothis is dangerous.
* Installed load of spring:PC200: 108,780 N (11,100 kg).PC200LC,PC210LC,PC22OLC: 126,420 N (12,900 kg)
PC25OLC: 173,260 N (17,680 kg)2) Apply hydraulic pressure slowly to compress
spring, and remove lock plate (3), then removenut (4).* Compress the spring to a point where the
nut becomes loose.* Release the hydraulic pressure slowly and
release the tension of the spring.* Free length of springPC200: 558 mmPC2OOLC, PC210LC, PC22OLC: 603.5 mmPC25OLC: 795 mm
3) Remove yoke (6) cylinder (7) and dust seal
(8) from spring (5).3. Disassembly of piston assembly
1) Remove lock plate (10) from piston (9) thenremove valve (11).
2) Remove snap ring (12), then remove U-packing(13) and ring (14).
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DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRINGASSEMBLY
1. Assembly of piston assembly1) Assemble ring (14) and U-packing (13) to
piston (9) and secure with snap ring (12).2) Tighten valve (11) temporarily, and secure with
lock plate (10).
2. Assembly of recoil spring assemblyUsing tool H,, install dust seal (8) to cylinder(7).
1)
2)
3)
4)
Assemble cylinder (7) and yoke (6) to spring(5) and set in tool H,.
Sliding portion of cylinder: GreaseA (G2-Ll)
Apply hydraulic pressure slowly to compressspring, and tighten nut (4) so that installedlength of spring is dimension “a”, hen secure
with lock plate (3).Jr Installed length “a” of spring:PC200: 437 mmPC2OOLC,PC21OLC, PC22OLC: 466 mmPC25OLC: 648 mmRemove recoil spring assembly (1) from tool
HI .
3. Assemble piston assembly (2) to recoil springassembly (1).
Sliding portion of piston, wear ring:A Grease (G2-Ll)
* Assemble the cylinder assembly so that themounting position of the valve is 90” to theside.
j, Fill the inside of the cylinder with 300 cc ofgrease (G2-Ll), then bleed air and check thatgrease comes out of the grease hole.
“ 2,
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DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLERASSEMBLY
1. Remove dowel pin (I), then remove support (2).
2. Remove floating seal (3) from support (2) and idler(4).
3. Pull out idler (4) from shaft (5) and support (7)assembly.* It is filled with oil, so drain the oil at this point or
lay a cloth to prevent the area from becomingdirty.
4. Remove floating seal (6) on opposite side fromidler (4) and shaft (5) and support (7) assembly.
5.
6.
Remove dowel pin (8), then remove support (7)from shaft (5).
Remove bushings (9) and (19) from idler (4).
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DISASSEMBLY AND ASSEMBLY IDLER
ASSEMBLY OF IDLERASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5) withdowel pin (8).
3. Using tool G,, install floating seal (6) to idler (4) andshaft (5) and support (7) assembly.* Coat the sliding surface of the floating seal with
oil, and be careful not to let any dirt or dust getstuck to it.
* Remove all grease and oil from the contactsurface of the O-ring and the floating seal.
4. Assemble shaft (5) and support (7) assembly toidler (4).
10
X14AVO21
6
X14AVO23
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DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLERASSEMBLY
1. Lower work equipment, then loosen lubricator (1)and relieve track tension. mA The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator more
than one turn. If the grease does not come outeasily, move the machine backwards andforwards.
2. Remove mounting bolts of track roller, then swingwork equipment 90” , jack up machine, and removetrack roller assembly (2) towards outside ofmachine.
Track roller assembly:PC200, PC2OOLC, PC21 OLC, PC220LC40 kgPC25OLC52 kg
INSTALLATION OF TRACKROLLER ASSEMBLY
Carry out installation in the reverse order toremoval.
* Adjust the track tension. For details, seeTESTING AND ADJUSTING, Testing andadjusting track tension.
lace the plug on the outside of the chassis,
*
*
and set the-track roller assembly in themounting position.Operate the work equipment levers to lower themachine slowly, then tighten the mounting boltstemporarily.Operate the work equipment levers to lower themachine completely to the ground, then tightenthe mounting bolts fully.
Track roller assembly mounting bolt:PC200, PC2OOLC, PC21 OLC, PC22OLC
--
i--I-
I
,K3
1st pass: Tighten to 196.1 + 19.6 Nm (20 + 2kgm)
2nd pass: 1. When using tool K,.Using an angle tightening wrench,tighten bolt 90 f 5” .
2. When not using tool KJ.
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DISASSEMBLY AND ASSEMBLY TRACK ROLLER
1)
2)
3)
Using the angle of the bolt head asthe base, make start marks on thetrack roller and socket.Make an end mark at a point 90 +5” from the start mark.Tighten so that the start mark onthe socket is aligned with the endmark on the track roller.
Track roller start mark
Socket I
End mark
2nd pass: I:0
21)
2)
3)
When using tool K,.Using an angle tightening wrench,tighten bolt 105 + 5” .When not using tool K,.Using the angle of the bolt head asthe base, make start marks on thetrack roller and socket.
Make an end mark at a point 105 +5” from the start mark.Tighten so that the start mark onthe socket is aligned with the endmark on the track roller.
track roll r end mark ISocket start markw Track roller assembly mounting bolt:
PC25OLC
I X14BR015
1st pass: Tighten to 196.1 f 19.6 Nm (20 f 2kgm)
Track roller start mark
. “..._.. _.
’rade roller end mark Socket start mark
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DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY OF TRACKROLLER ASSEMBLY
1. Remove pin (I), then remove collar (2).
2. Remove floating seal (3) from collar (2) and roller(4).
3. Pull out roller (4) from shaft (5).* It is filled with oil, so drain the oil at this point or
lay a cloth to prevent the area from becomingdirty.
4. Remove floating seal (6) on opposite side fromroller (4) and shaft (5).
5. Remove pin (7) then remove collar (8) from shaft(6).
6. Remove bushings (9) and (10) from roller (4).
Xl4BROl7
X14BR018
I X14BROl
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DISASSEMBLY AND ASSEMBLY TRACK ROLLER
ASSEMBLY OF TRACK ROLLERASSEMBLY
1. Using push tool 0, press fit bushings (9) and (10) toroller (4).
2.
3.
Assemble collar (8) to shaft (5) and install pin (7).
Using tool K,, install floating seal (6) to shaft (5).* When assembling the floating seal, clean the
contact surface of O-ring (6~) and floating seal(6a), remove all grease and oil, and dry it.Make sure that no dirt or dust sticks to thecontact surface of the floating seal.
4. Using tool K,, install floating seals (6) and (3) to theroller (4).* For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and (3d),see the precaution for Step 3.
5. Assemble shaft (5) to roller (4).
6.
7.
Turn over roller (4) and shaft (5) assembly.
Using tool K,, install floating seal (3) to collar (2).* For details of the precautions when installing
floating seals (3a) and (3c), see the precautions
for Step 3.
8. Assemble collar (2) to shaft (5) and install pin (1).
,KI
K1
3-c;
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DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER ROLLERASSEMBLY
1. Lower work equipment, then loosen lubricator (I),and relieve track tension. mlA The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator more
that one turn. If the grease does not come out,move the machine backwards and forwards.
2. Using hydraulic jack 0, push up the track to aposition where carrier roller assembly can beremoved, then remove carrier roller assembly(2).
Carrier roller assembly:m
PC200, PC2OOLC PC21 OLC, PC220LC21 kgPC25OLC31 kg
INSTALLATION OF CARRIERROLLER ASSEMBLY
a Carry out installation in the reverse order toremoval.
* Adjust the track tension. For details, seeTESTING AND ADJUSTING, Testing andadjusting track tension.
?%2
read of carrier roller assembly mounting bolt:Thread tightener (LT-2)
--
r-=--l-
X14BR028
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DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY OF CARRIERROLLER ASSEMBLY
1. Remove plug (1) and drain oil.
:Carrier roller assembly:
u PC200, PC200LC PC21OLC, PC22OLC230 - 250 ccPC25OLC450 - 500 cc - X14BRO31
2.
3.
4.
5.
6.
Set carrier roller assembly on stand 0.
Remove cover (2).
Remove ring (3).
Using tool L,, remove nut (4).
Using push tool 0, pull out shaft assembly (5) fromroller (6) with press, then remove inner race (7).
6
lIsE l9
7. Remove outer races (8) and (9) from roller (6). -i X14BR032
8. Disassembly of shaft assembly1) Using puller 0, remove inner race (10).2) Remove floating seals (11).3) Using push tool a,, remove collar (12) from
shaft (13).
X14BR030
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DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
ASSEMBLY OF CARRIERROLLER ASSEMBLY
1. Using push tool 6, press fit outer races (8) and (9)to roller (6).
2. Assembly of shaft assembly
1) Using push tool @, press fit collar (12) to shaft(13).jr When press fitting, be careful that there is
no scuffing.Fitting portion of shaft: SAE30
2) Using tool LJ, assemble floating seals (11).* When assembling the floating seal, clean
the contact surface of O-ring (11~) andfloating seal (1 la), remove all grease andoil, and dry it. Make sure that no dirt or duststicks to the contact surface of the floating
seal.3) Assemble floating seals (1 I), then using push
tool 8, press fit inner race (10).* For details of the precautions when
installing floating seals (11 b) and (1 Id),see the precaution for Step 2).
3. Assemble roller (6) to shaft assembly (5).
4. Using push tool @), press fit inner race (7).* When press fitting the bearing, rotate the roller,
and press fit to a point where the rotationbecomes slightly heavier.
5. Using tool L,, tighten nut (4) to a point where drillhole in shaft is aligned with drill hole in nut.
6. Install ring (3).
7. Using push scale 8, check that it rotates smoothly.
lla
llc 1
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DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
9.
10.
Using tool L,, apply basic pressure to roller oil fillerport, and check for leakage of air from seal.* Basic pressure: 98 kPa (1 kg/cm2)* Method of checking: The basic pressure shall
be maintained for 10 seconds and the indicatorof the gauge shall not go down.
Using tool L,, fill carrier roller assembly with oil,then tighten plug (1).
Carrier roller oil:PC200, PC2OOLC, PC21 OLC, PC22OLC230 - 250 cc (SAE30)PC25OLC450 - 500 cc (SAE30)
To vacuum tank
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DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOEASSEMBLY
1.
2.
3.
4.
5.
Stop machine at a point where master pin ismidway between idler and carrier roller, and wherethere is space to lay out track assembly on ground.
Lower work equipment, then loosen lubricator (1)and relieve track tension. m/A The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator morethan one turn. If the grease does not come out,move the machine backwards and forwards.
Using tool I, pull out master pin (2). m
Remove tool I, and move machine forward so thatthe position of temporary pin 0 is at front of idler,and set block 0 in position.
Remove temporary pin Q, and remove dust seal,then drive machine in reverse to lay out track (3).
INSTALLATION OF TRACK SHOEASSEMBLY
0 Carry out installation in the reverse order toremoval.
* Adjust the track tension. For details, seeTESTING AND ADJUSTING, Testing andadjusting track tension.
se tool I and press fit so that the protrusion ofthe master pin is dimension “a”.Protrusion ‘a” of master pin:PC200, PC2OOLC, PC21 OLC, PC22OLC4*2mmPC25OLC4.2 + 2 mm
hen assembling the dust seal, coat thebushing contact surface with grease (G2-Ll).
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DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANKASSEMBLY
1.
2.
3.
4.
5.
Drain oil from hydraulic tank.Hydraulic tank: 170 P
Remove R.H. side cover together with covermounting frame.
Remove engine hood (I), hood mounting bracket(2), cover (3), and engine room divider board (4).
Disconnect pump outlet hoses (5).
Remove pump suction tube (6) together with jointhose (7).
6. Remove connector (8) at side of hydraulic tank fromholder and disconnect, then open wiring harnessmounting clamp 0 and disconnect wiring harness(9) from hydraulic tank.
I
7. Disconnect hoses (IO), (1 I), (12) and (12A).
XlOBVOW
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DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
8. Remove nut of U-bolt (14) for clamp of hydraulic oilreturn tube (13) then disconnect tube (13) fromhydraulic tank, and pull towards muffler with rope.
9. Remove mounting bolts, and lift off hydraulic tankassembly (15).
Hydraulic tank: 135 kg
INSTALLATION OFTANK ASSEMBLY
Carry out installation inremoval.
HYDRAULIC
the reverse order to
Hydraulic tank mounting bolt: 276.9 f
31.9 Nm (28.25 f 3.25 kgm)
Refilling with oil (hydraulic tank)jr Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* For details, see TESTING AND ADJUSTING,
Bleeding air.
lOBV056
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DISASSEMBLY AND ASSEMBLY CONTROL PUMP
REMOVAL OF CONTROL PUMPASSEMBLY
A
0
1.
2.
3.
Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.
Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Hydraulic tank: Approx. 170 e
Remove control pump inlet tube (1).
Disconnect control pump outlet hoses (2).
Remove control pump assembly (3) then remove
coupling (4). m
INSTALLATION OF CONTROLPUMP ASSEMBLY
0 Carry out installation in the reverse order toremoval.
Control pump mounting bolt: 66.2 r 7.4Nm (6.75 f 0.75 kgm)
r----
Refilling with oil (hydraulic tank)j, Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMPASSEMBLY
A
0
0
1.
2.
3.
4.
Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.
Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Drain oil from damper case.
Remove engine hood cover, side cover by pump,chassis cover on top of main pump assembly, andmounting frame.
Disconnect control pump hoses (1) and (2) and Fservo hoses (3) and (4) then disconnect tube (5) at
pump end.
Remove connectors (6) and (7) from holder anddisconnect.j, Disconnect the clamps of the connector wiring
from the body also.
Disconnect R servo hose (8) and remove divider
board (9) between engine and pump.
5. Disconnect top mounting hoses (IO), (II), (12)(13), and (14) of main pump assembly.
6. Disconnect suction tube (15) at bottom of mainpump, move down together with tube (5) andsecure.
7. Remove cover (16) behind hoses (10) - (15).
r
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
8. Remove main pump assembly as follows. I1)2)
3)
4)
5)
Leaving 2 - 3 bolts, remove mounting bolts.Sling main pump assembly (17) and removeremaining mounting bolts.Install 2 guide bolts 0 on diametrically oppositesides.Using forcing screws 0, disconnect main pumpassembly (17).
