Troubleshooting

[Troubleshooting] Kobelco excavator fault
code fault code

Sep 6, 2014 | Repair Manual How to
Kobelco excavator repair SK200-2 SK200-3 fault code:

A-1ROM data is bad (not electromechanical A adjustment).
A-2 Electrical A bad adjustment.
A-3CPU exception.
B-1 arm upward pressure sensor is abnormal.
B-2, the big arm downward pressure sensor is abnormal.
B-3, the arm back pressure sensor is abnormal.
B-4, arm extended pressure sensor anomaly.
B-5, the bucket back pressure sensor is abnormal.
B-6, bucket extended pressure sensor anomaly.
B-7, rotary pressure sensor anomaly.
B-9, dextral pressure sensor anomaly.
B-10, sinistral pressure sensor anomaly.
C-1, P1 pump pressure sensor is abnormal.
D-1, P1 neutral cut proportional valve abnormalities.
D-3, the proportion of straight travel valve abnormalities.
D-4, a large proportion of boom confluence valve abnormalities (only -2 models).
D-5, the proportion of slow rotary valve abnormalities (only -2 models).
D-6, the arm of variable renewable proportional valve abnormalities (only -3 models).
E-1, P1 pump proportional valve abnormalities.
F-1, booster valve abnormalities.
F-2, the rotating brake solenoid is abnormal.
F-3, the traveling speed changeover solenoid valve abnormalities.
F-4, FC mode (micro-operations) solenoid valve abnormalities (only -2 models).
F-5, walk a straight line solenoid valve abnormalities (only -2 models).
G-1, the stepper motor current exception.
G-2, the stepper motor without a starting point indexing.
G-5, an engine flameout (Show E / G reversal).
Kobelco SK200-6 fault code:

An electromechanical controller failure.
1-1, instruments and electromechanical controller communication error.
1-2, the battery relay exception.
A-1, A is not electromechanical adjustment.
A-2, A electromechanical adjustment bad.
B-1, big arm autogenous pressure sensor is abnormal.
B-2, the big arm downward pressure sensor is abnormal.
B-3, the arm back pressure sensor is abnormal.
B-5, the bucket back pressure sensor is abnormal.
B-7, the pressure sensor is abnormal clockwise rotation.
B-8, the counterclockwise turning the pressure sensor is abnormal.
B-11, P1 negative pressure sensor anomaly.
B-15, back pressure sensor is abnormal.
D-3, the proportion of straight travel valve abnormalities.
D-6, the arm of variable renewable proportional valve abnormalities.
F-2, the rotating brake solenoid is abnormal.
F-3, the traveling speed changeover solenoid valve abnormalities.
G-1, the stepper motor current exception.
G-2, the stepper motor without a starting point indexing.
G-3, an engine speed sensor is abnormal.
H-1, throttle knob exception.
Kobelco excavator SK200-8 display fault code (engine systems) sensor systems:
P2228, the atmospheric pressure sensor fault (LO).
P2229, the atmospheric pressure sensor fault (HI).
P0192, rail pressure sensor fault (LO).
P0193, rail pressure sensor fault (HI).
P0191, rail pressure sensor failure.
P0237, boost sensor fault (LO).
P0108, boost sensor fault (HI).
P0117, the water temperature sensor fault (LO).
P0118, the water temperature sensor fault (HI).
P0182, fuel temperature sensor fault (LO).
P0183, fuel temperature sensor fault (HI).
P0335, the main speed sensor system failure, the engine will not start / stop the engine.
P0340, deputy speed sensor system failure, the engine will not start / stop the engine.
P2120, dual throttle sensor system failures, speed down (idling speed 800r / min).
P2121, a throttle sensor voltage is abnormal. P2122, a throttle sensor failure (LO).
P2123, a throttle sensor failure (HI).
P2126, throttle sensor 2 voltage is abnormal.
P2127, throttle sensor 2 fault (LO).
P2128, throttle sensor 2 fault (HI).
Switches, relays, system fault codes:

P0540, preheating device failure (open circuit / CND shorted).
P0540, preheating device failure (+ B short circuit).
P0617, the start switch circuit failure.
P0686, the main relay circuit failure.
Fuel pump system failure code:

P0629, the fuel supply solenoid circuit fault (+ B short-circuit), the engine can not start / stop the
engine.
P0628, fuel pump solenoid circuit fault (full output mode), the output decline.
P2635, history of abnormal pressure fuel pump.
P2635, fuel pump solenoid valve stuck.
P0088, rail pressure abnormalities, output declined.
Fuel injection system fault codes:

P1211, injector rail a solenoid valve drive system fault (GND short circuit), the output decline on
/ off cylinders (1, 4).
P1214 Injector solenoid valve drive system common rail 2 fault (GND short circuit), the output
decline on / off cylinder operation (two times, three times).
P1212, injector rail a solenoid valve drive system failures (+ short-circuit B / open circuit), the
output decline on / off cylinders (1, 4).
P1215, injector solenoid valve drive system common rail 2 failures (+ short-circuit B / open
circuit), the output decline on / off cylinder operation (two times, three times).
P1601, multi-point fuel injector correction exceptions, output declined.
P0201, injector solenoid valve circuit breaker, output drops on / off cylinder operation (1).
P0202, solenoid injector 2 circuit breaker, output drops on / off cylinder operation (two times).
P0203, solenoid injector 3 circuit breaker, output drops on / off cylinder operation (three times).
P0204, solenoid injector 4 circuit breaker, output drops on / off cylinder operation (four times).
P0263, cylinder correction fault 1.
P0269, cylinder correction failure 3.
EGR System:
P0489, EGR valve is a linear solenoid valve malfunction (open circuit / GND short circuit), the
output decline.
P0490, EGR valve is a linear solenoid valve malfunction (VB short circuit), the output decline.
P0404, EGR valve is stuck in an output drop.
P0405, EGR valve is a safety sensor fault (LO).
P0406, a safety sensor valve failure (HI).
Turbine system fault code:

P0234, turbo too large, the output decreases.
Engine system (state judge) fault code:
P0217, overheating, output declined.
P0219, the engine coaster. Communication: U1001, CAN communication interruption (vehicle).
ECU system:
P0611, ECU poor charging circuit (LO), the output decline.
P0200, ECU poor charging circuit (HI).
P0605, ROM exception.
P0606, CPU failure, the engine will not start the engine stopped.
P0607, CPU monitoring IC exceptions, output declined.
Kobelco excavator SK330-6E fault code (sequential) and the reasons are considered
Code
Troubleshooting
The reason is considered
07
Engine overtravel (red light)
E / G input speed sensor or timing sensor becomes the equivalent of a pulse above 2400rpm
connector inside the water
speed sensor, timing sensor installation lax
wiring is bad
rotary gear adhesion of a foreign body
speed sensor or timing sensor failure
electronic speed controller failure
11
Governor port (red light)
Instruction electronic regulator controller and rack position is inconsistent
rack sensor using VC 5V power supply lines, poor ground
Wiring PWM signal (rack position) signal abnormalities
wiring BUF VIS (rack sensor) signal abnormality
electronic speed controller for abnormal born PWM signal (control rack position)
abnormalities
Failure to adjust the internal servo motor drive circuit, etc.
14 + 15
Two speed sensor (red light)
The number of input pulses and the timing sensor speed sensor inconsistencies
Speed sensor or timing sensor wiring anomaly
Installation unusual speed sensor or timing sensor
connector inside the water
rotary gear adhesion of a foreign body
electronic speed controller failure
speed sensor or timing sensor failure
16
Throttle sensor 2 (no lights)
From the controller to the output voltage is below 0.2V or 4.8V above
electromechanical controller exception
Record abnormal
17
Electronic timer control (orange lights)
Rack rack position specified value and the actual measured signal is inconsistent
exception code 22 also appear to confirm the rack sensor anomaly
exception code 22 is not the same when
PWM (control rack position) command line anomalies
rack abnormal sensor output voltage VIST
internal rack does not work properly according to instructions
19
Atmospheric sensors
mechanical condition: flat no problem, there is a problem referred Heights jobs
Twenty one
Water temperature sensor
mechanical condition: starting the engine at low temperature properties deteriorate
Twenty two
Rack sensor (red light)
Rack sensor output voltage is below 0.5V or 4V above
rack sensor using VC 5V power supply lines, poor ground
governor side of the rack sensor anomaly
Wiring BUF VIST (rack sensor) line anomalies
Twenty three
Timer control valve (orange light)
Wiring broken or shorted measured out
TCV ADV, GCV RTD (injection timing control valve) wiring anomaly
Twenty four
Throttle sensor 1 (no lights)
From the controller to the output voltage is below 0.2V or 4.8V above
wiring anomaly
16 + 24
1,2 while the throttle sensor fault (orange light) from the controller, throttle potentiometer output
voltage of 0.2V or 4.8V less than
wiring anomaly
32
Boost sensor (orange light)
From booster sensor output voltage is below 0.5V or 4.8V above
electronic speed controller exception
to boost sensor wiring anomaly
boost sensor malfunction
air filter, suction hose system abnormalities
33
System error (red light)
System error
electronic speed controller exception
Power electronic speed controller, the bad ground
34
Q adjusting resistor (lamp lights)
mechanical condition: engine output to minimum resize
Forty five
Boost sensor (orange light)
In addition to the starter motor being started outside, the actual E / G rotation speed is very low
Engine emergency stop cables are hanging
pump torque becomes too large
poor engine output
65
Throttle SW (no lights)
mechanical condition: changes to the usual control mode
78
Heater relay (orange light)
to bad wiring heating relay
Kobelco excavator @ // SK200-6 fault code Description
Fault code Fault grounds

