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PC220LC-6
Shop manual
Komatsu PC220LC-6 Shop Manual
Hydraulic excavator
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Table of Judgment Standard Values
Testing and Adjusting
Tools for Testing, Adjusting and Troubleshooting
Measuringenginespeed
Measuring Intake Manifold Pressure
Measuring Intake Air Restriction
Measuring Lubricating Oil Pressure
Measuring Fuel (Filter) Inlet Restriction
Measuring Blowby Pressure
Measuring Engine Back Pressure
Measuringexhaustcolor
Measuring Coolant Temperature
Measuringvalveclearance
Checking and Adjusting Belt Tension for Air Conditioner Compressor
Adjustingenginespeedsensor
Testing and Adjusting Governor Motor Lever Stroke
Testing Clearance of Swing Circle Bearing
Testing and Adjusting Track Shoe Tension
Testing and Adjusting Hydraulic Pressure in Work Equipment, Swing, Travel Circuit
Testing and Adjusting TVC Valve Output Pressure (Servo Piston Input Pressure)
Testing and Adjusting LS Valve Output Pressure (Servo Pistion Input Pressure) and LS Differential Pressure
Testing and Adjusting Control Pump Circuit Oil Pressure
Testing EPC Valve, Solenoid Valve Output Pressure
Measuring PPC Valve Output Pressure and Testing PPC Shuttle Valve
Adjusting Work Equipment
Adjustingtravellever
Testing Travel Deviation
Testing Location Causing Hydraulic Drift of Work Equipment
Measuringoilleakage
Releasing Remaining Pressure in Hydraulic Circuit
Bleedingair
Troubleshooting
Points 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)
Points to Remember When Carring out Troubleshooting of Engine Throttle Controller System
Engine 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
Abnormality in Engine Throttle Controller Power Source System
(Engine Speed Stays at Low Idling)
E3:08] Abnormality in Fuel Control Dial Input Value Is Displayed
E3:18] Abnormality (Short Circuit) in Governor Motor Drive System Is Displayed
E3:01] Abnormality in Network Reception System Is Displayed
E3:05] Abnormality in Model Code Is Displayed
E3:06] Abnormality in Governor Potentiometer System Is Displayed
E3:07] Abnormality in Pump Controller Throttle System Is Displayed
E3:15] Abnormality (Short Circuit) in Battery Relay Output System Is Displayed
E3:16] Abnormality (Step-Out) in Governor Motor System Is Displayed
E-11 Engine Does Not Start
20-I 29
A) Idling Speed Is Irregular
B)Thereishunting
Lack of Output (Engine High Idling Speed Is too Low)
E-14 Engine Does Not Stop
Defective Operation of Battery Relay System (Engine Does Not Stop)
Table of Contents
Method of Using Troubleshooting Chart
S- 1 Starting Performance Is Poor (Starting Always Takes Time)
Enginedoesnotstart
Enginedoesnotturn
Engine Turns but no Exahaust Gas Comes out (Fuel Is Not Being Injected)
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
S-L 1 Oil Is in Cooling Water, or Water Spurts Back, or Water Level Goes down
Oil Pressure Lamp Lights up (Drop in Oil Pressure)
S-13 Oil Level Rises
Water Temperature Becomes too High (Overheating)
S-15 Abnormal Noise Is Made
S-16 Vibration Is Excessive
Table of Contents
Pump Controller System Circuit Diagram
Abnormality in Pump Controller Power Source System (Swing Brake Is Not Canceled, Etc)
[E2:36] Short Circuit in Rear Pump TVC Solenoid System Is Displayed
[E2:37] Disconnection in Rear Pump TVC Solenoid System Is Displayed
[E2:06] Short Circuit in Travel Speed Solenoid System Is Displayed
[E2:12] Disconnection in LS Select Solenoid System Is Displayed
E2:17] Model Selection Input Error Is Displayed
E2:18] Network Response Overtime Error Is Displayed
[E2:22] Short Circuit in LS Control EPC Solenoid System Is Displayed
C-L 1 [E2:23] Disconnection in LS Control EPC Soleniod System Is Displayed
[E2:24] Abnormality in Front Pump Pressure Sensor System Is Displayed [E2:25] Abnormality in Rear Pump Pressure Sensor System Is Displayed
E2:26] Abnormality in Pump Pressure Sensor Power Source System Is Displayed
C-14 [E2:27] Abnormality in Engine Speed Sensor System Is Displayed
Table of Contents
Logic
Pump Merge-Divider
Troubleshooting
Speeds of All Work Equipment, Swing, Travel Are Slow or Lack Power
There Is Excessive Drop in Engine Speed, or Engine Stalls
Abnormal Noise Generated (Around Pump)
No Work Equipment, Travel, Swing Move
Fine Control Ability Is Poor or Response Is Poor
Boom Is Slow or Lacks Power
Arm Is Slow or Lacks Power
Bucket Is Slow or Lacks Power
Excessive Hydraulic Drift (Boom, Arm, Bucket)
Excessive Time Lag (Engine at Low Idling)
H-13 Lack of Power When Pressure Rises
Other Equipment Moves When Single Circuit ~S.relieveb