Lift off main pump assembly (17). mj
Main pump assembly: 147 kg
INSTALLATION OF MAIN PUMPASSEMBLY
Carry out installation in the reverse order toremoval.
&Involute spline of main pump: Anti-friction compound (LM-G)
AMating surface of main pump case:Gasket sealant (LG-6)
0 Refilling with oil (damper)* Add engine oil through the oil filler to the
specified level. Then check the oil level again.
Refilling with oil (hydraulic tank)
j, Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed air from the main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
DISASSEMBLY OF MAIN PUMPASSEMBLY (HPV95 + 95)
1.
2.
3.
0
4.
a
Pump assemblySet pump assembly (1) to tool A.* Tool A: Unit repair stand (790-501-5000)
Bracket (790-901-2110)
Plate (790-901-2150)
HoseRemove hose (2) elbow and tee.
Rear pump assembly1) Sling rear pump assembly2) Remove eight bolts at rear pump end, then
remove rear pump assembly (3).* Leave the end cap at the front end.* Be careful not to drop the rear valve plate,
cylinder block, piston assembly or otherparts.
Disassembly of front pump assembly
Control valve assembly1) Remove control valve assembly (4).2) Disassembly of control valve assembly.lVC valve
9
ii)
iii)
iv)
v)
vi)
Remove solenoid assembly (5) thenremove sleeve (6) and spool (7).Remove seat (8) then remove springs (9)and (10).Remove plug (1 I), then remove piston(12).
Remove locknut (13) then remove plug(14) and lever assembly (15).Remove nut (16) from lever assembly (15),then remove washer (17), bearing (18), pin(19) and lever (20).Remove snap ring (21) then remove plug(22).
LS valvei) Remove locknut (23) then remove plug
(24) seat (25) spring (26) and seat (27).j, Measure the dimension between the end
face of locknut (23) and the end face ofplug (24).
ii) Remove plug (28) then remove sleeve(29), piston (30) and spool (31).
Remove filter (32) then remove spacer (33) andorifice (34).
Xl OAV18i
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
5.
6.
End cap and valve plate1) Remove bolt (35) then remove washer (36)
shim (37) and seat (38).* Check the number and thickness of the
shims, and keep in a safe place.2) Remove end cap (39).
* When the valve plate is stuck to the endcap, be careful not to drop it.
3) Remove valve plate (40).
Disassembly of end capi) Remove dowel pin (41) from end cap (39).ii) Remove bearing (42).iii) Remove snap ring (43).iv) Remove coupling (44) and ring (45).
Cylinder block and piston assemblyRemove cylinder block and piston assembly (46)from pump case (47).j, The cylinder block and piston assembly may
come off separately, so be careful not to dropthem.
XlOAV18
42
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
Disassembly of cylinder block and pistonassemblyPull out piston assembly (49) from cylinder block(48) and remove retainer guide (50) and preloadpin (51).j, When removing the piston assembly from the
cylinder block, the preload pin may come out,so be careful not to lose it.
0 Disassembly of piston assemblyPull out piston (53) from retainer shoe (52).
Disassembly of cylinder blocki) Set tool U to cylinder block (46).
* Tool U:Bolt (790-201-3330)Washer (792-422-l 120)Washer (01643-32460)
Washer (01643-31845)Nut (01580-01815)
ii) Hold bolt of tool U with wrench, tighten nut tocompress spring, and remove snap ring (54).
iii) Loose nut of tool U slowly to release tension ofspring (55) then remove tool U.
iv) Remove seat (56), spring (55) and seat (57)from cylinder block (48).* Check the assembly direction of seat (57).
7. Servo piston assembly1) Remove plug (58). (Front pump only)2) Remove plug (59), then remove spring (60).
48 ’
1XlOAV19'
53\
48/
58 59 60 Y 0AV201
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
3)
4)
5)
6)
8. Shaft and cradle assemblyRemove rocker cam (64) from shaft and cradleassembly (65).
1)
2) Remove four bolts, then remove shaft andcradle assembly (65) from pump case (47).
Using bolt (6mm), remove stopper (61).
Set tool V in position, and assemble spacer 0to left side of rod (62).* Tool V:
Holder assembly (791-463-l 100)Plate (791-463-I 150)Bolt (791-463-I 160)
Move to side and loosen piston (63) so that
width across flats of rocker cam comes off fromwidth across flats of cradle.Remove piston (63) then remove rod (62).* Check the assembly direction of rod (62).
I
I \64’ 1 \
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
Disassembly of shaft and cradle assembly1)
2)
3)
Push cradle (67) with push tool 0 to remove itfrom shaft (66). When removing, be careful tokeep cradle (67) straight.Remove snap ring (68) then remove washer(6%
Using push tool 0, remove bearing (70) fromshaft (66).* Bearing (70) divides into the flange ring
and the bearing, so be careful not to loseeither part.
A Check the installation direction of thebearing.
9. Disassembly of pump case.1) Loosen locknut (72) of minimum swash plate
angle adjustment screw (71) and removescrew (71) and seal washer.\j, Before loosening the locknut, measure
dimension L between the end face of thecase and the end face of the screw.
2) Rotate tool A 90”, remove snap ring (73) frompump case (47), then remove spacer (74).
3) Remove oil seal (75).
IO. If above disassembly operation is not needed,and only oil seal is replaced, replace oil seal asfollows.1) Remove snap ring (73) and spacer (74).2) Using bar 8, hit end face with hammer. Hit
through to core of oil seal (75), then twist toremove.j, Hit at a point midway between the inside
and outside circumference of the oil seal,and twist at two places on opposite sides(A and B in diagram) to remove.
* Be careful not to damage the shaft.
69
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
0
11.
12.
13.
14.
15.
16.
17.
Disassembly of rear pump assembly
Rear pump assemblySet rear pump assembly (3) to tool W.* Tool W: Unit repair stand (790-501-5000)
Bracket (790-901-2110)Plate (790-901-1371)Plate (790-901-I 390)
Control valve assemblySame operation as in Item 4.
Control pump assemblyRemove control pump assembly (76) then removecollar (77) and coupling (78).
Cylinder block and piston assemblySame operation as in Item 6.
Servo piston assemblySame operation as in Item 7.
Shaft and cradle assemblySame operation as in Item 8.
Disassembly of pump caseLoosen locknut (80) of minimum swash plate angle
adjustment screw (79) then remove screw (79).* Before loosening the locknut, measure thedimension between the end face of the locknutand the end face of the screw.
76
77
80/
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
ASSEMBLY OF MAIN PUMPASSEMBLY (HPV95 + 95)
Clean all parts, remove all burrs, and check for dirt ordamage. Coat the rotating and sliding surfaces of allparts with engine oil (EOI O-CD) before installing.
Always check the following parts before assembling.1)
ii)
iii)
1.
Check contact of cradle and rocker cam (for details,see procedure for checking contact)Check contact between cylinder block and valveplate (for details, see procedure for checkingcontact).Check contact between valve plate and end cap (fordetails, see procedure for checking contact).
Assembly of front pump assembly
Shaft and cradle assemblyAssembly of shaft and cradle assembly
1) Assemble flange ring to shaft (66) then usepush tool @to press fit bearing (70).
Press-fitting surface of bearing: Grease- (G2-Ll)
2)
0
* When press fitting the bearing, push theend face of the bearing inner race withpush tool @.
Assembly washer (69), and install snap ring(68).Method of selecting lock washer (69).I) After press fitting bearing (70) to shaft (66)
assemble washer (69) (removed during
disassembly).ii) Measure clearance dimension a betweenend face of assembled washer (69) andsnap ring groove.j, Clearance dimension a: 1.45 - 1.60
mmiii) If clearance is not within above standard
value, select washer from table below andassemble.
WasherPart No.
Xl OAV214
Snap ring groove
66 Xl OAV215
Washer
thickness(mm)
3.1 3.0 2.9 2.8
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
3) Using push tool 6, press fit cradle (67) to shaft(66) to make shaft and cradle assembly (65).
Press-fitting surface of bearing:A Grease (G2-Ll)
* When press fitting the bearing, push theend face of the bearing outer race withpush tool 6.
4) Set pump case (47) to tool A. (front pump only)Set the rear pump to tool W.
5) Fit dowel pin and O-ring to bottom surface ofinside of pump case (47) then install shaft andcradle assembly (65).
Cradle mounting bolt: 110.3 f 12.3Nm (11.25 f 1.25 kgm)
* Be careful that there is no rising and thatthe pin does not fail out.
* Be extremely careful that the O-ring doesnot come out or get caught.
2. Rocker camAssemble rocker cam (64) to shaft and cradleassembly (65).
.67
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
3. Piston1) Assemble spherical portion of rod (62) to rocker
cam.* When assembling the rod, assemble with
the spring seat surface facing to the left.2) Fit piston (63) set tool V on top of rod (opposite
from when loosening), set spacer 0 on left sideof rod (62), and tighten piston (63).
* Before tightening piston (63), move to theside so that the width across flats of therocker cam comes out from the widthacross flats of the cradle. (This is to Xl OAV2l i
prevent damage to the rocker cam andcradle when tightening the piston.
-Near # area of piston thread indiagram on right. Coat with threedrops of adhesive (Loctite 648).
Coat with three drops near area
Piston: 318.7 f 24.5 Nm (32.5 + 2.5kgm)
4. Positioning minimum swash plate angle.1) Set tool X in position.
* Tool X:Cage assembly (796-460-1400)Plate (796-460-1410)Plate (796460-1420)Bolt (01010-51025) X2Bolt (01010-51435) X2
2) Assemble backup ring and O-ring, and tightenscrew (71) until it contacts piston (63).* Install the seal washer and locknut (72) to
screw (71) at position A in the diagram onthe right before the tip of screw (71) entersthe piston hole of the case.
Screw: 12.3 f 2.5 Nm (1.25 f 0.25kgm)
3) Tighten locknut (72).Between case and screw: Gasket
- sealant (LG-7 or LG-5 (Loctite
5721575))
w Locknut: 220.6 + 24.5 Nm (22.5 +2.5 kgm)
Pump case
72
71 63
4) After completion of assembly, carry out a benchtest to check the minimum flow.
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
5) Assemble backup ring and O-ring to stopper(61) and install to case.
5. Cylinder block and piston assemblyAssembly of cylinder blockAssemble seat (57), spring (55) and seat (56)to cylinder block (48).* Assemble with the tapered portion on the
inside of seat (57) facing down.
0
1)
2)3)
4)
Set tool U to cylinder block (48).Hold bolt of tool U with wrench, tighten nut tocompress spring (55) then install snap ring(54).j, Check that the snap ring is fitted securely
in the groove.Remove tool U.
Assembly of piston assemblyAssemble piston (53) to retainer shoe (52).
Xl OAV20:
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
6.
5)
6)
7)
Assemble three preload pins (51) to cylinderblock (48).* To prevent the preload pin from coming
out, coat the pin with grease (G2-Ll).Assemble retainer guide (50) to cylinder block(48), then install piston assembly (49) to makecylinder block and piston assembly (46).* Align the spline for the cylinder block and
retainer guide.
Install cylinder block and piston assembly (46)to pump case (47).* Before assembling the cylinder block and
piston assembly, assemble the widthacross flats of the rocker cam to the cradlesecurely.
End cap and valve plate1) Assembly of end cap
i) Assemble ring (45) to coupling (44) thenassemble to end cap (39).
ii) Install snap ring (43).iii) Using push tool 8, press fit bearing (42) to
end cap (39).Press-fitting surface of bearing:
a Grease (G2-Ll)
iv) Install dowel pin (41) to end cap (39).
2) Assemble valve plate (40) to end cap (39) andinstall to pump case.* Check that there is no interference with the
bearing and pin.* Do not hit the valve plate or apply any
impact when assembling. (There is dangerthat this will damage the sliding surface orcause distortion.)
XlOAV191
41 42. \ r-l *@ ?9
Xi OAVtg
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
3) Assemble dowel pin and O-ring to end cap(39), then assemble coupling (44) and ring (45)to shaft (66), and install pump case.* Be careful that there is no rising and that
the pin does not fall out.* Be extremely careful that the O-ring does
not come out or get caught.Mating surface of pump case:
A Gasket sealant (LG-7 or LG-5(Loctite 5721575))
Mounting bolt: 176.5 ?r 19.6 Nm (18+ 2 kgm)
7. Measuring rotating torque of pump assembly1) Set tool Y to pump shaft.
* ToolY:Bolt (01435-01014)Torque wrench (795-630-I 803)
2) Set torque wrench to tool Y, rotate shaft at low
speed (3 - 5 set/l turn) and measure rotatingtorque.* Check that the shaft rotates smoothly when
measuring the rotating torque.Variation range: Max. 0 - 2.9 Nm (0 -0.3 kgm)Rotating torque: Max. 0 - 24.5 Nm (0 -2.5 kgm)
* If there is any abnormality in the rotatingtorque, disassemble again and check.
8. Spring and plug1) Assemble spring (60) then fit O-ring and install
plug (59). Plug (59): 107.9 + 14.7 Nm (11 +1.5 kgm)
2) Install plug (58). Front only.
WPlug (58): 126.0 f 39.7 Nm (12.85 +4.05 kgm)
XIOAVIS
58 59 60 Y, a\, 40‘
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
9. Positioning maximum swash plate angle1) Install seat (38), shim (37), washer (36) and
bolt (35) to end cap (39).* Install the same shim (37) (for determining
position of max. swash plate angle) as wasremoved during disassembly, or assemblethe standard shim shown below.
Shim part No. Thickness(mm)
No. of standardshims
708-21-24170 1 0.1 I ~~ 2
708-21-24180 0.2 2
708-21-24190 0.5 2
Bolt (35): 156.9 + 9.8 Nm (16 + 1 kgm)
2) After completion of assembly, carry out a bench
test of the performance, and make the finalshim adjustment.