1 electromechanical controller failure.
1-1, electromechanical controller communicates with unusual instrumentation.
1-2, battery relay exception.
A-1, not electromechanical A adjusted.
A-2, Electrical A bad adjustment.
B-1, big arm raw pressure sensor anomaly.
B-2, arm downward pressure sensor is abnormal.
B-3, arm retraction pressure sensor is abnormal.
B-5, bucket retraction pressure sensor is abnormal.
B-7, clockwise rotation pressure sensor is abnormal.
B-8, counterclockwise turning the pressure sensor is abnormal.
B-15, back pressure sensor is abnormal.
D-3, walking straight proportional valve abnormalities.
D-6, forearm variable renewable proportional valve abnormalities.
E-2, P2 pump proportioning valve abnormalities.
F-2, of the rotating brake solenoid is abnormal.
F-3, traveling speed changeover solenoid valve abnormalities.
G-1, stepper motor current exception.
G-2, stepper motors without a starting point indexing.
G-3, of the engine speed sensor is abnormal.
H-1, throttle knob exception.
Kobelco SK series digging machine / sensor system / fault code Description
Fault code Fault grounds

P2228, atmospheric pressure sensor fault (LO).
P2229, atmospheric pressure sensor fault (HI).
P0117, temperature sensor fault (LO).
P0118, temperature sensor fault (HI).
P0335, the main speed sensor system failure, the engine will not start / stop.
P0340, Vice speed sensor system failure, the engine will not start / stop.
P2121, a throttle sensor voltage is abnormal.
P2122, a throttle sensor failure (LO).
SK200-8
P1211 alarm is grounding alarm basin oil line
P0340 alarm is deputy speed sensor failure alarm
Z010 diesel common rail pressure alarm is low or the oil injector wear serious
SK130-8
00198 is the lack of oil pressure alarm
01008 alarm engine hydraulic switch disconnection alarm
SK75-8
G013 alarm refers to the engine throttle motor abnormalities progress
H013 alarm throttle line is bad
SK130-8
B173 alarm is connected to the low pressure sensor attachments appear disconnected the
electrical circuit fault.
SK140LC-8
10802 alarm is the intake pressure sensor connected to the line between ECU failures caused by
poor
00198 is the engine hydraulic switch disconnection alarm
G033 engine speed sensor circuit anomalies
SK200-8
P1092 is a common-rail diesel injection device alarm pressure sensor failure.
P0336 is the primary speed sensor alarm alarm
P0405 EGR valve is rising alarm sensor alarm
SK210-8
P0617 is a start switch malfunction alarm
P0404 EGR issuing warning alarm is
P2635 alarm diesel common rail high-pressure pump end solenoid valve failure
P0405 EGR valve security sensor alarm is not working
SK250-8
P0203 is a 3-cylinder injector alarm break alarm
10802 alarm is the engine speed sensor voltage is abnormal.
SK260-8
P0088 rail pressure abnormal alarm
P0404 alarm solenoid valve 4-cylinder engine failure alarm
Kobelco SK200-8 fault code (engine systems) sensor systems:
P2121, a throttle sensor voltage is abnormal. P2122, a throttle sensor failure (LO).
P2128, throttle sensor 2 fault (HI). Switches, relays system: fault codes,
P0686, the main relay circuit failure. Fuel pump system:
engine.
P0088, rail pressure abnormalities, output declined. Fuel injection system:
P1214 Injector solenoid valve drive system common rail 2 fault (GND short circuit), the output
EGR System:
output decline.
P0406, a safety sensor valve failure (HI). Turbine system:
P0234, turbo too large, the output decreases. Engine system (state judge):
P0219, the engine coaster. Communication: U1001, CAN communication interruption (vehicle).
ECU system:
P0605, ROM exception.
P0606, CPU failure, the engine will not start the engine stopped.
Kobelco SK-8] [fault code, the code following meanings:
A Kobelco SK-8 (engine systems) sensor systems:

P2121, a throttle sensor voltage is abnormal.
P2122, a throttle sensor failure (LO).
2 Kobelco SK-8 switches, relays system:
. P0686, the main fuel pump relay circuit fault system:
engine.
P0088, rail pressure abnormalities, output declined.
3 Kobelco SK-8 fuel injection system:
P1214, injector solenoid valve drive system common rail 2 fault (GND short circuit), the output
4 Kobelco SK-8EGR system:
output decline.
P0406, a safety sensor valve failure (HI).
5 Kobelco SK-8 turbo system:

P0234, turbo too large, the output decreases.
6 Kobelco SK-8 engine system (state judge):
P0219, the engine coaster.
7 Kobelco SK-8 Communication:
U1001, CAN communication interruption (vehicle).
8 Kobelco SK-8ECU system:
P0605, ROM abnormal .P0606, CPU failure, the engine will not start the engine stopped.
[Troubleshooting] Hitachi excavator fault

code fault code
Hitachi 200-3 240-3270-3 fault code:

11100-2 abnormal engine speed
11101-3 engine speed control knob sensor high pressure anomaly
11101-4 Low engine speed control knob sensor anomaly
11200-3 pump an oil pressure sensor high pressure anomaly
11200-4 pump an oil pressure sensor low pressure anomaly
11202-3 high pressure pump 2 oil pressure sensor anomaly
11202-4 pump 2 Low oil pressure sensor is abnormal
11206-3 pump an abnormal high pressure pump control pressure sensor
11206-4 pump a high-pressure pump control abnormal low pressure sensor
11208-3 pump two high-pressure pump control pressure sensor anomaly
11208-4 pump two high-pressure pump control abnormal low pressure sensor
11301-3 swing pilot pressure sensor high pressure anomaly
11301-4 swing pilot pressure sensor low pressure anomaly
11302-3 Boom pilot pressure sensor high pressure anomaly
11302-4 Boom pilot pressure sensor low pressure anomaly
11303-3 Stick to recover the pilot pressure sensor high pressure anomaly
11303-4 Stick to recover the pilot pressure sensor low pressure anomaly
11304-3 walking pilot pressure sensor high pressure anomaly
11304-4 walking pilot pressure sensor low pressure anomaly
11307-3 front attachment pilot pressure sensor high pressure anomaly
11307-4 front attachment pilot pressure sensor low pressure anomaly
11400-2 pump 2 maximum flow limit control solenoid valve current feedback abnormal
11400-3 pump 2 maximum flow limit high-current feedback control solenoid valve
abnormalities
11400-4 pump 2 maximum flow limit low-current feedback control solenoid valve abnormalities
11401-2 torque current feedback control solenoid valve abnormalities
11401-3 torque feedback control solenoid valve high current abnormal
11401-4 torque low current feedback control solenoid valve abnormalities
11402-2 solenoid valve unit (SF) (tap renewable) Current Feedback abnormal
11402-3 solenoid valve unit (SF) (mining regeneration) high current abnormal feedback
11402-4 solenoid valve unit (SF) (tap renewable) feedback low current abnormal
11403-2 solenoid valve unit (SC) (Stick Regeneration) Current Feedback abnormal
11403-3 solenoid valve unit (SC) (stick regeneration) high current abnormal feedback
11403-4 solenoid valve unit (SC) (Stick Regeneration) feedback low current abnormal
11404-2 solenoid valve unit (SG) (relief pressure control) Current Feedback abnormal
11404-3 solenoid valve unit (SG) (relief pressure control) high current abnormal feedback
11404-4 solenoid valve unit (SG) (relief pressure control) feedback low current abnormal
11405-2 solenoid valve unit (SI) (walking motor quick selection) Current Feedback abnormal
11405-3 solenoid valve unit (SI) (motor running quickly select) high current abnormal feedback
11405-4 solenoid valve unit (SI) (walking motor quick selection) feedback low current abnormal
11410-2 pump a maximum flow limit control solenoid valve (optional) Current Feedback
abnormal
11410-3 pump a maximum flow limit control solenoid valve (optional) high current abnormal
feedback
11410-4 pump a maximum flow limit control solenoid valve (optional) feedback low current
abnormal
11910-2 ECM received from the actual engine speed
11918-2 received from the monitor mode to
11911-2 safety from the ECM receives a signal
11920-2 from the ECM receives fuel flow
11914-2 ECM received from the radiator coolant temperature
11901-3 high-pressure hydraulic oil temperature sensor
11901-4 low pressure hydraulic oil temperature sensor
11905-3 boom bottom pressure sensor high pressure (optional) abnormalities
11905-4 boom bottom pressure sensor low voltage (optional) abnormalities
ECM
Sensor System
Malfunction
Code
Cause
636-2 camshaft angle sensor error (no signal) despite crank signal, but the signal does not appear
cam.
636-2 camshaft angle sensor abnormality (abnormal signal) does not match the cam signal
pulses.
723-2 crank speed sensor abnormality (no signal) despite crank signal, cam signal does not
appear.
723-2 crank speed sensor abnormality (abnormal signal) does not match the cam signal pulses.
636-7 camshaft phase mismatch of the crank angle sensor gap at the right cam pulse does not
exist.
172-3 intake air temperature sensor is abnormal (high error) after starting the engine intake air
temperature sensor within 3 minutes a voltage higher than 4.95 V
172-4 intake air temperature sensor is abnormal (low pressure anomaly) intake air temperature
sensor voltage is less than 0.1 V
110-3 coolant temperature sensor abnormality (abnormal high pressure) coolant temperature
sensor voltage higher than 4.85 V
110-4 coolant temperature sensor abnormality (low pressure anomaly) coolant temperature
sensor voltage is less than 0.1 V
102-4 pressurized intake air pressure sensor anomaly (high pressure anomaly) pressurized intake
air pressure sensor voltage greater than 4.9 V
102-3 pressurized intake air pressure sensor anomaly (low pressure anomaly) pressurized intake
air pressure sensor voltage is less than 0.1 V
10001-3 EGR abnormal position (brushless specification) EGR position output signal conditions
can not appear
108-4 atmospheric pressure sensor abnormality (abnormal high pressure) is higher than the
atmospheric pressure sensor voltage 3.8 V
108-3 atmospheric pressure sensor anomaly (low pressure anomaly) atmospheric pressure sensor
voltage is less than 0.5 V
174-3 fuel temperature sensor anomaly (high pressure anomalies) within 3 minutes after starting
the engine fuel temperature sensor voltage higher than 4.85 V
174-4 fuel temperature sensor abnormality (low pressure anomaly) fuel temperature sensor
voltage is less than 0.1 V
157-3 rail pressure sensor anomaly (high pressure anomaly) rail pressure sensor voltage greater
than 4.5 V
157-3 rail pressure sensor anomaly (low pressure anomaly) rail pressure sensor voltage is less
than 0.7 V
100-4 oil pressure sensor abnormality (abnormal high pressure) oil pressure sensor voltage
higher than 4.85 V
100-3 oil pressure sensor abnormality (low pressure anomaly) oil pressure sensor voltage is less
than 0.1 V
105-3 supercharged intake air temperature sensor is abnormal (abnormal high pressure) within
five minutes or more after starting the engine coolant temperature or time exceeds
50 C (122 F), the pressurized intake air temperature sensor voltage higher than 4.95V
105-4 pressurized intake air temperature sensor is abnormal (low pressure anomaly) pressurized
intake air temperature sensor voltage is less than 0.1 V
636-2 camshaft angle sensor error (no signal)

636-2 camshaft angle sensor abnormality (abnormal signal)
When the operation is not affected.
Can not be restarted after shutdown
723-2 crank speed sensor abnormality (no signal)

723-2 crank speed sensor abnormality (abnormal signal)
Output power does not drop
636-7 camshaft angle sensor is not affected when the phase mismatch action.
After the shutdown can not be restarted
172-3 intake air temperature sensor is abnormal (high pressure anomaly)
172-4 intake air temperature sensor is abnormal (low pressure anomaly)
110-3 coolant temperature sensor is abnormal (high pressure anomaly)
110-4 coolant temperature sensor abnormality (low pressure anomaly)

102-4 pressurized intake air pressure sensor anomaly (high pressure anomaly)
102-3 pressurized intake air pressure sensor anomaly (low pressure anomaly)
10001-3 EGR abnormal position (brushless specification) output power does not drop
108-4 atmospheric pressure sensor abnormality (abnormal high pressure)
108-3 atmospheric pressure sensor anomaly (low pressure anomaly)
174-3 fuel temperature sensor abnormality (abnormal high pressure)

174-4 fuel temperature sensor abnormality (low pressure anomaly)
157-3 rail pressure sensor anomaly (high pressure anomaly)
157-4 rail pressure sensor anomaly (low pressure anomaly)

Output power reduction: 70%
100-4 oil pressure sensor abnormality (abnormal high pressure)

100-3 oil pressure sensor abnormality (low pressure anomaly)
105-3 pressurized intake air temperature sensor is abnormal (high pressure anomaly)
105-4 pressurized intake air temperature sensor is abnormal (low pressure anomaly)
10002-2 EGR valve control abnormal valve target position and the actual upgrade to enhance the
position difference exceeds 20%
1347-0 Suction control valve drive system open, + B or shorted to ground
Suction control valve drive current is higher than 2400 mA or less than 50 mA. Or target current
and the actual current difference of 1000 mA or more
651-3 nozzle # 1 Open injector drive system without a monitor input signal
652-3 nozzle # 2 drive system open injector 2 no input signal monitor
653-3 nozzle # 3 drive system open injector 3 no input signal monitor
654-3 nozzle # 4 drives open injector 4 is no input signal monitor
655-3 nozzle # 5 drive system open injector 5 is no input signal monitor
656-3 nozzle # 6 drive system open injector 6 is no input signal monitor
157-0 common sump pressure anomaly (a) share the tank pressure exceeds 185 MPa
157-0 common sump pressure anomalies (two) a shared sump pressure abnormal, and shared
the tank pressure exceeds 190 MPa
157-2 common sump abnormal pressure (pump overpressure) when the suction control valve is a
power of 40% or more, or when the target pressure of the suction control valve 90 mm3 / sec or
less, the actual pressure is higher than the target oil tank sump pressure 40MPa (410 kg / cm2,
5820 psi)
633-7 pressure limiter opening pressure limiter Open
1240-1 no pressure feed to the pump (fuel leakage) the control valve when the suction power is
33% or less, or when the control valve is delivered to the suction pressure of 28000 mm3 / sec or
more and 1200 min 1-speed, the actual the tank pressure is higher than the target pressure of the
tank 50 MPa (510 kg / cm2, 7270 psi)
1239-1 no pressure feed to the pump (fuel leakage) when the pressure supplied to the control
valve so that the suction is 900 min 1-speed, the actual pressure of the tank is 15 MPa (150 kg /
cm2, 2180 psi) or less
A fault code: 11301-3
Problem: Rotary pilot pressure sensor high pressure anomaly
Cause: Voltage 4.75V or more
Affected control: (1) stick regeneration control (2) Attachment Flow Control (3) rotation alarm
control
Failure occurs when the machine is working symptoms: (1) a combination of arm swing back
and stick-in operation is slow (2) If the machine is equipped with a rotary alarm and when the
alarm works when the rotary, rotary continuous ringing alarm
Notes: (1) Check the wiring harness (2) replace the rotary pilot pressure sensor
2, fault code: 11301-4

Problem: Rotary pilot pressure sensor low pressure anomaly
Cause: The voltage of less than 0.25V
Affected control: (1) stick regeneration control (2) Attachment Flow Control (3) rotation alarm
control
Failure occurs when the machine is working symptoms: (1) a combination of arm swing back
and stick-in operation is slow (2) If the machine is equipped with a rotary alarm and when the
alarm works when the rotary, rotary continuous ringing alarm
Notes: (1) Check the wiring harness (2) replace the rotary pilot pressure sensor
Problem: Boom pilot pressure sensor high pressure anomaly
Cause: Voltage 4.75V or more
Affected control: (1) HP mode control (2 stick regeneration control (3) excavator regeneration
control (4) Automatic power boost control (5) Accessories Flow Control
Failure occurs when the machine is working symptoms: (1) HP control when the boom lifting
speed without lifting (2) recovery and boom arm combination to enhance the operating arm slow
Notes: (1) Check the wiring harness (2) replace Boom pilot pressure sensor
Problem: Boom pilot pressure sensor low pressure anomaly
Cause: The voltage is lower than 0.25V
Affected control: (1) HP mode control (2 stick regeneration control (3) excavator regeneration
control (4) Automatic power boost control (5) Accessories Flow Control
Failure occurs when the machine is working symptoms: (1) HP control when the boom lifting
speed without lifting (2) recovery and boom arm combination to enhance the operating arm slow
Notes: (1) Check the wiring harness (2) replace Boom pilot pressure sensor [Hitachi excavator
ZX240-3 several common fault code details]
(1) Excavators one cylinder injector fault, fault code 0001-11