H-16 in Compound Operations, Work Equipment with Larger Load Is Slow
In L/O, F/O Modes, Work Equipment Speed Is Faster that Specified Speed
In Swing + Boom RAISE, Boom RAISE Isslow
In Swing + Travel, Travel Speed Drops Excessively
Inswing+Armout,Armoutisslow
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
Travel Does Not Move (One Side Only)
Swing Acceleration Is Poor or Swing Speed Isslow
H-27 Excessive Overrun When Stopping Swing
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
Table of Contents
None of the Lamps on Monitor Panel Light up
Some of the Lamps on Monitor Panel (Gauge Display, Time Display) Do Not Light up
When Starting Switch Is Turned ON, Monitor Panel Lamps All Stay Lighted up and Do Not Go out
When Starting Switch Is Turned on (Engine Stopped), CHECK Items Flash (Fluid Levels for CHECK Items Are at Specified Level)
Coolantlevelflashes
Hydraulic Oil Level Flashes
M-8 Preheating Is Not Being Used but Preheating Display Lights up
When Starting Switch Is Turned on and Engine Is Started, CHECK Items Flash
A) Alternator System
Engine Oil Pressure Sensor System
M-L 0 When Starting Switch Is Turned on (Engine Stopped), CAUTION Items Flash (but When Charge Level, Engine Oil Pressure Do Not Light Up)
A) Alternator System
Engine Oil Pressure Flashes
Coolantlevelflashes
Coolant Temperature Flashes
Batterychargeflashes
Fuellevelflashes
No Abnormality Is Displayed on Monitor but Buzzer Sounds
When Starting Switch Is Turned on (Engine Stopped), Buzzer Does Not Sound for 1 Second CAUTION Items Are Flashing but Buzzer Does Not Sound
Liquid Crystal Night Lighting on Monitor Panel Does Not Light up (Liquid Crystal Display Is Normal)
Coolant Temperature Gauge Does Not Rise
Coolant Temperature Gauge Does Not Give any Display (None of the Gauge Lamps Light up Duringoperation)
Fuel Level Gauge Always Displays FULL
Fuel Level Gauge Does Not Give Display
Swing Lock Prolix Switch Is on (Prolix), but Monitor Panel Parking Display Does Not Flash
Swing Lock Switch Is Turned on (LOCK) but Monitor Panel Parking Display Does Not Light up
Defective Fuel Level Sensor System
Defective Coolant Temperature Sensor System
Defective Engine Oil Level Sensor System
Defective Coolant Level Sensor System
Defective Hydraulic Oil Sensor System
Working Light Does Not Light up
Panel Lighting Does Not Light up
Light Switch Is Not Being Used but Working Light Lights up
A) Wiperdoesnotwork
Wiper Switch Is Not Being Used but Wiper Is Actuated
Table of Contents
Precautions When Carrying out Operation
Special Tool List
Removal
Installation
Removal
Removal
Installation
Removal
Hydraulic Oil Cooler
Installation
Removal
Removal
Fuel Tank
Removal
Assembly
Removal
Assembly
Pc200-6, Pc2Oolc6, Pc21Olc-6, Pc22Olc-6
Assembly
Travel Motor
Assembly
Removal
Removal
Removal
Assembly
Removal
Swing Circle
Removal
Recoil Spring
Assembly
Disassembly
Idler
Assembly
Removal
Track Roller
Disassembly
Removal
Carrier Roller
Disassembly
Assembly
Removal
Removal
Removal
Removal
Main Pump
Disassembly
Assembly
Removal
Removal
Control Valve
Control Valve Assembly
Disassembly
Assembly
Pressure Compensation Valve
Assembly
Disassembly
Assembly
Removal
Tvc
30-I 25
Removal
Removal
Ls Control Epc Valve
Removal
Solenoid Valve
Removal
Swing Ppc Valve
Disassembly
Travel Ppc Valve
Removal
Boom Lock Valve
Boom Cylinder
Removal
Arm Cylinder
Removal
Bucket Cylinder
Hydraulic Cylinder
Assembly
Work Equipment
Removal
Bucket
Installation
Removal
Table of Contents
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)
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
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c l a s s i c ma c h i n e r y . n e t
Table of
Contents
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Chapters
Table of Contents
232
Troubleshooting
293
Troubleshooting of Engine Throttle Controller System (E Mode)
340
Table of Contents
367
Table of Contents
390
Table of Contents
433
Table of Contents
464
Table of Contents
496
Table of Contents
658
Table of Contents
Troubleshooting
Tools for testing, adjusting and troubleshooting
254
Troubleshooting
293
Points to remember when troubleshooting
294
Sequence of events in troubleshooting
295
Checks before troubleshooting
303
Details of troubleshooting and troubleshooting procedure
335
Troubleshooting of engine throttle controller system (E mode)
340
Points to remember when carring out troubleshooting of engine throttle controller system
341
Method of using troubleshooting chart
368
Troubleshooting
436
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