IO. Installation of oil seal.1)
2)
3)
Check that there are no burrs or flashes at thecorners of the shaft.Using tool Z, press fit oil seal (75).j, Tool 2:
Push tool (791-463-1141)Spacer (790-21 o-2740)
Assemble spacer (74) and install snap ring(73).
I_
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
II_ Control valve assembly1) Assembly of control valve assembly0 LS valve
i) Assembly spool (31) piston (30) andsleeve (29) to body, then fit O-ring andinstall plug (28).
.Plug‘ (28): 110.3 f 12.3 Nm (11.25f 1.25 kgm)
j, Check that the relative movements ofthe body and spool (31), sleeve (29)and piston (30) are smooth.
ii) Assemble seat (27) spring (26) and seat(25) then fit backup ring and O-ring andinstall plug (24).
iii) Install locknut (23).Locknut (23): 68.6 4 9.8 Nm (7 f 1
kgm)
* Install so that the dimension betweenthe end face of locknut (23) and the
end face of plug (24) is the dimensionmeasured during disassembly.
iv) After completion of assembly, carry out abench test of the performance and makefinal adjustment of plug (24).
0 TVC valvei) Fit O-ring and assemble plug (22), then
install snap ring (21).ii) Install pin (19), washer (17) bearing (18)
and nut (16) to lever (20) to make leverassemblv (15).
Nut‘ (l6): 10.8 f 1.0 Nm (1.1 f 0.1
kgm)
Nut (16):A 648)
Thread tightener (Loctite
j, Check that the movement of lever (20)and bearing (18) is smooth.
15
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
iii) Fit O-ring to plug (14), then install to leverassembly (15) and body.* Tighten to a point where the tip of the
plug is in contact with plug (22) thenturn back at least 180” and move fromthe mark to the position in the diagramon the right @=O.
iv) install locknut (13).
w Locknut (i3): 29.4 + 4.9 Nm (3 f0.5 kgm)
* Check that the movement of lever (20),plug (22) and plug (14) is smooth.
v) Assemble piston (12) then fit O-ring andinstall plug (11).
Plug (11):0.15 kgm)
vii) Install O-ring,assembly (5).
11.3 ?_ 1.5 Nm (1.15 +
then install solenoid
Solenoid assembly mounting bolt:
13.2 f 1.5 Nm (1.35 + 0.15 kgm)
- Mating surface of solenoidassembly: Gasket sealant (LG-7 orLG-5 (Loctite 5721575))
viii) Using tool AA, check that there is noleakage of oil or air from the mating surfacewith the solenoid assembly.
ix)
* Tool AA:Oil leak tester (799-301-1500)
* Air pressure: 0.5 MPa (5 kg/cm2)After completion of assembly, carry out abench test of the performance and make
final adjustment of plug (14).
Direction to loosen plug
Position I#J 0” when mark0
AAXlOAV221J
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
12. Rear pump assemblyAssemble dowel pin and O-ring to end cap, slingrear pump assembly (3), then align with spline ofshaft and install.* When slinging, be careful not to drop the
cylinder block, piston assembly, or other parts.
-Mating surface of pump case: Gasketsealant (LG-7 or LG-5 (Loctite 572/575)
mMounting bolt: 176.5 f 19.6 Nm (18 + 2
kgm)
13.
14.
HoseInstall elbow, tee and hose (2).
DHose: 24.5 f 4.9 Nm (2.5 + 0.5 kgm)
Pump assemblyRemove pump assembly from tool A.
2)
3)
Assemble orifice (34), and install spacer (33)filter (32) and O-ring.
Orifice (34): 9.8 f 2.0 Nm (I .O f 0.2kgm)
After completion of assembly, carry out benchtest of servo valve assembly (4) as anindividual part to check performance and carry
out adjustment.Fit O-ring and filter to control valve assembly(4) and install to pump case.* Be extremely careful that the O-ring and
filter do not fall out.* Tighten the mounting bolts gradually in turn
on opposite sides.Mounting bolt: 66.2 + 7.3 Nm (6.75+ 0.75 kgm)
Mating surface of servo valve:a Gasket sealant (LG-7 or LG-5
(Loctite 572/575)
Xl 0AV223
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
0
15.
Assembly of rear pump assembly
Shaft and cradle assemblySame operation as in Item 1. (Set pump case totool W.)
16. Rocker camSame operation as in Item 2.
17. PistonSame operation as in Item 3.
18. Positioning minimum swash plate angle
1)2)
3)
4)
Set toolX in position. _ -Assemble backup ring and O-ring, tightenscrew (79) until it contacts piston (63) thentighten locknut (80).
Screw: 12.3 + 2.5 Nm (1.25 f 0.25kgm)
Locknut: 220.6 f 24.5 Nm (22.5 +2.5 kgm)
After completion of assembly, carry out a benchtest to check the minimum flow.Assemble backup ring and O-ring to stopper(61) and install to case.
19.
20.
Cylinder block and piston assemblySame operation as in Item 5.
Pump case1) Remove rear pump case from tool W. Xl OAV2O
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
21.
22. Spring and plugSame operation as in Item 8.
23. Positioning maximum swash plate angle
Same operation as in Item 9.
2) Set front pump and end cap assembly (81) totool A.
Xl OAK’25
3) Assemble dowel pin and O-ring to end cap,sling rear pump case (82), then align spline ofshaft and install.* When slinging, be careful not to drop the
cylinder block, piston assembly or otherparts.
Mating surface of pump case:
- Gasket sealant (LG-7 or LG-5(Loctite 572/575)
Mounting bolt: 176.5 + 19.6 Nm (18f 2 kgm)
XlOAV22E
Measuring rotating torque of pump assembly1) Set tool Y to pump shaft.2) Set torque wrench to tool Y, rotate shaft at low
speed (3 - 5 set/l turn) and measure rotatingtorque.
* Check that the shaft rotates smoothly whenmeasuring the rotating torque.
Variation range: Max. 0 - 2.9 Nm (0 -0.3 kgm)Rotating torque: Max. 0 - 49 Nm (0 - 5kgm)
* If there is any abnormality in the rotatingtorque, disassemble again and check.
XlOAVlSE
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
24. Control pump assembly1) Install collar (77).2) Fit coupling (78) to drive shaft, fit O-ring and
install control pump assembly (76).Mounting bolt: 66.2 + 7.4 Nm (6.75 +0.75 kgm)
Mating surface of control pump: Gasket
- sealant (LG-7 or LG-5 (Loctite5721575))
25. Control valve assemblySame operation as in Item1 1.
26. HoseSame operation as in Item 13.
27. Pump assemblySame operation as in Item 14.
78
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
CHECKING CONTACT BETWEENCYLINDER BLOCK AND VALVEPLATE, ROCKER CAM ANDCRADLE
Valve plate and end cap
1. Checking contact between cylinder block andvalve plate.*
*
1)
2)
3)
4)
5)
This check is unnecessary if both the cylinderblock and valve plate are replacement parts(new parts).This check applies if one of the parts is areplacement part or a restored part.
Make a centering tool for the cylinder block andvalve plate.Jr The tool can be made from plastic, bakelite
or any other soft material.
Remove all oil and grease from the parts to bechecked.* Do not wipe with a cloth.Set the tool in position, then paint the cylinderblock with inspection paint.* Coat thinly with paint.Push the valve plate with a force of 39.2 - 49.0N (4 - 5 kg) against the cylinder block. Turn thevalve plate 90” , then turn it back to the originalposition. Repeat this process 2 or 3 times.Remove the valve plate, transfer the contactsurface to a tape, and check the contactsurface.
* The contact of the spherical surface of thevalve plate and cylinder block must fulfillthe conditions below and cover the wholecircumference without any break.I) The contact at the seal portion (range
from bottom to a90.5) must be at least80%.
ii) The contact at the land portion (rangefrom 490.5 to 4112) must be at least60%.
1 Seal portion 1 Land portion
Valve plate 1 Min. 80% I Min. 60%
Cylinder blockI
Centering tool
Xl OAV22i
Contact at seal pot-ho
Cylinder block Min. 80% Min. 60%
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
2. Checking contact of rocker cam and cradle*
*
1)
2)
3)
4)
This check is unnecessary if both the rockercam and cradle are replacement parts (newparts).This check applies if one of the parts is areplacement part or a restored part.
Remove all oil and grease from the parts to be
checked.j, Do not wipe with a cloth.Paint the cradle with inspection paint.* Coat thinly with paint.Put the rocker cam on top and push with aforce of 39.2 - 49.0 N (4 - 5 kg), and move itbetween the maximum swash plate angle andthe position where it contacts the stopper.Repeat this process 2 or 3 times.Remove the rocker cam, transfer the contactsurface to a tape, and check the contactsurface.*
1)
ii)
iii)
The standard for the contact surface is as
given below.
Contact within the central portion (32 - 44mm) must be at least 90%.Contact in range between central portion(32 - 44 mm) and 60 mm must be 50 -90%.Contact of area outside 60 mm width(outside) must be less than 50%. (It is notpermitted to have contact only at theoutside and no contact at the center.)
[Reference] If the contact IS not wlthln the
standard value, and lapping is carried out, itmust always be carried out for both partstogether.* Parts with any scratches or damagemust not be used.
Rocker cam
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
3. Checking contact between valve plate and endcap.*
*
1)
2)
3)
4)
This check is unnecessary if both the valveplate and end cap are replacement parts (newparts).This check applies if one of the parts is areplacement part or a restored part.
Remove all oil and grease from the parts to bechecked.* Do not wipe with a cloth.Paint the end cap with inspection paint.j, Coat thinly with paint.Push the valve plate with a force of 39.2 - 49.0N (4 - 5 kg) against the end cap, turn the valveplate 90” , then turn it back to the originalposition. Repeat this process 2 or 3 times.Remove the valve plate, transfer the contactsurface to a tape, and check the contactsurface.* The contact of the plane surface between
the valve plate and end cap must cover atleast 80% without any variation.
Contact must cover at least 80%of this surface without any
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DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP INPUTSHAFT OIL SEAL
1. Remove main pump assembly. For details, seeREMOVAL OF MAIN PUMP ASSEMBLY.
2. Remove snap ring (I), then remove spacer (2).
3. Lever up oil seal (3) with a screwdriver to remove.
j , When removing the oil seal, becareful not to damage the shaft.
INSTALLATION OF MAIN PUMPINPUT SHAFT OIL SEAL
0 Carry out installation in the reverse order to
removal.
Lip of seal: Grease (G2-Ll)
-Coat the outside circumference of theoil seal with grease (G2-Ll) thinly, thenpress fit.
* Using tool N, press fit oil seal (3).
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVEASSEMBLY
A Run the engine at low idling, operate the cylinder tothe end of its stroke without relieving the circuit,
0
a
1.
2.
3.
4.
5.
lower the work equipment to the ground, then stopthe engine. For details, see TESTING AND
ADJUSTING, Releasing pressure in hydrauliccircuit. After stopping the engine, do as follows.Loosen the oil filler cap slowly to release thepressure inside the tank.Operate the control levers.* Operate the control levers several times to
release the pressure in the accumulator.Start the engine and run at low idling for approx. 5seconds, then stop the operation and operate thecontrol levers.j, Repeat the above operation several times to
release the remaining pressure completely.
Open engine hood and remove divider covers (l),then disconnect intake connector.
Disconnect hoses (2) (3) and (4) remove 2connectors (5) from holder, then disconnect.* Remove the hose mounting elbow from the
valve body.
Remove block (6).
Disconnect hoses (7) and (8) and block (9).* When disconnecting block (9) loosen the
mounting bolts of the block tube flange first.
Disconnect tubes (IO), (II), and (12) and hoses(13), (14) and (15).* Disconnect 6 tubes and 7 hoses.* With hoses (15) there is another hose under
each of the hoses.
II \/ -’ XlOBHlSO
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
6. Disconnect hoses (16) and (17).
7. Sling control valve assembly (18) then removemounting bolts, and lift off control valve assembly.
Control valve assembly: 170 kg
INSTALLATION OF CONTROLVALVE ASSEMBLY
Carry out installation in the reverse order toremoval.
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVEASSEMBLY
*
1.
2.
3.
4.
5.
6.
7-spool control valve (1 service valve)
Release the remaining pressure in the hydrauliccircuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in hydrauliccircuit.
Open engine hood and chassis bodywork cover,remove divider cover (I), then disconnect intakeconnector (2).
Disconnect hoses (3) (4) and (5) and remove 2connectors (6) from clip, then disconnect.* Remove the hose mounting elbow from the
valve body.
Remove block (7).
Disconnect hoses (8) and block (9).* When disconnecting block (9) loosen the
mounting bolts of the flange for the tubes at thebottom first.
Disconnect hose (IO), and remove tube (11) andblock (12).
Disconnect hoses (13) and (14), and remove tubes(15) and (16).
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
7. Remove tubes (17) (18), and (19) and disconnecthoses (20) and (21).
8. Disconnect hosesbottom of valve.
(22), (23), and (24) mounted to
9. Lift off control valve assembly (25).
PlControl valve assembly: 185 kg
kg
INSTALLATION OF CONTROLVALVE ASSEMBLY
7-spool control valve (1 service valve)
Carry out installation in the reverse order toremoval.
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY OF CONTROLVALVE ASSEMBLY
*
a
1.
2.
3.
4.
The set pressure of the safety valve and armcounterbalance valve cannot be adjusted when theyare installed on the machine, so do notdisassemble.
The following explanation describes the 6-spoolcontrol valve.
Main relief valve, main unload LS relief valves1) Remove main relief valve (1).2) Remove main unload LS relief valve (3).
Unload valves, safety-suction valves, suctionvalves1) Remove unload valves (4) and (5).2) Remove safety-suction valves (6) (7) (8) (9)
(IO), and (11).3) Remove suction valves (12) (13) (14), and
(15).
Pressure compensation valvesj, Before moving any pressure compensation
valve, check and mark its mounting position.1) Remove bucket DUMP pressure compensation
valve (16) R.H. travel REVERSE pressurecompensation valve (17) boom RAISEpressure compensation valve (18), right swingpressure compensation valve (19), L.H. travelREVERSE pressure compensation valve (20)and arm IN pressure compensation valve (21).* After removing the pressure compensation
valves, remove check valve (22) from eachpressure compensation valve mount.