Main Symptom
a individual cylinder diesel engine does not fire.
b. diesel power is low.
Cause
a.1 cylinder injector solenoid wire circuit, short-circuit.
b.1 electromagnetic coil inside the cylinder injector open circuit, short circuit.
system response ECM will record fault code, fault code can be viewed on the display module
or ET. Reason if the generated code is a common fault short circuit or open circuit, then there are
two cylinders will be affected, since they use the same wires to injector on.
(2) fault code 0002-11: two cylinder injector fault
Main Symptom
a. individual cylinder diesel engine does not fire.
Cause
a 2 cylinder injector solenoid wire circuit, short-circuit.
system response ECM will record fault code, can be viewed on the display module or ET fault
code. Reason if the generated code is a common fault short circuit or open circuit, then there are
two cylinders will be affected, since they use the same guide. Line receiving the injectors.
(3) fault code 0003-11: three-cylinder injector fault
Main Symptom
Cause
two cylinders will be affected, since they use the same wires to injector on
(4) fault code 0004-11: four-cylinder injector fault
Main Symptom
a individual cylinder diesel engine does not fire.
Cause
a 4-cylinder injector solenoid coil wire open circuit, short circuit.
(5) fault code 0005-11: five-cylinder injector fault
Main Symptom
Cause
(6) fault code 0006-11: 6-cylinder injector fault
Main Symptom
Cause
(7) fault code 0041-03: 8V DC power supply and battery positive short-circuit
Main Symptom If the voltage is significantly lower than 8V, it will have a significant impact
on diesel engines, diesel engines will be limited to low idle state.
cause of the malfunction is detected ECM ECM or ECM charging more than Is readout signal
voltage higher than 8.45V sustained Is.
system response ECM will record the fault code, fault code can be viewed on the display
module or .ECM ET all digital sensor data is marked as invalid data, and all the digital sensor
data are set to default values.
(8) fault code 0041-04: 8V DC power supply and ground short
Main Symptom If the voltage is significantly lower than 8V, it will have a significant impact
on diesel engines, diesel engines will be limited to low idle state.
cause of the malfunction is detected ECM ECM or ECM charging more than Is readout signal
voltage higher than 8.45V sustained Is.
system response ECM will record the fault code, fault code can be viewed on the display
module or .ECM ET all digital sensor data is marked as invalid data, and all the digital sensor
data are set to default values.
Hitachi excavator -2, -3 Series Maintenance fault code analysis
Excavator fault code fault code analysis, fault phenomenon

09EC Hitachi excavator sensor failure or sensor harness shorted
10EC sensor harness connection is bad, bad contact
Hitachi excavator excavator N sensor fault on behalf of the 13 abnormal sensor harness
connection between N and EC bad
17 Hitachi excavators PVC failure, excavator engine does not work
Fault code 18PVC failure, excavators can not properly work
19 PVC failure excavator, excavators can not work
Hitachi excavator Hitachi excavator fault on behalf of 21 PVC failure, Hitachi excavator engine
and machine function failure, not a job
22 HITACHI oil pump control is not normal
Fault code 25 excavators DP sensor and wiring harness is not connected, poor contact
26 Hitachi excavators DP sensor and wiring harness shorted
Hitachi excavator P sensor fault on behalf of the 27 excavators and harness shorted
28P Hitachi excavator sensor and harness bad contact, the input signal from the sensor is lower
than 0.25V
29A sensor fault code and harness shorted, excavators input signal is greater than 4.75V
30 Hitachi excavator A bad sensor and wiring harness connector, sensor input signal falls below
0.25V
Hitachi excavator fault generation 31 R sensor and harness bad contact, T sensor input signal is
greater than 4.75V
32 T Hitachi excavator bad sensor or wiring harness connector, sensor input signal falls below
0.25V
Fault code 33 excavator arm to enhance pilot pressure sensor or wire shorted, Hitachi excavator
sensor input voltage is higher than 4.75 volts
Failure on behalf of the 34 Hitachi excavator excavator arm to enhance pilot pressure sensors,
sensor wire is disconnected
35 excavator arm low voltage sensor input signal is greater than 4.75
Hitachi excavator Hitachi excavator arm fault code 36 low voltage sensor input signal is too
small, or forearm low pressure sensor wire is disconnected
Hitachi (HLTACHL) explain in detail excavator fault code troubleshooting steps:

1 fault code 0164-04: injection-driven pressure sensor and ground short
Main Symptom
a. diesel low power operation.
b. diesel engine idling bad.
Cause ECM detects all of the following conditions:
. a fuel injector drive signal voltage is lower than 0.1V pressure sensor at least 0.6s;
b.5V sensor battery positive supply line and short-circuit fault code does not currently exist
0262-03;
c.5V sensor power lines and ground short circuit fault code does not currently exist 0262-04;
. d has at least a power supply to the ECM 2s;
e. cooling mode does not currently exist.
code .ECM the injector driving pressure marked as invalid data, and the use of 17.5MPa pressure
injection as the default .ECM will drive pressure control the valve current is set to a fixed value.
2 fault code 0164-11: injector actuation pressure sensor mechanical failure
Main Symptom
b. diesel engine idling bad.
c. Under normal operating temperature of the diesel engine difficult to start.
d. below the normal operating temperature of the diesel engine is easy to start.
Cause ECM detects one of the following situations:
. a difference between the actual injection pressure and injection required to drive the driving
pressure exceeds 3MPa;
b. leading to the fuel injection pressure control valve drive maximum or minimum output current
for longer than the time required This fault code indicates that there is a mechanical fault, ECM
and the electronic control system is operating normally.
or ET.
Troubleshooting perhaps only at operating temperatures have failed. If the system recently
repaired, then the injector drive system may exist air start the engine for several minutes under
1500r / min speed, to exclude residual air.
3 fault code 0168-02: System voltage ripple
Main Symptom
a. diesel engine does not fire.
b. diesel engine stops running.
Cause ECM detects any of the following situations:
. a diesel engine can not be started, the battery voltage drops below 9V, rebounded after 0.06s;
b. diesel engine can not be started, the battery voltage is three times lower in the last 7s, less than
9V.
or ET. Only when the diesel engine ECM will record operating code.
4 fault code 0172-03: intake air temperature sensor and battery positive open / short
Main Symptom diesel low power operation.
a.ECM read signal voltage above 4.92V at least 8s;
0262-03;
d. supply of power to at least the existing ECM 2s.
code .ECM intake air temperature will be marked as invalid data, and the use of a temperature of
85 degrees as the default.
5 fault code 0172-04: intake air temperature sensor shorted to ground
Main Symptom diesel low power operation.
a.ECM read below 0.2V signal voltage of at least 8s;
0262-03;
code .ECM intake air temperature will be marked as invalid data, and the use of a temperature of
85 degrees as the default.
6 fault code 0175-03: oil temperature sensor and battery positive open / short
The main symptom is no symptoms.
a.ECM read signal voltage above 4.92V at least 8s;
0262-03;
or ET .ECM oil temperature will be marked as invalid data, and adjust the oil temperature values
into the coolant temperature value. If the coolant temperature sensor is faulty, one should use the
following values:
. a diesel engine running, the oil temperature is set at 65 degrees;
When b. diesel engine stops running, the oil temperature is set to -10 degrees.
[Troubleshooting] hyundai excavator fault

code fault code
hyundai-9 series excavators fault code:
101 3 hydraulic oil temperature sensor circuit Voltage above normal or shorted high voltage
4 hydraulic oil temperature sensor circuit Voltage below normal or shorted to low voltage
1050 working device (idling) higher than normal pressure sensor data
A working device (idling) lower than normal pressure sensor data
2 working device (idle) pressure sensor data error
4 working device (idle) pressure sensor circuit Voltage below normal or shorted to low voltage
1080 Walking (idling) higher than normal pressure sensor data

A walk (idling) lower than normal pressure sensor data
2 Walking (idle) pressure sensor data error
4 Walking (idle) pressure sensor circuit Voltage below normal or shorted to low voltage
1200 primary pump (P1 pump) pressure sensor data is higher than normal
A main pump (P1 pump) pressure sensor data below normal
Two main pump (P1 pump) pressure sensor data error
4 main pump (P1 pump) pressure sensor circuit Voltage below normal or shorted to low
voltage
1210 Main pump (P2 pump) pressure sensor data is higher than normal
A main pump (P2 pump) pressure sensor data below normal
Two main pump (P2 pump) pressure sensor data error
4 main pump (P2 pump) pressure sensor circuit Voltage below normal or shorted to low
voltage
1220 pressure sensor data overload higher than normal