2) Remove bucket CURL pressure compensationvalve (23) R.H. travel FORWARD pressurecompensation valve (24) boom LOWERpressure compensation valve (25) left swingpressure compensation valve (26) L.H. travelFORWARD pressure compensation valve (27),and arm OUT pressure compensation valve(28).* After removing the pressure compensation
valves, remove check valve (29) from eachpressure compensation valve mount.
LS select valveRemove LS select valve (30).
5. LS shuttle valves, pump merge-divider valve,arm counterbalance valve1) Remove LS shuttle valves (31) and (32).2) Remove pump merge-divider valve (33), then
remove spring (57) and valve (58).3) Remove arm counterbalance valve (34) then
remove spring (59) and (60).
6. Remove covers (35) and (36).
7. Arm control valve, boom control valve, bucketcontrol valve1) Remove case (37) then remove spring (38)
and retainer (39).2) Remove spool assembly (40).
* Do not disassemble spool assembly (40).3) Remove case (41) then remove spring (42),
shim (43) and retainer (44).j, Shim (43) is only for the boom control
valve.
8. Swing control valve1) Remove case (45) then remove spring (46),
shim (47), and retainer (48).2) Remove spool assembly (49).
* Do not disassemble spool assembly (49).3) Remove case (41) then remove spring (42)
and retainer (44).
9. R.H. travel control valve, L.H. travel control
valve1) Remove case (50) then remove spring (51)
and retainer (52).2) Remove spool assembly (53).
* Do not disassemble spool assembly (53).3) Remove case (54) spring (55) and retainer
(56).
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
Right side of machineFrom front of machine
16 17 18 19 29 2122
Left ide of machine
From rear of machine
Front of machineFrom top of machine
11 15 10 14 9 XlOBH202
XlOBH203
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY OF CONTROL VALVEASSEMBLY0 Before assembling, coat the sliding surface with
engine oil.1. R.H. travel control valve, L.H. travel control
valve1)
2)
3)
Assemble spool assembly (53) to valve body.
Assemble retainer (56) and spring (55) tospool, then fit O-ring to case (54) and install.Case mounting bolt: 30.9 f 3.4 Nm(2.9 f 0.5 kgm)
Assemble retainer (52) and spring (51) tospool, then fit O-ring to case (50) and install.
Case mounting bolt: 30.9 f 3.4 Nm(2.9 + 0.5 kgm)
2. Swing control valve1)2)
3)
Assemble spool assembly (49) to valve body.Assemble retainer (44) and spring (42) tospool, then fit O-ring to case (41) and install.
Case mounting bolt: 30.9 + 3.4 Nm(2.9 f 0.5 kgm)
Assemble retainer (48), shim (47) and spring(46) to spool, then fit O-ring to case (45) andinstall.
Case mounting bolt: 30.9 + 3.4 Nm(2.9 f 0.5 kgm)
3. Arm control valve, boom control valve, bucketcontrol valve1) Assemble spool assembly (40) to valve body.2) Assemble retainer (44), shim (43) and spring
(42) to spool, then fit O-ring to case (41) andinstall.
Case mounting bolt: 30.9 f 3.4 Nm(2.9 f 0.5 kgm)
* Shim (43) is only for the boom controlvalve.
3) Assemble retainer (39) and spring (38) tospool, then fit O-ring to case (37) and install.
Case mounting bolt: 30.9 + 3.4 Nm(2.9 + 0.5 kgm)
4. Covers1) Fit O-ring to cover (36) and install.2) Fit O-ring to cover (35) and install.
Mounting bolt: 166.7 + 9.8 Nm (17 f
1 kgm)* Tighten the mounting bolts in the order
shown in the diagram.
5. LS shuttle valve, pump merge-divider valve, armcounterbalance valve1) Assemble valve (60) and spring (59) to valve
body, and install arm counterbalance valve(34).
Mounting bolt: 66.2 f 7.4 Nm (6.8 +0.8 kgm)
* Tighten the mounting bolts in the ordershown in the diagram.
2) Assemble valve (58) and spring (57) to valvebody, and install pump merge-divider valve(33).
Mounting bolts: 166.3 f 9.4 Nm (17+ 1 kgm)
* Tighten the mounting bolts in the ordershown in the diagram.
3) Install LS shuttle valves (32) and (31).
Mounting bolt: 66.2 + 7.4 Nm (6.8 +0.8 kgm)6. LS select valve
Install LS select valve (30).LS select valve: 127.5 f 19.6 Nm (13 f2 kgm)
7. Pressure compensation valvesCheck marks made on each pressurecompensation valve when disassembling andinstall in correct position.
1) Before installing pressure compensation valvesbelow, install check valves (29) and (22).
2) Fit O-rings, then install arm IN pressurecompensation valve (28) L.H. travelFORWARD pressure compensation valve (27),left swing pressure compensation valve (26)boom LOWER pressure compensation valve(25), R.H. travel FORWARD pressurecompensation valve (24) and bucket CURLpressure compensation valve (23).
3) Fit O-rings, then install arm OUT pressurecompensation valve (21) L.H. travel REVERSEpressure compensation valve (20) right swingpressure compensation valve (19) boomRAISE pressure compensation valve (18), R.H.travel REVERSE pressure compensation valve(17) and bucket DUMP pressure compensationvalve (16).
Pressure compensation valve:225.5 f 19.6 Nm (23 + 2 kgm)
8. Unload valves, safety-suction valves, suctionvalves1) Fit O-rings and install suction valves (15) (14)
(13) and (12).Suction valve: 147.1 + 9.8 Nm (15 f1 kgm)
2) Fit O-ring and install safety-suction valves (1 I),(IO), (9) (8) (7) and (6).
Safety-suction valve: 147.1 ?I 9.8Nm (15 f 1 kgm)
3) Fit O-ring and install unload valves (5) and (4).Unload valve: 98.1 f 9.8 Nm (10 f1 kam)
9. Main relief valve, main unload LS relief valve1) Fit O-ring and install main unload LS relief
valve (3).
wMain unload LS relief valve: 85.9f 7.4 Nm (8.8 + 0.8 kgm)
2) Fit O-ring and install main relief valve (1).
Q=Main relief valve: 53.9 f 4.9 Nm(5.5 f 0.5 kgm)
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
Right side of machineFrom front of machine
16 17 18 19 20 21 22 Left side of machine
From rear of machine 29 23 24 25 30 26 27 288 13 7 12 6
Front of machineFrom top of machine
0
3
1
il r’ s lb i4
XlOBH204
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DISASSEMBLY AND ASSEMBLY PUMP MERGE-DIVIDER VALVE
DISASSEMBLY OF PUMPMERGE-DIVIDER VALVEASSEMBLY
1.
2.3.
4.
Remove plug (2) from valve body (I), then removespring (3) and spool (4).Remove plate (5).Remove plug (6), then remove spring (7) and spool(8).Remove plug (9).j, After disassembling, if there is any abnormality
in body (1) or spools (4) or (8) replace thewhole pump merge-divider valve assembly.
ASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY
0 Before assembling, coat the sliding surface with 3. Fit O-ring to plate (5) and install to valve body.engine oil. 4. Assemble spool (4) and spring (3) then fit O-ring to
plug (2) and install.1. Fit O-ring to plug (9) and install to valve body (1).
mPlug (2): 152.3 f 24.8 Nm (15.5 f 2.5
Plug (9): 38.7 f 5.4 Nm (4.0 f 0.6 kgm) kgm)
2. Assemble spool (8) and spring (7) then fit O-ring toplug (6) and install.
Plug (6): 38.7 f 5.4 Nm (4.0 + 0.6 kgm)
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DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
DISASSEMBLY OF PRESSURECOMPENSATION VALVEASSEMBLY
(A-D1
0 The structure of the parts for pressurecompensation valves A, B, C, and D is the same,but the part number for the assembly is different, sobe careful when assembling.
1. Remove piston sub-assembly (2) and piston (3)from sleeve (I), then remove seals (4).* Sub-piston assembly (2) is assembled to
pressure compensation valve A and D, andpiston assembly (3) is assembled to pressurecompensation valves B and C.
2. Remove spring (5), then remove ring (6) and O-rings (7) and (8) from sleeve (1).
* After disassembling, if there is any abnormality insleeve (I), seal (4), piston sub-assembly (2) orpiston (3) replace the whole pressurecompensation valve assembly.
ASSEMBLY OF PRESSURECOMPENSATION VALVEASSEMBLY
0 Before assembling, coat the sliding surface withengine oil.
1. Install O-rings (8) and (7), and ring (6) to sleeve (1).2. Assemble spring (5), then assemble seals (4) to
piston sub-assembly (2) and piston (3), and installto sleeve.
Pressure compensation valvesA: For bucket CURL/DUMP, boom RAISEB: For R.H. travel FORWARD/REVERSE, L.H. travel
FORWARD/REVERSEC: For left/right swingD: For boom LOWER. arm IN/OUT
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DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN RELIEFVALVE ASSEMBLY
1.
2.
3.
4.
*
/ ' 3
, _
3 - - - - - o17
4/ *C/ g
Loosen nut (I), and remove sleeve (2), piston (3)retainer (4) spring (5) piston (6) and poppet (7)then remove nut (1) from sleeve (2).
Remove sleeve (8), then remove sleeve (9), spring(IO), retainer (1 I), piston valve (12), and valve (13).
Remove seal (4), backup ring (15), and O-ring fromsleeve (8).
Remove plug (16), then remove rings (18) and (19)and O-ring from sleeve (17).
After disassembling, if there is any abnormality inany part marked s, replace the whole main reliefvalve assembly.
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DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
ASSEMBLY OF MAIN RELIEFVALVE ASSEMBLY
0
1.
2.
3.
4.
5.
*
Before assembling, coat the sliding surface withengine oil.
Fit plug (16) to sleeve (17) and install rings (19) and(18), and O-ring.
Plug: 22.1 f 2.5 Nm (2.25 + 0.25 kgm)
Assemble valve (13) to sleeve (17) and installpiston (12) retainer (II), spring (IO), and sleeve
(9).
Install sleeve (8) and assemble poppet (7) piston(6) and spring (5).
Sleeve: 85.9 f 7.4 Nm (8.8 ?r 0.8 kgm)
Assemble nut (I), O-ring, retainer (4) and piston (3)to sleeve (2), and install to sleeve (8).
Tighten nut (1) to specified torque.Nut: 68.7 f 9.9 Nm (7 f 1 kgm)
After installing to the control valve assembly, adjustthe pressure. For details, see TESTING ANDADJUSTING, Testing and adjusting oil pressure ofwork equipment, swing, travel circuits.
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DISASSEMBLY AND ASSEMBLY TVC . LS VALVE ASSEMBLY FOR FRONT PUMP
REMOVAL OF TVC . LS VALVEASSEMBLY FOR FRONT PUMP
aa
1.
2.
3.
Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hydraulictank.Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Hydraulic tank: Approx. 170 e
Disconnect TVC LS valve inlet hose (1).
Disconnect n/C solenoid wiring connectors (2).
Remove TVC LS valve assembly (3). m
INSTALLATION OF TVC . LSVALVE ASSEMBLY FOR FRONTPUMP
0 Carry out installation in the reverse order toremoval.
* Be careful not to let the O-ring or filter fall outwhen installing.
* Tighten the mounting bolts gradually onopposite sides in turn.
mTVC LS valve mounting bolts: 66.2 +7.4 Nm (6.75 + 0.75 kgm)
f m XlOAV287
XlOBH208
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
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DISASSEMBLY AND ASSEMBLY NC. LS VALVE ASSEMBLY FOR FRONT PUMP
REMOVAL OF TVC . LS VALVEASSEMBLY FOR REAR PUMP
AA
a
1.
2.
3.
4.
5.
Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the ground
and stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.Remove the hydraulic tank strainer, and using toolB, stop the oil.
When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.
Hydraulic tank: Approx. 170 P
Disconnect TVC LS valve inlet hose (1).
Disconnect hose (2).
Disconnect NC solenoid wiring connectors (3).
Remove bracket (4).
Remove TVC LS valve assembly (5). MI
INSTALLATION OF TVC . LS
VALVE ASSEMBLY FOR REARPUMP
Carry out installation in the reverse order toremoval.
* Be careful not to let the O-ring or filter fall outwhen installing.
* Tighten the mounting bolts gradually onopposite sides in turn.
TVC LS valve mounting bolts:66.2 + 7.4 Nm (6.75 & 0.75 kgm)
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
; --.XlOAV287
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DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE
REMOVAL OF LS CONTROL EPCVALVE ASSEMBLY
1. Remove cover.
2. Disconnect wiring connector (1).
3. Disconnect hose (2).
4. Remove LS control EPC valve assembly (3)m
INSTALLATION OF LS CONTROLEPC VALVE ASSEMBLY
0 Carry out installation in the reverse order toremoval.
LS control EPC valve mounting bolt:11.3+ 1.5 Nm (1.15 f 0.15 kgm)
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DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID VALVEASSEMBLY
A
1.
2.
3.
4.
Disconnect the cable from the negative (-) terminalof the battery.
Remove 5 solenoid wiring connectors (1) from clip
and disconnect.* Mark the male and female ends of each
connector with tags to prevent mistakes whenconnecting.
Disconnect hoses (2) and (3) installed to bottom ofvalve.* Fit tags on the hoses.
Disconnect hoses (4) installed to top of valve.* Fit tags on the hoses.
Remove mounting bolts, then remove solenoid
valve assembly (5).
When removing solenoid valve as an individualpart.i) If mounting nut (6) is removed, only coil
assembly needs to be removed. %ii) qhen washing valve, loosen mounting nut 7
and remove. ml
INSTALLATION OF SOLENOIDVALVE ASSEMBLY
0 Carry out installation in the reverse order toremoval.
w Nut (6): 7.4 f 0.98 Nm (0.8 f 0.1 kgm)
XlOBH213
Nut (7): 50.5 f 3.4 Nm (5.2 + 0.35 kgm)
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT. SWING PPC VALVE
REMOVAL OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY
A
1.
2.
3.
4.
5.
Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.
Remove armrest and rubber boot, remove cover,and disconnect wiring connector (1).
Remove boot (2) from cover, raise boot, thenremove lever (3).* Mark the mounting position of the lever before
removing.
Remove 4 mounting bolts (5) of cover (4) thenremove.jr Remove the lock with a screwdriver and
gradually lift the cover up to remove.
Remove joint bolt (6), and disconnect hose(7).F]
Remove mounting bolts, raise PPC valve assembly(8), then disconnect hoses (9) and (IO), andremove.
mj, Mark the connecting position of the hoses
before disconnecting.
INSTALLATION OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY
0 Carry out installation in the reverse order toremoval.
Hose mounting joint bolt: 29.4 f 4.9 Nm(3.0 + 0.5 kgm)
m
Hose mounting joint bolt: 39.2 + 4.9 Nm(4.0 + 0.5 kgm)
* If there is excessive play in the control levers,adjust the PPC valve. For details, see TESTINGAND ADJUSTING, Adjusting PPC valve.
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT. SWING PPC VALVE
DISASSEMBLY OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY
1.
2.
3.
4.
5.
Remove nut (l), then removedisc (2) and boot (3).
Remove bolt, then remove plate (5).* Do not remove joint (4) unless it is to be
replaced.
Remove seal (6) and collar (7).
Pull out piston (8), and remove retainer (9) springs(10) and (11) and shim (12).* Spring (1) consists of a set of two types of
springs with different installed loads, so checkthe mounting position (oil port) and mark withtags to prevent mistakes when installing.
Pull out valve (13) from body (14).
L XlOBH218
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT. SWING PPC VALVE
ASSEMBLY OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY
1.
2.
Assemble valve (13) to body (14).
Assemble shim (12) and spring (11) to valve (13).* When assembling spring (1 I), set the end with
the small coil diameter (inside diameter) at shim(12) end.
3. Assemble spring (IO), retainer (9) and piston (8).* The number of loops in the coil for spring (10)
is different for each of the hydraulic portsbelow, so be careful when installing.
*
* The position of each port is marked on thebottom of the valve body.
Piston: Grease (G2-Ll)
* When assembling piston (8), coat theoutside of the piston and the inside of thehole in the body with grease.
4. Fit O-ring to collar (7) and assemble in body (14)then install seal (6).
5. Install plate (5).
mMounting bolt: 13.2 f 1.5 Nm (1.35 f0.15 kgm)
6. Install joint (4).Sliding portion of joint: Grease (G2-Ll)
Female thread of body: ThreadA tightener (LT-2)
* Coat two places on the female thread with onedrop each of Loctite as shown in the diagrambelow.
5-7m
_.(zzl-XlOBH219
Joint: 44.1 f 4.9 Nm (4.5 + 0.5 kgm)
* Keep strictly to the tightening torque.
7. Assemble boot (3) and disc (2), and tighten with nut(I).
Nut: 112.7 f 14.7 Nm (11.5 f 1.5 kgm)
* After assembling the disc, adjust the height ofthe disc. For details, see TESTING ANDADJUSTING, Adjusting PPC valve.
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DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPCVALVE ASSEMBLY
A
1.
2.
3.
4.
5.
6.
7.
Lower the work equipment completely to the groundand stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then set the safety lock lever to the LOCK position.
Remove floor mat.
Remove travel PPC valve bottom cover.
Remove pedals (1) and levers (2).
Remove cover (3).
Remove covers (4) then remove springs (5).
Disconnect dampers (6). m
Disconnect 6 PPC hoses (7) and remove travelPPC valve assembly (8). ml
INSTALLATION OF TRAVEL PPCVALVE ASSEMBLY
0 Carry out installation inremoval.
the reverse order to
--Adjust the travel lever. For details, seeTESTING AND ADJUSTING, Adjusting travel
Cover mounting bolt: 19.6 + 2 Nm (2.0f 0.2 kgm)
Sliding portion of pin: Grease (G2-Ll)
Hose mounting joint bolt (width acrossflats: 30 mm): 39.2 f 4.9 Nm (4.0 f 0.5kgm)
Hose mounting joint bolt (width acrossflats: 22 mm): 29.4 f 4.9 Nm (3.0 + 0.5kgm)
\\ &_ [I
XlOBH223
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DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY OF TRAVEL PPCVALVE ASSEMBLY
1. Remove cover and cam assembly (1) then removeshims (2).* Check the number and thickness of shims (2)
for each mounting position, and keep in a safe
place.
2. Remove plate (3).
3. Remove seal (4) and collar (5).
4. Pull out piston (6) and remove retainer (7) springs(8) and (9) and shims (10).* Check the number and thickness of shims (10)
for each mounting position, and keep in a safeplace.
5. Pull out valve (11) from body (12.)
ASSEMBLY OF TRAVELVALVE ASSEMBLY
PPC
1. Assemble valve (11) in body (12).
2. Assemble shims (10) and spring (9) to valve (11).It Assemble the same number and thickness of
shims (10) as was removed duringdisassembly.Standard shim thickness: 0.3 mm
* Spring (9) is not symmetrical at the top andbottom, so assemble with the small coildiameter (inside diameter) at the shim end.
3. Assemble spring (8) retainer (7), and piston (6).
aOutside circumference of piston, bodyhole: Grease (G2-Ll)
4. Fit O-ring to collar (5) and assemble in body (1 I),then install seal (4).
5. Assemble plate (3).
6. Fit cover and cam assembly (1) and assembleshims (2) then tighten with bolt.
eSliding portion of shaft, connectingportion of lever and piston: Grease (G2-Ll)
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DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
* Assemble the same number and thickness ofshims (2) as was removed during disassembly.Standard shim thickness: 1.6 mm
WMounting bolt (a): 27.9 + 3.4 Nm(2.85 f 0.35 kgm)
Mounting bolt (b): 30.9 f 3.4 Nm(3.15 + 0.35 kgm)
XlOBH225
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DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
REMOVAL OF BOOM LOCKVALVE ASSEMBLY
A
1.
2.
3.
Lower the work equipment completely to theground, then release the remaining pressure in thehydraulic circuit. For details, see TESTING ANDADJUSTING, Releasing pressure in hydraulic
circuit.
Disconnect tube (1) and hoses (2).
Disconnect tube (3).
Remove mounting bolts of bracket (4) then removeboom lock valve (5) together with bracket (4).
INSTALLATION OF BOOM LOCK
VALVE ASSEMBLYCarry out installation in the reverse order toremoval.
Refilling with oil (hydraulic tank)Jr Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding airj, Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
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DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDERASSEMBLY
A Extend the arm and bucket fully, lower the workequipment completely to the ground, and put thesafety lock lever in the lock position.
1.
2.
Disconnect grease hose (1).
3.
Sling boom cylinder assembly (2) and remove lockbolt (3). m
Remove plate, then remove head pin (4).* V
g 2There are shims installed, so check the num erand thickness, and keep in a safe place.
4. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.* Set stand 0 under the cylinder assembly, and
adjust the position for slinging.
A Release the remaining pressure in thehydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
5. Disconnect hoses (5).
6. Remove plate, then using forcing screws 0, removebottom pin (6) and remove boom cylinder assembly(2). m* There are shims installed, so check the number
and thickness, and keep in a safe place.Boom cylinder assembly:
PC200-6, PC210-6: 200 kgPC220-6, PC250-6: 255 kg
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DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOMCYLINDER ASSEMBLY
Carry out installation in the reverse order toremoval.
en tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.
m
AInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Greasing after assembling pin: GreaseA (LM-G)
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.* Adjust the shim thickness so that the clearance
between cylinder rod (7) and plate (8) is below1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm
m
Inside surface of bushing whena assembling pin: Anti-friction
compound (LM-P)
Greasing after assembling pin:- Grease (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clearancebetween cylinder bottom (9) and bracket (IO) isbelow 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm
Refilling with oil (hydraulic tank)j, Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding airj, Bleed the air from the cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
0. 5 - 1. 5 mmXlOBM006
IMax. 1 mm
i o
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DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDERASSEMBLY
A
1.
2.
3.
4.
5.
6.
Extend the arm cylinder piston rod approx. 200 mm,lower the work equipment completely to the ground,then set the remaining safety lock lever to the LOCKposition.
Set block 0 between arm cylinder and boom.
Remove plate, then remove head pin (1). m
Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.A Release the remaining pressure in the
hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
Disconnect hoses (2).
Disconnect grease hose (3).
Raise arm cylinder assembly, remove plate ,remove bottom pin (4), then remove arm cylinderassembly (5).* There are shims installed, so check the
and thickness, and keep in a safe place.Arm cylinder assembly:PC200-6, PC210-6: 270 kgPC220-6, PC250-6: 310 kg
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DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM t LI I.-lCYLINDER ASSEMBLY I
Carry out installation in the reverse order toremoval.
aInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Greasing after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
m
-
Inside surface of bushing when
assembling pin: Anti-friction compound(LM-P)
Greasing after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
j, Adjust the shim thickness so that the clearancebetween cylinder boom (6) and bracket (7) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
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DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
A Extend the bucket cylinder piston rod approx. 200mm, lower the work equipment completely to theground, then set the safety lock lever to the LOCKposition.
1.
2.
Set block 0 under arm top.
Set block 0 between link and arm, and block 0between bucket cylinder and arm.
3.
4.
Remove lock bolt (1). p1
Remove plate, then remove head pin (2).*
mThere are shims installed, so check the numberand thickness, and keep in a safe place.
5. Start engine, and retract piston rod, then tie piston
rod with wire to prevent it from coming out.A Release the remaining pressure in the
hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
6. Disconnect 2 hoses (3).
7. Raise bucket cylinder assembly, remove plate,remove bottom pin (4) then remove bucket cylinderassembly (5).* There are shims installed, so check the
and thickness, and keep in a safe place.
Bucket cylinder assembly:PC200-6, PC210-6: 170 kgPC220-6, PC250-6: 200 kg
REMOVAL OF BUCKETCYLINDER ASSEMBLY
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DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKETCYLINDER ASSEMBLY
0 Carry out installation in the reverse order toremoval.
W]* When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5mm.
m1
A
A
When aligning the position of the pin hole,
Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Greasing after assembling pin: Grease(LM-G)
never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween link (6) and link (7) is below 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm
Inside surface of bushing whenA assembling pin: Anti-friction
compound (LM-P)
Greasing after assembling pin:
a Grease (LM-G)
When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween the cylinder bottom (8) and bracket (9)is below 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm
Refilling with oil (hydraulic tank)j, Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
0.5 - 1.5 mmX10BM006
Max. 1 mm
‘ 7XlOBMOl:
XlOBM014
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULICCYLINDER ASSEMBLY
1. Piston rod assembly1) Remove piping from cylinder assembly.2) Remove mounting bolts, and disconnect head
assembly (1).
3) Pull out piston rod assembly (2).* Place a container to catch the oil under the
cylinder.4) Disassemble piston rod assembly as follows.
i) Set piston rod assembly (2) in tool 0,.ii) Using tool O,, remove nut (3).
* Width across flats of nut. Unit: mm
PC200,PC210 1 95 1 95 1 85
PC220,PC250
95 95 95
iii) Remove piston assembly (4).iv)
v)
vi)vii)
Remove plunger (5).Boom and arm cylinder only.
Remove collar (6).Boom and arm cylinder only.
Remove head assembly (7).Remove cap (8), and pull out 12 balls (9)then remove plunger (10).
Arm cylinder only.
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
2. Disassembly of piston assembly1) Remove rings (11).2) Remove wear rings (12).3) Remove piston ring (13).
3. Disassembly of cylinder head assembly1) Remove O-ring and backup ring (14).2) Remove snap ring (ICI), then remove dust seal
(W.3) Remove rod packing (17).4) Remove buffer ring (18).5) Remove bushing (19).
XlOBR051
19
19
17
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULICCYLINDER ASSEMBLY
* Be careful not to damage the packing, dust seals,and O-rings.
j, Do not try to force the backup ring into position.Warm it in warm water (50 - 60°C) before fitting it.
1. Assembly of cylinder head assembly1) Using tool O,, press fit bushing (19).2) Assemble buffer ring (18).3) Assemble rod packing (17).4) Using tool 06, install dust seal (16), and secure
with snap ring (15).5) Install backup ring and O-ring (14).
2. Assembly of piston assembly1) Using tool O,, expand piston ring (13).
* Set the piston ring on the tool O,, and turnthe handle 8 - IO times to compress thering.
2) Set tool O4 in position, and retract piston ring
(13).
3) Assemble wear ring (12).4) Assemble ring (1 I).
* Be careful not to open the end gap of thering too wide.
Ring groove: Grease (G2-Ll)
13
14
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3. Piston rod assembly I1)
2)3)
4)
5)
6)7)
Set plunger (IO) to piston rod, and assemble 12balls (9) then secure with cap (8).* Check that there is a slight play at the tip of
the plunger.Arm cylinder only.
Assemble head assembly (7).Fit O-ring and backup ring, and assemble collar(8).
Boom and arm cylinder only.Assemble plunger (5).
Boom and arm cylinder only.Assemble piston assembly (4).
Set piston rod assembly (2) to tool 0,. I titUsing tool 02, tighten nut (3).
Nut: Thread tightener (LT-2)
m Nut:
Unit: Nm (kgm)Cylinder
I Boom I Arm I Bucket
8) Assemble piston rod assembly (2).Seal: Grease (G2-Ll)
*
*
30- 1440
Set the end gap of the ring at the horizontal(side) position, align the center of shaft andcylinder tube, then insert.After inserting, check that the ring is notbroken and has not come out, then push infully.
XlOBR049
L
End Sap in ring
XlOBRO56
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
9) Tighten head assembly (1) with mounting bolts.
WMounting bolt:
Cylinder Tightening torque
PC200, PC21 0Boom
270 f 39 Nm (27.5 * 4.0 kgm)
PC220, PC250Boom I
373 f 54 Nm (38.0 f 5.5 kgm)
1 373 + 54 Nm (38.0 f 5.5 kgm)
Bucket 270 * 39 Nm (27.5 + 4.0 kgm)
IO) Install piping.