A pressure sensor data overload below normal
2 Overload pressure sensor data errors
4 overload pressure sensor circuit Voltage below normal or shorted to low voltage
1230 a negative feedback pressure sensor data is higher than normal

A pressure sensor is a negative feedback data below normal
Two negative feedback pressure sensor 1 data errors
4 negative feedback pressure sensor 1 circuit Voltage below normal or shorted to low voltage
1240 Negative feedback data is higher than normal pressure sensor 2

A negative feedback pressure sensor 2 data below normal
Two negative feedback pressure sensor 2 data error
4 negative feedback pressure sensor 2 circuit Voltage below normal or shorted to low voltage
1250 pilot pump (P3 pump) pressure sensor data is higher than normal
A pilot pump (P3 pump) pressure sensor data below normal
Two pilot pump (P3 pump) pressure sensor data error
4 pilot pump (P3 pump) pressure sensor circuit Voltage below normal or shorted to low voltage
1270 boom pilot pressure sensor data to rise higher than normal
A large increase in pilot pressure sensor data arm below normal
2 big boom pilot pressure sensor data errors rise
4 arm rose pilot pressure sensor circuit Voltage below normal or shorted to low voltage
1330 arm to the inside / outside and bucket-crowd pilot pressure sensor data is higher than
normal
A forearm to the inside / outside and bucket-crowd pilot pressure sensor data below normal
2 arm to the inside / outside and bucket-crowd pilot pressure sensor data errors
4 arm to the inside / outside, and a bucket to close the pilot pressure sensor circuit Voltage
below normal or shorted to low voltage
[TROUBLESHOOTING] DOOSAN
EXCAVATOR FAULT CODE FAULT CODE
Several common fault codes DOOSAN excavator Case
This article from the SF excavator repair plant consolidation Share
(1) Excavators fault code 0091-08: throttle position signal anomalies
Main Symptom throttle switch must be used to set up an alternate engine speed.
Cause: ECM detects the throttle signal frequency is greater than or less than 150Hz 2000Hz
time of 2s.
system response: ECM will record fault code, fault code can be viewed on the display module
or .ECM ET throttle position are marked as invalid data.
In one of the following occurs before the recent diesel engine speed to maintain the desired
speed.
a.ECM receive different engine speed signal from the alternate throttle switch.
b. signals from the entry into force of the throttle switch and hold it for 2s or more.
(2) Excavators fault code 0094-03: the fuel pressure sensor and battery positive open circuit,
short circuit
main diesel engine shutdown or failure phenomenon is not running.
Cause: ECM detects all of the following conditions:
a.ECM read signal voltage higher than 4.8V continued 8s;
. b has at least the power supply of the ECM 2s;
c 5V sensor supply line and battery positive short-circuit fault code does not currently exist
0262-03;
d.5V sensor power lines and ground short circuit fault code does not currently exist 0262-04;
e. diesel engine is not running or running a diesel engine has been going on for at least 3min.
or ET .ECM will
Fuel pressure is marked as invalid data, and the use of 600kPa pressure as the default.
(3) fault code 0094-04: Fuel pressure sensor shorted to ground
main diesel engine shutdown or failure phenomenon is not running.
a ECM reads the signal voltage higher than 4.8V continued 8s;
0262-03;
e diesel engine is not running or running a diesel engine has been going on for at least 3min.
or ET .ECM will
Fuel pressure is marked as invalid data, and the use of 600kPa pressure as the default.
(4) fault code 0100-03: oil pressure sensor and battery positive open / short
Main Symptom
b. diesel engine speed is reduced.
a ECM reads the signal voltage higher than 4.8V continued 8s;
0262-03;
e. diesel engine is not running.
or ET .ECM will
Oil pressure is marked as invalid data, and the use of 600kPa pressure as the default.
(5) fault code 0100-04: oil pressure sensor shorted to ground
Main Symptom
b. diesel engine speed is reduced.
a.ECM read signal voltage higher than 0.2V continued 18s;

c.5V sensor battery positive supply line and short-circuit fault code does not currently exist
0262-03;
e. diesel engine is not running.
system response ECM will record fault code, can be viewed on the display module or ET oil
pressure fault code .ECM will be marked as invalid data, and the use of 600kPa pressure as the
default.
(6) fault code 0110-03: coolant temperature sensor and battery positive open / short
Main Symptom
a. diesel will not go into cold mode.
b. diesel engine does not fire.
c. diesel low power operation.
d. diesel engine speed is reduced.
a ECM reads the signal voltage continues to 4.92V or more 8s;
b. supply of power to at least the existing ECM 2s.
or ET .ECM will
Coolant temperature is marked as invalid data and the use temperature 90 as defaults.
(7) fault code 0110-04: coolant temperature sensor shorted to ground
Main Symptom
a. diesel engine does not fire.
b. diesel low power operation.

c. diesel engine speed is reduced.
a ECM read below 0.2V signal voltage sustained 8s.
b. supply of power to at least the existing ECM 2s.
system response BCM will record fault code, can be viewed on the display module or ET
fault code .ECM coolant temperature will be marked as invalid data, and the use of temperature
90 as the default value when the fault code for the current fault codes, diesel does not go into
cold mode.
[Troubleshooting] Sumitomo excavator fault

code fault code
Sumitomo series digging machine fault codes
7000 P1 pressure sensor