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORKEQUIPMENT ASSEMBLY
A Extend the arm and bucket fully, lower the workequipment to the ground, and set the safety locklever to the LOCK position.
1.
2.
Disconnect grease hose (1).
Sling boom cylinder assembly (2), and remove lockbolt (3). mj
3. Remove plate, then remove head pin (4). m* There are shims installed, so check the number
and thickness, and keep in a safe place.
4. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out, andlower it onto block.*
A
Disconnect the boom cylinder on the opposite
side in the same way.Release the remaining pressure in thehydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
5. Disconnect hoses (5) and (6) and secure it to valvewith rope.* Hoses (6) are for machines equipped with an
additional attachment circuit.
6. Disconnect wiring connector (7) for working lamp.
7. Sling work equipment assembly, remove plate, thenremove foot pin (8) using tool P, and remove workequipment assembly (9).j, There are shims installed, so check the
and thickness, and keep in a safe place.Work equipment assembly:PC200-6: 3,300 kgPC210-6: 3,650 kgPC220-6: 3,850 kgPC250-6: 4,250 kg
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORKEQUIPMENT ASSEMBLY
0.5-1.5mmXlOBM006
Carry out installation in the reverse order toremoval.
&IlhFl
en tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.
AInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clearancebetween cylinder rod (10) and plate (11) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm
m
Inside surface of bushing when- assembling pin: Anti-friction
compound (LM-P)
Grease after assembling pin:a Grease (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clearancebetween boom (12) and bracket (13) is below 1mm.j, Standard shim thickness: 0.8 mm, 1 O mm,
1.5 mm
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
I
IMax. 1 mmx17FRo42
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DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKETASSEMBLY
A Set the back of the bucket facing down, lower thework equipment completely to the ground, and setthe safety lock lever to the LOCK position.
1. Remove lock bolt (1). m
2. Remove connecting pin (2) between link andbucket.
L$%2
* There are shims installed, so check the num erand thickness, and keep in a safe place.
3. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.
4. Remove lock bolt (3). ml
5. Remove plate (4) then remove connecting pin (5)between arm and bucket. mlj, There are shims installed, so check the number
and thickness, and keep in a safe place.
6. After raising work equipment, swing to disconnectbucket assembly (6).
Bucket assembly: See your Operator’ sManual, beginning on page 5-16.
6
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DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION OF BUCKETASSEMBLY
Carry out installation in the reverse order toremoval.
en tightening the locknut, tighten so that theclearance between the plate and the nut is 0.5 -1.5 mm.
-Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.* Adjust the shim thickness so that the clearance
between bucket boss (7) and link (8) is below 1mm.* Standard shim thickness: 0.8 mm, 1.5 mm
m
-Inside surface of bushing whenassembling pin, inside surface, endface of collar (10): Anti-frictioncompound (LM-P)Grease after assembkng pin:
- Grease (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
*
*
Set the O-ring at the end face of the bucketboss securely.Adjust the shim thickness so that the clearancebetween arm top (9) and spacer (10) is 0.5 -1.0 mm.j, Standard shim thickness: 0.5 mm, 1 O mm
0.5 - 1.5 mmXlOBM006
Max. 1 mm
0.5- l.Omm
Coat with anti-frictioncompound ILM-P)
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DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY
1.
2.
3.
4.
5.
6.
Remove bucket assembly. For details, seeREMOVAL OF BUCKET ASSEMBLY.
Secure front link to arm with wire.
Pull in arm so that it is easy to remove pin at armcylinder head, then lower arm and bucket cylinderassembly (1) on to block 0.A Set the safety lock lever to the LOCK position.
Set block 0 between arm cylinder and boom.
Remove plate, then remove arm cylinder head pin(2). WJ
Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.A Release the remaining pressure in the
hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
Disconnect 2 hoses (3) and 2 hoses (4).* Install blind plugs at the male end and in the
disconnected hoses.* Hoses (4) are for machines equipped with an
additional attachment circuit.
Remove plate, then remove connecting pin (5)between arm and boom.j, There are shims installed, so check the
and thickness, and keep in a safe place.
After raising boom, swing to remove arm andbucket cylinder assembly (1).
Arm, bucket cylinder assembly:PC200-6: 950 kgPC210-6: 1,100 kgPC220-6: 1,100 kgPC250-6: 1,250 kg
0’ Xl7FRO43
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DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION OF ARM 6 7ASSEMBLY
0 Carry out installation in the reverse order toremoval.
-Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
-Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clearancebetween boom top (6) and arm bottom (7) isbelow 1 mm.* Standard shim thickness: 0.8 mm
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
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DISASSEMBLY AND ASSEMBLY BUCKET. ARM
INSTALLATION OF BUCKET. 6 7ARM ASSEMBLY
Carry out installation in the reverse order toremoval.
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween the boom top (6) and arm bottom (7)is below 1 mm.* Standard shim thickness: 0.8 mm
I-
Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Grease after assembling pin: Grease- (LM-G)
A When aligning the position of the pin hole,never insert your fingers in the pin hole.
X17FR04r
-Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
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DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM ASSEMBLY
1. Remove bucket and arm assembly. For details, seeREMOVAL OF BUCKET, ARM ASSEMBLY.
2. Lower boom assembly completely to the groundand set safety lock lever to LOCK position.
3.
4.
Disconnect grease hose (1)
Sling boom cylinder assembly (2), and remove lockbolt (3). ml
5. Remove plate, then remove head pin (4).* There are shims installed, so check the
and thickness, and keep in a safe place.
6. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out, andlower it onto block.* Disconnect the boom cylinder on the opposite
side in the same way.A Release the remaining pressure in the
hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.
7. Disconnect hoses (5) and (6), and secure to valvewith rope.* Hoses (6) are for machines equipped with an
additional attachment circuit.
8. Disconnect wiring connector (7) for working lamp.
9. Raise boom assembly and remove plate, removefoot pin (8) using tool P, then remove boomassembly (9).* There are shims installed, so check the
and thickness, and keep in a safe place.Boom assembly:PC200-6: 1,650 kgPC210-6: 1,750 kgPC220-6: 1,950 kgPC250-6: 2,000 kg
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DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION OF BOOMASSEMBLY
Carry out installation in the reverse order toremoval.
A*
WI
A*
When tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.
Inside surface of bushing when- assembling pin: Anti-friction
compound (LM-P)
Grease after assembling pin:- Grease (LM-G)
When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween cylinder rod (10) and plate (11) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm
Inside surface of bushing when- assembling pin: Anti-friction
compound (LM-P)
Grease after assembling pin:- Grease (LM-G)
When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween boom (12) nd bracket (13) is below 1mm.* Standard shim thickness: 0.8 mm, 1 O mm,
1.5 mm
Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified
level. Run the engine to circulate the oil throughthe system. Then check the oil level again.
Bleeding air* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.
0.5-1.5mmXlOBM006
I_
IMax. 1 mmX17FRO42
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DISASSEMBLY AND ASSEMBLY OPERATOR’ S CAB
REMOVAL OF OPERATOR’ S CABASSEMBLY
A
1.
2.
3.
4.
5.
Disconnect the cable from the negative (-) terminalof the battery.
Remove floor mat (1).
Remove operator’ s seat assembly (2).Operator’ s seat assembly: 40 kg
Remove knob (3).
Remove 4 caps (4) and clip (5) then remove middlepanel (6).
Remove bottom panel (7).j, The panel is held by a clip, so remove the clip
when removing the panel and be careful not todamage it.
6. Disconnect washer hose (8).
7. Remove plate (9) then remove cover (10).
X13CHOOS
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DISASSEMBLY AND ASSEMBLY OPERATOR’ S CAB
8. Disconnect air conditioner hose (11) and speakerwiring connector, then remove cover (12).* When removing the cover, the speaker wiring
connector cannot be seen, so lift up the coverto disconnect the wiring.
9. Remove divider board (13).
10. Remove air conditioner ducts (14) (15) and (15A).
11. Disconnect wiring connectors CN-HOI (16) CN-HO2 (17), CN-HO3 (18) CN-HO4 (IS), CN-HO5 (20)CN-HO6 (21) and CN-ACI-AC2 (23).
12. Disconnect air conditioner cable (24).
19
__-
I 24 . .
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DISASSEMBLY AND ASSEMBLY ENGINE THROTTLE CONTROLLER
REMOVAL OF ENGINETHROTTLE CONTROLLERASSEMBLY
A Disconnect the cable from the negative (-) terminalof the battery.
1. Remove plate (I), then remove cover (2).
2. Disconnect air conditioner hose (3) and speakerwiring connector, then remove cover (4).* When removing cover (4), the speaker wiring
connector cannot be seen, so be careful.
3. Remove divider board (5).
4. Disconnect wiring connector (6) and removeengine throttle controller assembly (7).
INSTALLATION OF ENGINETHROTTLE CONTROLLERASSEMBLY
0 Carry out installation in the reverse order toremoval.
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DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
REMOVAL OF PUMPCONTROLLER ASSEMBLY
A
1.
2.
3.
4.
4.
Disconnect the cable from the negative (-) terminalof the battery.
Remove plate (I), then remove cover (2).
Disconnect air conditioner hose (3) and speakerwiring connector, then remove cover (4).* When removing cover (4) the speaker wiring
connector cannot be seen, so be careful.
Remove divider board (5).
Remove air conditioner duct (7).
Disconnect 3 wiring connectorspump controller assembly (9).
(8) then remove
INSTALLATION OF PUMPCONTROLLER ASSEMBLY
Carry out installation in the reverse order toremoval.
XOECHO14
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DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITORASSEMBLY
A1.
2.
Disconnect the cable from the negative (-) terminalof the battery.
Remove screws (I), then lift up monitor assembly
(2).
Disconnect wiring connectors (3), then removemonitor assembly (2).
INSTALLATION OF MONITORASSEMBLY
0 Carry out installation in the reverse order toremoval.
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40 MAINTENANCE STANDARD
Final drive (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) .............Final drive (PC25OLC-6) ...........................................Swing machinery.. ...............................................Swingcircle .....................................................Track frame, recoil spring (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6)Track frame, recoil spring (PC25OLC-6) ..............................Idler (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) ..................Idler (PC250LC-6) ................................................Carrier roller (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) ...........Carrier roller (PC25OLC-6) .........................................Track roller (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) ............Track roller (PC25OLC-6) ..........................................Track shoe (PC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6) ............Trackshoe(PC250LC-6) ..........................................Hydraulicpump ..................................................Controlvalve ....................................................Safety-suction valve for service valve .................................Swing motor .....................................................Travel motor (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) ...........Travel motor (PC25OLC-6) .........................................Work equipment, swing PPC valve ...................................Travel PPCvalve .................................................Service PPC valve ................................................PPC shuttle, travel junction valve ....................................EPCsolenoidvalve ..............................................Center swivel joint ................................................Boom holdingvalve ...............................................Hydraulic cylinder (PC200-6, PC2OOLC-6, PC21 OLC-6) ..................Hydraulic cylinder (PC22OLC-6, PC25OLC-6) ..........................Workequipment .................................................
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .
..................... 40- 2
..................... 40- 4
..................... 40- 6
..................... 40- 8
..................... 40- 9
..................... 40- 10
..................... 40- 11
..................... 40- 13
..................... 40- 15
..................... 40- 16
..................... 40- 17
..................... 40- 18
..................... 40- 19
..................... 40- 21
..................... 40- 23
..................... 40- 25
..................... 40- 31
..................... 40- 32
..................... 40- 33
..................... 40- 34
..................... 40- 35
..................... 40- 36
..................... 40- 37
..................... 40- 38
..................... 40- 40
..................... 40- 41
..................... 40- 43
..................... 40- 44
..................... 40- 46
..................... 40- 48
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FINAL DRIVEPC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6
m524.5283.5Nm47.5f2.5kQm)
\
1st :98Nm( I OkQm
2nd:75f5’
277+32Nm28i3kQm)
(-__A i__-___--l_ _ ___--_----’
X07HH031
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Unit: mm
Check item Criteria 1 Remedy
Backlash between No. 1 sun Standard clearance Clearance limit1 gear and No. 1 planetary gear 0.19 - 0.52 1 .oo
2 1 Backlash between No. 1 0.20 - 0.61 1. 10planetary gear and ring gear
3 Backlash between No. 1 0.06 - 0.22 -
planetary carrier and motor
4 Backlash between No. 2 sun 0.15 - 0.49 1 .ooaear and No. 2 olanetarv aear Replace
5 Backlash between No. 2 0.19 - 0.60I
1.10planetary gear and ring gear I
6 Backlash between No. 2 0.15 - 0.44 1 .ooplanetary carrier and No. 1 sungear
7 End play of sprocket shaft 0 - 0.10 -8 Amount of wear on sprocket Repair limit: 6
tooth
Standard size Repair limit Rebuild or
9 Width of sprocket tooth replace71 68
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MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVEPC250LC-6
wInitial tightening t orque: 98 N-M
w
(10 kgm) 382.2 +39.2 N
Additional tightening angle: 120”: (39 +4 kgm)
\ \
533
-M2
\
m 60.8 27.4 N-M ,(6.75 50.75 kgm) \
637 +49 NM(65 +5 kgm)
-66.2 +7.4 N-M(6.75 to.75 kgm)
w 68.6 +9.8 N-M-
r
.8 258.8?6 kgm)
WM
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MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Check item Criteria 1 Remedy
1Backlash between No. 1 sun Standard clearance Clearance limitgear and No. 1 planetary -ear 0.19 - 0.54 1 .oo
2 Backlash between No. 1 0.21 - 0.62I
1.10planetary gear and ring gear
3 Backlash between No. 1 0.06 - 0.22 -
planetary carrier and motor
4 Backlash between No. 2 sun 0.19 - 0.54 1 .oo1gear and No. 2 planetary gear 1
5 Backlash between No. 2 0.21 - 0.62I
1.10planetary gear and ring gear I
6 Backlash between No. 2planetary carrier and No. 1 sungear
0.39 - 0.67 1.20
Replace
7 End play of sprocket shaft 0.10 - 0.15 -8 Amount of wear on sprocket Repair limit: 6
tooth
Standard size Repair limit Rebuild or
9 Width of sprocket tooth replace87 84
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MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
110.5+12.5Nm(11.25i1.25kgm:
277 + 32Nm(28, .25+3.25kgm)
5
1
6
Ip_.r-----7
6
\‘ fi6.5+19 .5Nm
(18+2kgm 1
X09DH031
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MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
No.
planetary carrier and swingpinion
9 Backlash between swing pinion 0.22 - 1.32 2.00and swing circle
10 Clearance between plate and 0.38 - 1 .I6 - Apply hardplanetary carrier chrome plating,
Wear of swing pinion surface Standard size Repair limit recondition, or
11 contacting with oil seal125 PO.100
replace124.7
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MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
pzi-1 / ‘ 11PC200, PC210, PC220 1 St:
PC250:
2nd:
823.8- 1029.7 Nm(84- 105 kgm)
191.3 ‘ 19.6 Nm(19.5 22 kgm)48 +5
PC200, PC210: 804.4 283.4 Nm(82 28.5 kgm)
PC220:
PC250:
A-A
999.6 2102.9 Nm
(102 210.5 kgm)
823.8-1029.7 Nm(84-105 kgm)
X09DH032
No. Check Item Criteria I Remedy
Axial clearance of bearing Standard clearance Clearance limit1 (when mounted on chassis) Replace
0.5 - 1.6 3.2
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TRACK FRAME, RECOIL SPRINGPC250LC-6
X14AH013
Unit: mm
No. Check Item Criteria Remedy
Standard size Tolerance Repair limit
1 Vertical width of idler gear Track frame 123 +2 127-1
I I II I
Idler support 120 f 0.5 118 Rebuild orreplace
Track frame 266 +3 2712 Horizontal width of idler guide -1
_Idler support 261 259
Standard size Repair limit
Free limit Installed Installation Free length Installation3 Recoil spring length load load Replace
795 X 241 646 173.3 Nm(17,680 kg) -
138.6 Nm(14,140 kg)
40-I 0
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MAINTENANCE STANDARD IDLER
IDLERPC200-6, PC2OOLC-6PC21 OLC-6, PC22OLC-6
21 + 5kgm)
t
,:
“ : ,: :
,’ :’
:j ::
,’‘ _ _f’
.
m--J--k4I .
_,’iI? I/--.
i
ZPI
I-I
X14AVOO8
40- 11
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Unit: mm
No.
1
2 Outside diameter of
3 Width of protrusion
4
5 Width of tread
6
7
8
9
Check item
Outside diameter ofprotrusion
Standard size
560
Criteria
Repair limit
-
Remedy
tread Rebuild or
85 - replace
Total width I 164 I - I
Clearance betweenshaft and bushing
Clearance betweenshaft and support
65 -0.250 -0.110-0.290 -0.220
0.03 - 0.180 - Replace
Interferencebetween idler andbushing
Standardsize
72
Tolerance
Shaft Hole
+0.089 -0.006+0.059 -0.072
Standard Interferenceinterference limit
0.065 - 0.161 - Replacebushina
1 I I
Side clearance of I Standard clearance I Clearance limit Iidler (each)
0.39 - 1 .oo 1.5
40- 12
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MAINTENANCE STANDARD IDLER
IDLERPC25OLC-6
2
4151.9 224.5 Pm
15.5 22.5 kgm)\
4c
--
X14AVOO9
40-I 3
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No.
1
2
3 Width of protrusion
4
5
6
7
8
9
Unit: mm
Check item
Outside diameter ofprotrusion
Standard size
630
Criteria
Repair limit
-
Remedy
Outside diameter oftread
590 578
Rebuild or
101 - replace
Total width I 190 I - I
Width of tread
Clearance betweenshaft and bushing
Clearance betweenshaft and support
Interferencebetween idler andbushing
Side clearance ofidler (each)
Standard Tolerancesize
Shaft Hole
80 -0.225 +0.130
-0.325 -0.010
80 -0.225 -0.085-0.290 -0.195
Standard Tolerancesize
Shaft Hole
87.6 +0.087 -0.027+0.037 -0.079
Standard clearance
0.68 - 1.22
Standard Clearanceclearance limit
Replace
0.215bushing
- 0.455 1.5
0.030 - 0.205 - Replace
Standard Interferenceinterference limit
0.064 - 0.166 - Replacebushing
Clearance limit
2
40- 14
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MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLERPC200-6, PC2OOLC-6PC21 OLC-6, PC220LC-6
w 14.7i4.9Nm(1.5+_0.5kgm)
X14BR008
No.
1
2
3
4
5
6
Check item
Outside diameter of flange (outside)
Outside diameter of tread
Width of tread
Standard size
165
140
43
Criteria
Repair limit
-
130
50
Remedy
Rebuild orreplace
interference between shaft andbearing
Interference between roller andbearing
Side clearance of roller
Standard Tolerancesize
Shaft Hole
50 0 0-0.016 -0.012
80 0 -0.021-0.013 -0.051
Standard clearance
0.01 - 0.18
Standard interferenceinterference limit
- 0.016 - -0.012 Replace
0.008 - 0.051
Clearance limit
-
40- 15
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MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLERPC25OLC-6
No. Check item Criteria Remedy
1 Outside diameter of flange (outside)Standard size
200
Repair limit
_
14.7 a.9 Nm(1.5 +a5 kgm)
X14BR009
3
Outside diameter of tread
Width of tread
168
49.5
158
57.5
rieuull” “ I
replace
4
5
Clearance between shaft andbearing
Interference between roller andbearina
Standardsize
55
80
Tolerance
Shaft Hole
+ 0.021 0+ 0.002 -0.015
0 -0.021-0.013 -0.051
Standard Interferenceinterference limit
0.002 - _0.036 Replace
0.009 - 0.059 _
6 Side clearance of rollerStandard clearance
0. 01 - 0.24
Clearance limit
-
40- 16
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MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLERPC200-6, PC2OOLG6PC21 OLC-6, PC22OLC-6
No. Check item I Criteria I Remedy
Outside diameter of flange(outside)
Standard size
186
Repair limit
_
Outside diameter of tread 1 154 I 142 1 Rebuild or
7 Side clearance of roller
a=14.724.9Nm(1.5tO.Skgm)
244.1 Nm54.5 kgm)
------- I -I
_ 3-4 X14BROlO
Unit: mm
Width of tread
Width of flange
ral-“ dc;e44.5 52
24.5_
Clearance between shaftand bushing
Standardsize
Tolerance Standard Clearance limitclearance
Shaft Hole I I
Interference between rollerand bushing
60
Standard
size
- 0.215 + 0.195 0.215 - 0.510 1.5- 0.315 0
ReplaceTolerance Standard Interference bushing
interference limitShaft Hole
_67 + 0.153 + 0.030 0.023 - 0.153
+ 0.053 0
Standard clearance Clearance limit
0.41 - 0.95 1.5Replace
40-I 7
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MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLERPC250LC-6
u 666.6 t-66.6 Nm(67 57 kgm)
No. Check item Criteria I Remedy
1
2 Outside diameter of tread
3 Width of tread
-_
--i__ _._A
3 4
X14BROll
Unit: mm
Outside diameter of flange(outside)
Width of flange
Clearance between shaffand bushing
Interference between rollerand bushing
Side clearance of roller
Standard size Repair limit
216
180
49
-
168
55
Rebuild orreplace
Standardsize
Tolerance Standard Clearance limitclearance
Shart Hole
65 - 0.215 + 0.186 0.151 - 0.501 1.5- 0.315 - 0.064
Standardsize
ReplaceTolerance Standard Interference bushing
interference limitShaft Hole
72 0.108_
+ - 0.006 0.014-0.144+ 0.008 - 0.036
Standard clearance Clearance limit
0.41 - 0.95 1.5Replace
40- 18
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MAINTENANCE STANDARD TRACK SHOE
TRACK SHOEPC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6
\\ -
9 X15AD006
40- 19
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MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No.
1
2
3
4
5
6
7
8
Check item Criteria I Remedy
Link pitch
Outside diameter ofbushinn
Standard size Repair limit
190.25 194.25
59.3 54.3
Turn orreplace
Height ofgrouser
Height of link
Triple 26 16
Swamp 102.5 90.5Lugwelding,
. -^L..:IA ^-, ~““ I I” “ I
replace
Interference betweenbushing and link
Interference betweenregular pin and link
Interference betweenmaster pin and link
Protrusion of bushing
Standardsize
59 1 MM& 1 +0;74 1 o.lgll 1 0.100
37.8 +0.230 +0.062 0.138 - 0.130+0.200 0 0.230
4.85
Replacewith oversize
Adjust
9 Tightening torque of shoe Initial tightening torque: 392 f 39.2 Nm (40 f 4 kgm) Tightenbolt Additional tightening angle: 120” f IO”
40-20
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TRACK SHOEPC25OLC-6
4
3
9
40- 21
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MAINTENANCE STANDARD TRACK SHOE
No.
1
2
5
6
7
8 Protrusion of bushing
9 Tightening torque ofshoe bolt
Check item
Link pitch
Outside diameter ofbushing
Height of grouser
Height of link
Interference betweenbushing and link
Interference betweenregular pin and link
Interference betweenmaster pin and link
Criteria
Standard size Repair limit
61.9
31
116
Standardsize
44.6 (Shaft)44.35 (Hole)
44.4 (Shaft) +0.230 +0.062 0.188 - 0.08044.35 (Hole) +0.200 0 0.280
5.25 f 0.3
Initial tightening torque: 390 f 49 Nm (40 f 5 kgm)Additional tightening angle: 120” f IO”
Unit: mm
Remedy
Turn orreplace
Lugwelding,rebuild orreplace
Rebuild orreplace
Replace
Replacewith oversize
Adjust
Tighten
40- 22
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MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Qa 66.1L7.35Nrn(6.75+0.75kgm)
-2
_ 17.151t2.45Nm(1. 5+0.25kgm)
15*7.35Nm.75+0.75kgm)
\
m 66.15f7.35Nm(6f5f0.75kgm)
_ 68:6f9.8Nm(7f lkgm)
XlOAV269
40- 23
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MAINTENANCE STANDARD HYDRAULIC PUMP
CONTROL PUMP, RELIEF VALVE
w 53.9*4.9Nm(5.5&0.5kgm)
No.
4
P-B
1
l--B
,66.15+7.35Nm(6.75+0.75kgm)
XlOAV270
Unit: mm
Radical clearance between gear
Control relief valve springor deformations
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CONTROL VALVE
* Figure shows 9-spool control valve (with 3 service valve).9-spool control valve includes 6-spool, 7-spool and 8-spool control valves.
w 166.7 f 9.8 Nm w 166.7 2 9.8 Nm17,= 1 kgm) 17 e 1 kgm)
30.9 z 3.4 Nm3.15 f 0.35 kgm)
w 66.2 ~7.4 Nm m 66.2 +7.4 Nm w 30.9 =3.4 Nm6.75 +0.75 kgm) 6.75 + 0.75 kgm)
\ / /3.15 2 0.35 kgm)
a 66.2 2 7.4 Nm m‘l66.7 * 9.6 Nm6.75 2 0.75 kgm) 17 + 1 kgm)
XlOBH176
40- 25
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MAINTENANCE STANDARD CONTROL VALVE
No.
1
2
3
m 75.5 2 9.; Nm7.7 2 1 kgm)
75.5 * 9.8 Nm7.7 2 1 kgm)
XlOBH177
Unit: mm
Check item Criteria Remedy, I I I
Spool return spring
Spool return spring
Spool return spring
Free lengthX O.D.
54.2 X 34.8
54.2 X 34.6
54.2 X 34.8
Standard size
installedlength
51.2
51.2
51.2
Installed load
416.5 N(42.5 kg)
420.4 N(42.9 kg)
393.0 N(40.1 kg)
-
-
333.2 N(34 kg)
336.1 N(34.3 kg)
Replace spring ifany damages ordeformations arefound.
314.6 N(32.1 kg)
40- 26
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MAINTENANCE STANDARD CONTROL VALVE
m 166.7 2 19.6 Nm m 166.7 * 19.6 Nm(17 + 2 kgm)
\ 5 6
w75.5&9.8Nm
/ (7.7+lkgm)
75.5f9.8Nm
‘ 6
4 3 \m 53.9f4.9Nm
K-K (5.5f0.5kgm)
No. Check item
1 Main unload spring
4 Relief spring
4 3 \m 53.9+4.9Nm
(5.5+0.5kgm)L-L
85 .85f7.35Nm(8 .75+0:75kgm)
XlOBH178
Unit: mmI
Criteria I Remedv
Free lengthX O.D.
43x19. 4
20.9 X 17.2
23.2 X 7.2
30.7 X 9.6
Standard size
Installedlength Installed load
Rep2
Free length
32 260.7 N(26.6 kg)
26.3I
369.5 N(37.7 kg) -
Replace spring ifany damages ordeformations arefound.
5 Unload spring
6 Check valve spring
110.7 N(11.3 kg)
--i4.4 N
(0.45 ka)
40- 27
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w 147.1 2 9.8 him w 392.3 L 19.6 Nm
15 + 1 kgm) 40 +2 kgm)
\ /
w 14<1*9.8Nm m 3i2.3 + 19.6 Nm m 16.1 r 9.8 Nm A 19.6 Nm15 or 1 kgm)
w i2.3
D-D40 2 2 kgm) 15 + 1 kgm) E-E 40 2 2 kgrri
147.7 = 9.8 Nm15 t 1 kgm)
m 392.3 + 19.6 Nm
40 t 2 kgm)
w 392.3 2 19.6 Nm m 147.1 * 9.8 Nm w 392.3 2 19.6 hlmMO+2 kgm) 15 * 1 kgm) (40 + 2 kgm)
I
w 392.3 it 19.6 Nm40 k 2 kgm)
F-F
107.9 - 147.1 Nm11-15 kgm)
w 147 =9.8Nm 392.3 + 19.6 Nm
15 t 1 kgm) 40 = 2 kgm)
G-GXlOBH179
40- 28
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MAINTENANCE STANDARD CONTROL VALVE
-147.li9.8Nm m 392.3F19.6Nm(15+lkgm) (40 +Zkgm)
\ /
147.1+9.8Nm(15+lkgm)
/ \W 147.lf9.8Nm m 392.3+_19.6Nm(15* Ikgm) (40+2kgm)
H-H
m 392.3+19.6Nm(40+2kgm)
m 147.1’ &9.8Nm w 392.3+19.6Nm(15+lkgm) (40+2kgm)
N-NXlOBH180
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limitArm counterbalance valve
1 spring Free length Installed Installed load Free length Installed loadx O.D. length
70.8 X 16.1 55 192.1 N 153.9 N(19.6 kg)
_(15.7 kg)
Regeneration valve spring 31.5x10.3 19.5 5.9 N 4.4 N(0.6 kg) - (0.45 kg)
ifPiston return spring 48.1 X 10.8 30 15.7 N 12.7 N
Replace spring
(1.6 kg)_
(1.3 kg)any damages ordeformations arefound.