7001 P2 pressure sensor
7002 N1 pressure sensor
7003N2 pressure sensor
7004 wear overload pressure sensor
7005 bottom pressure sensor wear
7006 rod pressure sensor
7020 wear upper pressure sensor
7021 rotary pressure sensor wear
Walking through the pressure sensor 7022
7023 wear arm pressure sensor
7040 fuel level sensor
7041 oil temperature sensor
7045 monitor thermistor
7060 boom angle sensor
7061 arm angle sensor
7062 deviation angle sensor
7063 back to the oil filter blockage pressure switch
7200 swing brake solenoid valve
7201 walking speed solenoid valve
7202 boost solenoid valve
7203 BZ walking alarm
7204 saving solenoid valve
7205 REL charge pump stops
7206 spare circuit return valve
7207 slewing brake release valve
7208 fan reverse solenoid valve
7209 air conditioning temperature signal output
7210 Crane
7211 turning signals and bucket stop
7212 safety lock solenoid valve
7240 pump output proportional valve
7241 pump flow proportional valve
7242 - Fan proportional valve
7243 big arm proportional valve
7244 arm proportional valve
7245 deviation proportional valve
7400.7402.7403 temperature
7404 oil
7405.7406 Dorian backward pressure temperature
7420 generator voltage
7421 level
7422 oil pressure
7423 air filter
7424 back to the oil filter
7600 CAN
7601 monitor communications
7602 ECM communication
7603 Controller B Communications
7604 Controller S Communications
7605 ECM
7606 EEPROM
0087 no pumping pressure
0088 rail pressure anomaly
0089 pumping high pressure
0090 SCV drive system
0107 atmospheric pressure sensor (voltage at the end)
0108 atmospheric pressure sensor (high voltage)
0112 supercharged forward air temperature anomalies (voltage at the end)
0113 booster forward air temperature anomalies (high voltage)
0117.0118 water temperature is too low or high
0182.0183 fuel temperature
0192 rail pressure (low voltage)
0193 rail pressure (high voltage)
0201 0206 glib driver circuit breaker (corresponding to each cylinder)
0219 limit operation
After 0237.0238 boost pressure sensor voltage low or high
0335.0336 crankshaft position sensor system
0340.0341 cam position sensor
0380 preheat sensor
0487 EGR sensor
Host fault code list
(A) an electrical fault (input) [7000-7199]
Fault location fault codes determine the timing of the failure mode occurred prerequisite
judgment recovery judgment
The conditions DTC display
P1 pressure sensor GND short / open 7000 ignition switch is turned from no voltage 0.25 V
0.25 V <voltage <4.75 V
Supply short-circuit voltage 4.75 V
Pressure sensor P2 GND short / open 7001 ignition switch is turned from no voltage 0.25 V
0.25 V <voltage <4.75 V
N1 pressure sensor GND short / open 7002 ignition switch is turned from no voltage 0.25 V
0.25 V <voltage <4.75 V
N2 pressure sensor GND short / open 7003 from the ignition switch is turned on without
voltage 0.25 V 0.25 V <voltage <4.75 V
Overload pressure sensor GND short / open 7004 Select the applicable regional EU voltage
from the ignition switch is turned 0.25 V 0.25 V <voltage <4.75 V
Bottom pressure sensor GND short / open 7005 choose a crane voltage 0.25 V 0.25 V
<voltage <4.75 V from the ignition switch is turned
Pressure sensor GND link short / open 7006 choose a crane voltage 0.25 V 0.25 V <voltage
<4.75 V from the ignition switch is turned
The upper part of the bodys pressure sensor GND short / open 7020 ignition switch is turned
from no voltage 0.25 V 0.25 V <voltage <4.75 V
Rotary Pressure Sensor GND short / open 7021 ignition switch is turned from no voltage
0.25 V 0.25 V <voltage <4.75 V
Walking pressure sensor GND short / open 7022 ignition switch is turned from no voltage
0.25 V 0.25 V <voltage <4.75 V
Arm off pressure sensor GND short / open 7023 from the ignition switch no voltage 0.25 V
0.25 V <voltage <4.75 V
Fuel oil level sensor open from 7040 no resistance after the ignition is turned 100 2
<resistance <100
Short-circuit resistance 2
Oil temperature sensor open 7041 3 minutes after the engine is started without resistance
67200 (voltage 4.93 V) 111 <resistance <67200 0.5 V <voltage <4.93V)
Short circuit from the ignition switch is turned resistance 111 (voltage 0.5 V)
Monitor thermistor (* 1) Open 7045 no receipt from the ignition switch is turned fault bit is not
received from the monitor from the monitors fault bit
Short circuit
Boom angle sensor GND short / open 7060 choose a crane or anti-interference voltage 0.2 V
0.2 V <voltage <4.8 V from the ignition switch is turned
Short-circuit voltage 4.8 V power supply
Arm angle sensor GND short / open 7061 choose a crane or anti-interference voltage 0.2 V
0.2 V <voltage <4.8 V from the ignition switch is turned
Deviation angle sensor GND short / open 7062 choose a crane or anti-interference voltage
0.2 V 0.2 V <voltage <4.8 V from the ignition switch is turned
Back to the oil filter clogging pressure switch open after 7063 from the ignition switch is
turned to the front of the engine start without pressure switch off pressure switch open
Show the project is not abnormal electrical system message. In addition, users no longer
DTC screen display. However, DTC recorded in the maintenance screen (DIAG) in.
(2) electrical fault (output) [7200-7399]
Rotary brake solenoid valve open from 7200 no output after the ignition is turned Output
Monitor Output = Output Monitor
Short circuit
Walking speed solenoid valve open from 7201 no output after the ignition is turned Output
Short circuit
7202 boost solenoid valve open after the ignition is turned from no output Output Monitor
Output = Output Monitor
Short circuit
BZ walking alarm (* 1) Open 7203 after turning the ignition switch from no output Output
Short circuit
7204 saving solenoid valve open after the ignition is turned from no output Output Monitor
Short circuit
REL Open 7205 charge pump stops after the ignition is turned from no output Output
Short circuit
Spare oil return circuit from the solenoid valve open 7206 no output after the ignition is turned
Output Monitor Output = Output Monitor
Short circuit
Swing open from the solenoid valve open 7207 no output after the ignition is turned Output
Short circuit
Fans reverse solenoid valve open from 7208 no output after the ignition is turned Output
Short circuit
Air conditioning temperature signal output (* 1) Open 7209 from the ignition switch is turned
on no output Output Monitor Output = Output Monitor
Short circuit
BZ cranes open after 7210 no output from the ignition switch is turned Output Monitor
Short circuit
REL rotating lights and lock open 7211 bucket from the ignition switch is turned on no output
Output Monitor Output = Output Monitor
Short circuit
Lock rod from the solenoid valve open 7212 no output after the ignition is turned Output
Short circuit
Pump output proportional valve open without current 30 mA 30 mA after 7240 engine start
<current <3 A
Short-circuit current from the ignition switch is turned 3 A
Pump flow proportional valve open without current 30 mA 30 mA after 7241 engine start
<current <3 A
After the fan proportional valve open 7242 engine start no current 30 mA 30 mA <current
<3 A
After the big boom proportional valve open 7243 engine start no current 30 mA 30 mA
<current <3 A
After the arm proportional valve open 7244 engine start no current 30 mA 30 mA <current
<3 A
Deviation proportional valve open after the engine starts 7245 no current 30 mA 30 mA
<current <3 A
(3) mechanical failure [7400-7599]
Abnormally high temperature 1 7400 one minute after starting the engine coolant temperature
sensor = normal CAN communication = normal ECM5 V supply voltage = normal temperature
105 temperature <105
Unusually high temperatures 2 7402 temperature 110 temperature <105
Abnormal high temperature 3 7403 temperature 120 temperature <120
7404 abnormal high temperature oil 1 minute after starting the engine oil temperature sensor =
normal oil temperature 95 temperature <95
Abnormally high temperature pressurized backward 1 7405 supercharged engine start one
minute after the last-air temperature sensor = normal CAN communication = normal ECM5 V
supply voltage = normal pressurized air temperature 80 backward backward pressurized air
temperature 70
Unusually high temperatures 2 7406 booster backward temperature 90 temperature
pressurized backward <90
No abnormal voltage, low voltage AC motor 7420 10 seconds after starting the engine pressure
10 V power generating pressure> 10 V
Coolant level is too low 7421 no level switch is open level switch off the ignition switch is
turned from
Low engine oil pressure after 7422 abnormal engine start 30 seconds oil pressure sensor =
normal CAN communication = normal ECM5 V supply voltage = normal pressure 40 kPa
pressure> 10 40 kPa
Air filter clogged 7423 10 seconds after starting the engine without vacuum switch on the
vacuum switch off
Back to the oil filter clogged 7424 10 seconds after starting the engine oil filter pressure switch
back to normal pressure switch off pressure switch open
(4) mechanical failure [7600-7799]

CAN Bus Bus after 7600 unusual open bus from the ignition switch without disconnecting or
passive failure condition is not satisfied
Abnormal condition monitor communications receiver after the ignition switch from 7601 no
monitor is not open packets sent occurring not established
Conditions for receiving information packets sent Exception Monitor error occurred is not
established
Communication ECM timeout 7602 condition after the ignition is turned from no information
has not issued ECM does not hold
Controller B Communications timeout 7603 Choose from the ignition switch is turned on there
is a crane or anti-interference controller B information has not issued condition is not satisfied
Conditions controller S communication timeout after 7604 opened from the ignition switch S
does not send a message without a controller not established occur
ECM mismatch 7605 10 seconds after starting the engine models only select models ECM
calibration number invariably reply
EEPROM data anomalies 7606 from the ignition switch is turned on without the last store to
check The calculation checks and store the last inspection = The calculation checks and
[Air conditioning failure] excavator repair air
conditioning system failure
One, failure analysis and diagnosis
Before troubleshooting, vehicles should be parked in a well-ventilated, away from ignition