Check valve spring 13.0 X 6.5 9.5 2.0 N 1.5 N(0.2 kg)
-(0.15 kg)
5 Load spring 30.4 X 16.7 27 428.3 N 343N(43.7 kg) - (35.0 kg)
6 Check valve spring 13.6 X 5.5 10 2.0 N 1.5 N(0.2 kg)
_(0.15 kg)
7 Piston return spring 36.9 X 11 .I 28 29.4 N
(3 kg)_ 23.5 N
(2.4 kg)
40-29
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MAINTENANCE STANDARD CONTROL VALVE
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1
w 140+22Nm
(14.25+2.25kgm)
m 147 + 1ONm(15 + lkgm)
XlOBH182
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Suction valve spring
1Free length Installed Installed load Free length Installed load
X O.D. length Replace spring ifany damages or
16.3 X 21.3 1.5 2.1 N 1.6 N deformations are(0.21 kg) - (0.16 kg) found.
2 Piston spring 20X7 14 2.1 N 1.6 N(0.21 kg)
_(0.16 kg)
40- 31
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MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
m 166.7+19.6Nm
(17.0tZ.Okgm)m 122.6f63.7Nm
(12.5f6.5kgm)
n
m 373t49.ONm(38.0+5.0kgm)
X09DH033
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limitReplace spring if
1 Check valve spring Free length Installed Installed load Free length Installed any damages orX O.D. length load deformations are
found.62.5 X 20.0 35.0 3.5 N 2.8 N_
(0.36 kg) (0.29 kg)
40-32
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MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTORPC200-6, PC2OOLC-6PC21 OLC-6, PC220LC-6
8.83+0.98Nm(0.9+0.lkgm)
23.5F3.9Nm
18.63*8.83Nm(l.g+O.gkgm) w 279+24_5Nm m 419k46.6Nm
-23.5&3.9Nm(28.5&2.5kgm) (42.8f4.7kgm)
(2.4f0.4kgm)
X07HH032
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Spool return spring Free length Installed Installed load Free length Installed loadX O.D. length
58.43 X 30.0 42.0 426.3 N 341 .O N Replace spring if_(43.5 kg) (34.8 kg) any damages or
deformations are2 Check valve spring 33.0 X 13.8 23.0 1.3 N 1.0 N found.
(0.13 kg) -(0.10 kg)
3 Regulator piston spring 61.1 X23.2 30.0 398.9 N 319.5 N(46.7 kg) - (32.6 kg)
40-33
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MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
m 6.8 + 1.9Nm(0.7 ko.2kgm)
B-B
m 12.7 + 2.9Nm(1.3+0.3k9m)
D-D
E-EX07HH033
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Centering spring (for P3, P4) Free length Installed Installed load Free length Installed loadX O.D. length
42.4X 15.5 34 17.6 N 13.7 N(1.8 kg)
-(1.4 kg)
2 Centering spring (for PI, P2) 44.4 x 15.5 34 29.4 N 23.5 N(3.0 kg)
-(2.4 kg)
3 Metering spring 26.5 X 8.2 24.9 16.7 N 13.7 N(1.7 kg)
-(1.4 kg)
Replace spring ifany damages ordeformations arefound.
40-35
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MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
m 27.9+3.4Nm(2.85+0.35kgm)
m 17.6&3.9Nm(1.8+0.4kgm)
w 30.9&3.4Nm(3.15t0.35kgm)
XlOBHl83
Unit: mm
No. Check item Criteria Remedy
I I IStandard size Repair limit
I I 1 I1 Metering spring Free length Installed Installed load Free length Installed load
X O.D. length Replace spring ifany damages or
26.5 X 8.15 24.7 16.7 N 13.7 N deformations are(1.7 kg)
_(1.4 kg) found.
2 Centering spring 48.1 x 15.5 32.5 107.8 N 86.2 N
(11 kg)_
(8.8 W
40- 36
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MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
w 78.5Nm(8.0’(p)
m 2.9Nm(0.3kgm)
XlOBH184
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Centering spring Free length Installed Installed load Free length InstalledX O.D. length load
Replace spring if
64.6 X 16.6 40.5 46.1 N 44.1 N any damages or_
(4.7 kg) (4.5 kg) deformation arefound.
2 Metering spring 26.0 X 10.5 25.0 25.5 N 24.5 N_(2.6 kg) (2.5 kg)
40-37
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MAINTENANCE STANDARD PPC SHUTTLE, TRAVEL JUNCTION VALVE
PPC SHUTTLE, TRAVEL JUNCTION VALVE
m34.3?4.9Nm(3.5+0.5kgm)
34.3r4.9Nm\(3.5+0.5kgm)
17.15+2.45Nm
107.8+14.7Nm
3
m 66.15&/7.35Nm(6.75*0.75kgm)
XlOBH185
40-38
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MAINTENANCE STANDARD PPC SHUTTLE, TRAVEL JUNCTION VALVE
A-A
XlOBH186
Unit: mm
No. Check item CriteriaRemedy
Standard size I Repair limit II I I I
1 Spool return spring Free length Installed Installed load Free length Installed load Replace spring if
X O.D. length any damages ordeformations are
23.6 X 13.3 20 14.7 N 11.8 N found.
1 (1.5W- 1 (1.2kg) 1
40-39
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MAINTENANCE STANDARD EPC, SOLENOID VALVE
EPC, SOLENOID VALVE
LS CONTROL EPC VALVE
m 11.3F1.5Nm(1.15+0.15kgm)
w 9:8+_2.ONm(1 +0.2kgm)
XlOBH187
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limitReplace EPC
1 Return spring Free length Installed Installed load Free length Installed valve assembly if
X O.D. length load any damages ordeformations are
9.0 x 11.4 7.9 3.1 N(0.32 kg)
_found.
_
40-40
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MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
4 PORT SWIVEL JOINT
x10zz021
Unit: mm
No. Check item Criteria Remedy
Standard size Standard clearance Clearance limit1 Clearance between rotor and shaft Replace
90 0.056 - 0.105 0.111
40-41
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MAINTENANCE STANDARD CENTER SWIVEL JOINT
6 PORT SWIVEL JOINT
x1ozzo22
Unit: mm
No. Check item Criteria Remedy
Standard size Standard clearance Clearance limit
1 Clearance between rotor and shaft Replace100 0.056 - 0.105 0.111
40- 42
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MAINTENANCE STANDARD BOOM HOLDING VALVE
BOOM HOLDING VALVE
* For machines equipped with arm holding valve, the Maintenance Standard of the arm holding valve is the sameas this valve.
IA
2
/m 15.0fl.Okgm
AA
No. Check item Criteria
XlOBH188
Unit: mm
Remedy
1
2
Pilot valve spring
Check valve spring
Free lengthX O.D.
26.5 x 11.2
37.2 X 16.2
Standard size
Installedlength
25.0
30.0
Repair limit
Installed load
4.7 N(0.48 kg)
Free length Installed load Replace spring ifany damages ordeformations are
3.7 N found._(0.38 kg)
35.3 N 28.4 N
(3.6 kg)_
1 (2.9 kg) 1
40-43
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MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDERPC200-6, PC2OOLC-6PC21 OLC-6
BOOM CYLINDER
-270+39.ONm(27.,5&4.Okgm)
m 8.6k0.86kNt-n(880Ifr88kgm) (Width ac ross flat: 95mm)
XIQBR042
ARM CYLINDER
-372.4+53.9Nm(38.0i5.5kgm)
m 10.2+1.0kNm(1 ,FO? 104kgm) (Width across flat: 95mm)
XIOBR043
BUCKET CYLINDER
m 270+_39Nm m 7.1*0.7kNrn(720+72kgm) (Width across flat: 85mm)
XIOBR044
40-44
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MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm
Remedyo. Check :em Crite Ia
Cylinder -ante Standard Clearanceclearance limit
Hole
+0.257+0.048
BoomClearancebetweenpiston rodand bushing
Replacebushing+0.222
+0.047Arm
Bucket 80 -0.030 +0.258-0.076 +0.048
0.078 - 0.334 0.434
Clearancebetweenpiston rodsupport pin
and bushing
Boom 80 -0.030-0.060
80 -0.030
-0.076
+0.457+0.370
+0.457
+0.370
Arm
Bucket +0.424+0.350
0.380 - 0.500 1.0
I
0.400 - 0.533 I 1 .o0.211+0.124
Replacepin orbushing
Clearancebetweencylinderbottomsupport pinand bushing
Boom
Arm 80 -0.030-0.076
-t70 -0.030
-0.076
+0.457+0.370
0.400 - 0.523 1.0
+0.424+0.350
Bucket
40-45
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MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDERPC22OLG6, PC250LG6
BOOM CYLINDER
m 270+39Nm(27.5i4.Okgm)
m 10.2+1.0kNm(1,040 + 104kgm) (Width across flat: 95mm)
ARM CYLINDER
m 373k54Nm(38iOF5.5kgm)
m 10.2 l .OkNm(1 y + 104kgm) (Width across fiat: 95mm)
BUCKET CYLINDER
w 270+39Nm(27.5f4.0kgm)
w 10.2+1.0kNm(1,1?40+ 104kgm) (Width across flat: 95mm)
XlOBR047
40- 46
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MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm
Remedyo. Check item Criteria
Cylinder
BoomClearancebetweenpiston rodand bushing
ReplacebushingArm 100 1 XI:&;; 1 ;;:W;; 1 0.083 - 0.347 1 0.447
90 1 XLCI;; 1 N:Wt; 1 0.084 - 0.347 1 0.447ucket
Boom 80 1 4:;;; 1 Ml:tl;; 1 0.400 - 0.517 1 1 Olearancebetweenpiston rodsupport pin
and bushing
Arm 80 1 4l:tl;; 1 ;;:;A; 1 0.400 - 0.533 / 1 .O
Bucket 80 1 4:;;; 1 G:;;; 1 0.400 - 0.533 1 1.0
Boom 80 1 4:CD& ) W& 1 0.400 - 0.533 1 1.0 Replacepin orbushing
Clearancebetweencylinderbottomsupport pinand bushing
3Arm 80 1 4:;;; 1 4:;;; 1 0.400 - 0.533 1 1.0
Bucket 80 1 4:;;; 1 NM; / 0.400 - 0.533 / 1 .O
40-47
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MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENTD
G
I
A-A
B-B
E-E
F-F
D-D G-G X17FR024
40- 48
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MAINTENANCE STANDARD WORK EQUIPMENT
No.
3
4
Check item
Clearance betweenconnecting pin andbushing of revolvingframe and boom
Clearance betweenconnecting pin andbushing of boomand arm
Clearance betweenconnecting pin andbushing of arm andlink
Clearance betweenconnecting pin andbushing of arm andbucket
Clearance betweenconnecting pin andbushing of link andbucket
Clearance betweenconnecting pin andbushing of link andlink
T-Standard
size
90
90
70 (PC200)(PC21 0)
80 (PC220)(PC250)
80
80
70 (PC200)(PC21 0)
80 (PC220)(PC250)
Criteria
Tolerance I Standard I Clearance
-0.036 +0.153 0.133 - 1.0-0.071 +0.097 0.224
-0.030 +0.335 0.305 - 1 .o-0.076 +0.275 0.411
-0.030-0.076
-0.030 +0.337 0.303 - 1 .o-0.076 +0.273 0.413
-0.030 +0.335 0.303 - 1 .o-0.076 +0.275 0.411
rUnit: mm
Remedy
Replace
40-49
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MAINTENANCE STANDARD WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT
1. ARM PORTION
i
, 1 ,I I
x-x
X17FRO25
40-50
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MAI NTENANCESTANDARD WORKEQUI PMENT
Uni t: mm
Appl i cabl e machi ne
No.
PC200- 6 PC210- 6 PC220- 6PC250- 6
1 080 ' 0 080 ' o . ' 080 ; I
2 107. 3-y 107. 3+I . 5O 107. 3y
3+0. 5
3100+0. 5
3100+0. 5
3100
4 09~0. 0710. 036 09~0. 071 0. 036 - 0. 03609~0. 071
5 361. 7+1 361. 7k. l 403. 9 f 1
6 187. 2 f 0. 5 187. 2 f 0. 5 200 f 0. 5
7 829. 1 f 1 829. 1 f 1 920*1
8 2, 919 2, 919 3, 038
9 2, 631. 3 I 2, 631. 3 I 2, 563. 2 1
10 410*1 41Okl 4651t l
11 640 f 0. 2 640 f 0. 2 585 f 0. 2
12 600 f 0. 5 600 f 0. 5 600 f 0. 5
13 458. 1 458. 1 446. 3
14 1, 486 1, 498. 3 1, 551. 7
15 080 080 080
16 326. 5 *I 326. 5 f 1 326. 5 f 1
17 080 080 080
Arm w dth0
183 - o. 5 31l _oq5
03 - o. 5
Bushi ng nst al l ed 325 325 325
M n. 1, 680 1, 680 1, 60519
Max. 2, 800 2, 800 2, 625
40-51
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MAINTENANCE STANDARD WORK EQUIPMENT
2. BUCKET PORTION
Adjustable Device Configuration View B -B
6
7
Standard Configuration