sources, terrain broad overhaul cool place. Analysis and diagnosis of faults, is generally used
visual, ears, feel intuitive method of measurement and instrumentation testing Combination for.
1. Intuitive method: through an intuitive feeling is to determine whether there is a fault.
(1) Visually: Check the engine drive belt wear is serious. Check whether the correct
compressor pulley, the compressor is firmly installed. Check the condenser fins, no damage
should be neat, clean and free of congestion. Check the evaporator should be clean and free of
obstructions, well-ventilated, if any should be cleaned up. carefully check the refrigerant pipe
and fittings shall be clean and free of oil, if oil, there may be a leak here. Check whether the
system piping scratches, bending dead fold, crushed or broken, if it should be ruled out.
Check the water line connection is reliable heating, hot water valve opening and closing if freely.
machine running for some time, with or without external components frosting, icing.
observe refrigerant sight glass flow from the state: first starting the engine, making it stable at a
certain speed, sustained two minutes, and then observe the state of the refrigerant flow from the
sight glass. As is clear, but no air conditioning blow-out, then the refrigerant leakage has; if the
bubble, then the lack of refrigerant or refrigerant containing air, water, refrigerant shortage, the
refrigerant can be carried out by increasing the difference between the bubble remains as
eliminated, then the cooling pipe containing air, water, refrigerant should be discharged again
evacuated, pressure, injection of the refrigerant; if the oil lines, then the leakage of refrigerant is;
if dirt contamination of the system has been described , needs cleaning.
(2) ears: ears that listen for the fans, compressors and air-conditioning system sounds normal.
(3) feel: that the hand check the belt tension, the requirements of elastic fit. Forcing an
intermediate position of the belt 98N can be used, to be able to press 7 ~ 10ram appropriate.
Also, feel Drier temperature and out of the tube should be no difference.
2. Instrument measuring method: mainly to test checks through the manifold pressure gauge,
thermometer, multimeter, leak detectors and so on.
(1) manifold pressure gauge to check: the manifold pressure gauge connected to the compressor
high and low detection interface, and operating under the compressor stationary state, according
to the reading table, can find fault. When the ambient temperature at 30 ~ 35 , the compressor
speed in 1800 ~ 2000r / min, the best thing as air-conditioning switch, fan maximum speed, the
low-pressure valve pressure is the pressure 0.13 ~ 0.20MPa, high pressure valves for 1.47 ~ 1.67
MPa, indicate cooling system properly.
(2) checking by the thermometer: the air conditioner is working properly, the condenser inlet
temperature of about 70 , the condenser temperature of the outlet tube is about 50 ; reservoir
under normal conditions is about 50 ; evaporator under the premise of no frost, the outlet
temperature is usually around 10 ~ 14C .
(3) Leak Check: You can check the leak tightness through the air conditioning system.
(4) with a multimeter to check: Use a multimeter to check whether the system circuit normally-
off, the contact is good, electrical components are working properly and so on.
Second, the system components common faults
1. Compressor: (1) leakage compressor shaft seal leaks, including leaks, leak out of air intake,
cylinder head leak, leak oiler, cylinder rupture and leak before the shell O-ring seal is not good
cause and so on. (2) abnormal sound appear abnormal sound may be improperly adjusted air gap,
insufficient refrigerant inlet valve discharge valve spring or spring break, clutch slippage.
2. Clutch: (a) with fixed compressor, causing overload mating surfaces slippery, overheating and
ablation. (2) fixed coil and rotating parts of friction, causing damage to the solenoid coil,
solenoid coil resistance of a few ohms, too big too small have said is not normal. (3) the clutch
gap misalignment, the clearance value is generally 0.45 ~ 0.75mm.
3. Condenser and evaporator: (1) common failure is due to vibrations caused by leaks, repair
welding process should be carried out. (2) the surface is dirty, so the deterioration of thermal
performance, application brush and water to clean, but not washed with high-pressure water in
order to avoid fin deformation, distortion, effects of heat conduction.
4. Tank: (1) tank desiccant filter is damaged, desiccant leakage. (2) When the system desiccant
temperature, the pressure is too high, easy to make fusible plug to melt, causing refrigerant
leakage.
5. Expansion Valve: The most common failure expansion valve is clogged, causing blockage of
reasons, one system cleanliness is not good, and second, there is water vapor in the system. If the
system of internal contamination, it is timely for the system to be cleaned; larger if the water
vapor within the system, remove the dryer, replace the desiccant.
6. Low voltage switch: When low voltage switch is turned to work, mainly the fault is high or
low pressure system appears, the switch continues to open, remove the check, if not comply
should be replaced.
Three. Common causes of system failures and

Troubleshooting air conditioning systems can generally be divided into: electrical failure,
mechanical failure, malfunction, such as refrigerants and refrigerant oil caused. These faults are
concentrated expression: System no refrigeration, ineffective or produce abnormal noise, etc., the
following table lists the common faults and causes of air conditioning systems.
[Hydraulic system fault diagnosis and

troubleshooting] characteristics and working
principle of the hydraulic system
OLSS system
Features:
OLSS (open center load sensing system) is a swash plate type variable piston pump by
controlling the swash plate angle (fuel supply) to reduce the fuel consumption of the energy-
saving system, so that the system can be used to reduce the work loss of hydraulic pressure, fine
control and improved control of the pump flow. Because the actuator does not work, the pump
discharge of oil through the oil channel in the center of each stem, so called open center load
sensing system.
Optional four kinds of work conditions: heavy, standard, fine and lifting.
The effective use of an engine power
Detection has been set speed and actual speed of the engine, even if the job load changes, the
pump displacement (swash plate angle) will be controlled. Load of the engine is always kept
constant, thus ensuring the effective use of engine power. Design of a pump with the
conventional system the engine is different, a hydraulic pump may be greater than the power
output of the engine.
2 pressure off control
CO functions implemented using the valve. Pressure off control is to reduce the work function of
the overflow losses. When the outlet pressure of the pump close to the set relief pressure, the
pump discharge oil is minimized.
3 Flow Control
NC valves and jet sensor using functions implemented.

When the joystick in the neutral position, the pump discharge oil minimized to reduce waste
control valve in position when traffic.
When you need a working device micro-movements, may be issued in accordance with the
joystick on the pump flow command stroke, supply the required flow. Reducing waste fine job of
traffic.
Cutting using pressure control and flow control of the hydraulic system can significantly reduce
the heat.
How it works: By TVC valve, Pi CO pressure control valves and variable valve NC swing angle
of the pump (pump displacement), to meet the constant power of the premise, the pump
displacement is independent of the external load, and only operated valve opening amount that
handle control lever angle related.
TVC valve, CO NC valves are valves and constant torque control valve shut-off valve and
negative pressure control valve. Compared with the traditional system, the total power of the
variable, the fuel consumption can be reduced to improve fine control hydraulic pressure loss
reduction. Using a computer and an electronic control system can control more accurate and
sensitive.
CLSS system
Features:
Mining operations are not subject to the micro-loading effects steady; use the main stem of the
actuator stroke control compound action more accurate. Because the actuator does not work, the
pump discharge of oil is not the center of the valve stem oil through various channels, so that in
the closed position the load sensing system.
CLSS system consists of a main pump (two), valves and actuators (cylinders, motors) control
components. The main pump by the pump, TVC valve, LS valve.
Four kinds of pumps valve control function
1 LS Control Function
According to operation of the actuator and the engine speed changes from the LS, EPC valve to
the outlet pressure of the LS valve, the pump flow rate to change the switching point of the LS
valve (LS set differential pressure).
Therefore, the pump discharge oil best time increases the microcontroller performance composite
operating performance to achieve optimum control.
2 pressure cut-off function

Use of pump pressure sensor, pump controllers and TVC valve functions implemented. When
the pump outlet pressure exceeds the set pressure, the pump discharge amount of oil is
minimized.
3 two relief function through
When the job is often a relief pressure of 32.5MPa.
When the secondary overflow feature to work, the overflow pressure rises to 35 .5MPa.
Therefore, the operating force is further increased.
4 micro-controller function if you choose microcontroller operation mode, you can control the
LS valve of the pump, reduce the pump discharge oil, in order to improve the performance of
micro-operations and trimming accuracy.
The working principle of control of the main pump swash angle, so that the differential pressure
across the valve LS LS unchanged. If the pressure is less than the pressure value LS LS valve
setting, the pump swash angle becomes larger; If the pressure differential is greater than the
value of LS LS valve setting, the pump swash angle becomes smaller.
When the compound action actuator control valve outlet pressure compensating valve on the
main stem downstream pressure is kept constant, the pump flow is allocated according to each
stem stroke and with the implementation of components independent of external loads.
EX-2 control system
The system includes a pump control system and a valve control system. A valve controller and
an engine controller integrated in the microcomputer, a variety of sensors and switches the signal
into said controller, to control the flow rate of the system. The controller outputs control signals
to the various components, such as solenoid valves or the pump displacement engine throttle
control motor. Also control the hydraulic system flow through pumps, valves and other
components, while improving operating efficiency. The system is closed center load sensing
system.
Features
Can achieve load sensing, speed sensing, flow distribution, condition selection control.
A load-sensing, including variable piston pump, pressure sensor and unloading valve. At both
ends by the main control valve pressure regulating optimal displacement pump flow to meet the
actual needs of the actuator. This will not only save energy but also to precisely control the speed
of the actuator.
2 Check the actual speed of the engine speed sensor and its set speed compared to that change by
changing the pump displacement pump input torque to make more efficient use of engine power.
3 flow distribution flow distribution control so many can be done with a single pump actuator
composite action and provide the required flow rate possible. Although the implementation of
the different elements of each external load.
4 Select control this condition variable pressure compensating valve system adjusts to provide
the most jobs speed, smooth operations, such as the special requirements of different kinds of
work for the implementation of components. This system is a subsystem of the flow distribution
control.
Works
When differential pressure sensors that control the pump outlet valve outlet pressure is less than
1 5MPa, valve controller instruction to increase pump displacement solenoid pump swash angle;
when pressure is greater than 1 5MPa, reduced pump swash angle.
The composite action of the differential pressure sensor sensing only the high pressure control
valve. According to feel the action signal, the solenoid valve controller instruction
compensating valve flow proportional valve control execution flow element.
Komatsu excavator maintenance and

technical knowledge
1, What is OLSS system?
Komatsu excavator OLSS system is open-center load sensing system. It is by controlling the
swash plate type variable displacement piston pump swash plate angle of approach, in order to
reduce the fuel consumption of energy-saving systems. When the job due to the action of the
system can reduce the loss of hydraulic pressure, to increase the fine control, control the pump
output.
2, what is the nozzle sensor?
When the dispensing valve is in the neutral position, all hydraulic oil tank are refluxed through
the sensor. A sensor has a throttle and relief B, pressure relief valve overcurrent 1.6Mpa, ie Pt
pressure is 1.6Mpa, Pd and tank connected, the pressure is substantially zero. When the
dispensing valve is in operation, the oil passage is shut off, Pt pressure instantaneously drops to
zero. Variable system is to use the differential pressure signal to achieve variable.
3, Pt pressure is too high and too low impact on variable system?
Common faults sensor Pt pressure is not normal, and sometimes even higher pressure will reach
5Mpa, the reason is the pressure relief valve of a foreign body stuck. Once the Pt pressure is too
high, make piston flow becomes very small, no excavation work force opportunities arise. If the
pressure is too low Pt, piston flow becomes very large, if the pressure drops to zero, the engine
will start when the excavator flameout.
4, TVC valve structure and working principle is what?
TVC valve is a drain on the main pump pressure Pp1, after Pp2 and TVC valve output pressure
Pc2, balance spring force to be controlled.
When the main pump load hours (when the switch is turned on L state), due to the discharge of
oil pressure of the main pump Pp1 and Pp2 low. Therefore, a slide valve 2 is pushed to the lower
end of the spring. As a result, the oil pump control pressure Pc and the discharge valve TVC
output becomes the same as the pressure Pt2. At this point, TVC valve output pressure Pt2
becomes maximum, the servo valve piston tilt angle becomes so large, the flow is also the
largest.
When the load of the main pump is large (when switch S is turned on state), since the main pump
delivery pressure Pp1 and Pp2 increases, the piston is pushed outside the spool 2 is moved
upward, since the cutout a hole on the valve spool bore and b the oil is throttled, and the hole and
c b hole (discharge hole) of the opening becomes large. Therefore, when the output pressure Pt2
drop TVC valve, the servo valve so that the piston the inclination angle becomes smaller, the
flow rate also will be smaller.
When the switch is turned on in the L state, the electromagnetic valve 7 is powered on, the shaft
6 pushes the piston 5 moves upward, to enhance the effect of the spring 1.
TVC valve solenoid valve on the line fails, the job will be lost when the machine is fine-tuning
the role, there is no automatic functions. When the solenoid valve line failure, excavators work
will be affected. 7, electronically controlled automatic deceleration system OLSS How does it
work?
When the job at the middle position lever mechanism, which automatically reduces the engine
speed, and job agencies began job, that is, pull the lever to the working position without moving
the throttle lever engine speed automatically accelerate to the crude door working position speed.
Will automatically switch to the deceleration ON, when no movement industry organizations and
travel agencies link (in the middle position), the computer sends a signal from the control box
starter solenoid valves, hydraulic cylinders extend, the engine speed will be reduced to the
industry 4s 1150r / min, then the throttle lever position remains unchanged. If the job agencies
began work immediately closed solenoid valve, hydraulic rod and governor lever handle is
automatically reset to the original position, speed is automatically restored to its original speed.
5, TVC valve adjustment screw on how to adjust?
When the machine manufacturers have adjusted the factory, the average user can not arbitrarily
to adjust.
To adjust, the method is to install a pressure gauge in two piston pump oil outlet, the two pumps,
hydraulic adjustment within the specified value (32Mpa) then TVC valve adjustment screw spin
out some. Throttle, the big arm raised to the boom overload relief valve overflow valve, observe
the engine speed changes. If the engine load is not heavy, can be screwed into the adjusting
screw and then some (semi-circle around the thread, not too much). Using the same method to
enhance the arm again, and observe the changes in engine load and speed. If there is still no
change, then adjust the screws into some until the lifting arm felt when the engine load, at which
point the adjustment screw and then exit the semi-circle, lifting the arm again until confirmed no
load arm raised, speed is not can be significantly decreased.
6, Komatsu PC200, PC300, PC400, PC600 excavator TCC valve with TVC valve any different.
TVC valve function just more electronic control, if the electronic control part is broken, just like
TCC valve. From Figure 2, and Figure 3 shows, TVC valve uses only one two three-way valves
to regulate the hydraulic pressure Pc, while the TCC valve 3 with two two-way valves to regulate
the hydraulic pressure Pc. Their functions are the same. Structurally complex TCC valve failure
abound. Because the parts are many, to be especially careful during disassembly. Many users
because no parts diagram, installed a few, or installed in the wrong direction do not know.
7, when the lifting arm will turn off the engine, the engine will stall when starting to walk, which
is the TVC valve adjustment screw on the right?
Have a great relationship, sometimes the problem is here, but it is not absolute. Flameout occurs
when launched, can adjust the screws a little try, if there is no reaction, the screws should be
transferred back to the original position.
8 What is the role of CO valve? Its structure and working principle is what?
CO valve is divided power regulator. When the oil discharge pressure of the main pump is less
than the pressure regulator overload pressure, a slide valve 2 is pushed to the following spring, so
a bore hole and b turn to each other, so that T. V. C valve output pressure valve output pressure
Pt equals CO Pc0. At this time, the output pressure becomes maximum CO Pc0 valve, the servo
valve so that the inclination angle of the primary pump reaches a maximum. Therefore, the pump
flow is also the largest. When the main pump discharge pressure is close to the oil pressure
regulator overload pressure, Pp2 push the piston 3, plus Pc0 pressure pushes the piston 4. Both
thrust over a stretch of the spring, the slide valve 2 Bianxiang on mobile. Since the effect of the
cut on the valve spool, a passage hole to the narrower hole b, b and c bore hole to the discharge
hole is widened, and therefore, CO valve output pressure drops, the servo valve so that the piston
the inclination angle becomes smaller, pump flow also will be smaller. CO valve is divided
power regulator, which means it can only regulate themselves a piston flow.
9 What is the NC valve? Construct NC valve is like?
NC valve is of evolution from the early PNC Komatsu variable system. Return pressure
difference is in the position signal and non-middle position and asked to control the NC valve
moves up and down to control Pc purpose of using hydraulic distribution valve.
NC valve is a sensor output of the jet by the NC valve output pressure Pt and the pressure Pi and
the output pressure with the NC valve spring force of the jet sensor, and just to get equilibrium
controlled.
Jet sensor is out of the control valve after checking the return flow back to the tank, the signal
pressure to get NC valve Pt and Pd.
10, the relationship between the sensor and the NC valve jet is like?
NC valve is a signal sent by the sensor work on the jet. Relationship between the jet and the NC
valve sensor shown in Figure 15. Its working principle is: When the control valve is in the
neutral position, the jet pressure sensor reaches a maximum (1.6MPa). Thus, the output pressure
of the jet sensor Pt piston thrust force of the spring is greater than the jet pressure Pd of the
sensor and the other output, so the spool is pushed down. At this point channel c and b bore hole
between the narrow channel between b and d bore hole (exhaust hole) widens, so the output
pressure valve NC Pi becomes minimum. The inclination angle of the servo valve so that the
piston becomes smaller. Pump flow rate becomes smaller. When the operating lever is pulled,
the pressure difference (Pt-Pd) narrow jet of the sensor, reaches a minimum value. To achieve
zero pressure. So spool up reset. c between the hole and the passage hole is widened b, NC valve
output pressure increases, the inclination angle of the servo valve so that the piston becomes
large, the pump flow rate increases.
Komatsu PC200-2, construction PC300-2 and PC400-2 excavator NC valve is somewhat

different, but the principle is the same.
Due to the structure of NC valve is relatively simple, so much trouble, there are many small
problems are man-made, if not assembled, no clean when cleaning the assembly, and even some
tubing wrong and so on. Therefore, we must figure out NC valve 2 hose connector, one Pt
mouth, and the other is Pd mouth, once reversed, the excavator will be a heavy load, will be
black smoke when mentioning the big arm. PC200-5 excavator shown Pt NC port and the valve
port Pd, see Figure 14.
11, servo valve important variable in the system do?
You can say its a very important role because of its relatively high operating frequency, so often
seen in this part of the fault. When the input signal pressure Pi, the d-hole of the control piston
acting on the cavity C, the pump control pressure Pc is transmitted to the b holes. If Pi is slightly
increased, the hydraulic pressure applied to the chamber C is slightly increased. Accordingly, the
control piston and the spring push the left, to the servo valve piston lever arm as a fulcrum, the
left rocking, so that the pilot valve to the left. Since moving, b bore hole and a pilot valve is
turned on, the pump control pressure Pc passed to the servo valve piston chamber B, push the
servo piston moves to the left, so that piston tilt angle becomes larger, the flow increases.
When the arm lever the pin as the center of rotation in the clockwise direction so that the pilot
valve moves to the right, with the hole blocked b and c a well bore and excretion circuit
corresponds to an input signal R of the discharged oil pressure is increased.
Description of the situation where the servo piston moves rightward as follows: Suppose the
servo piston in a position in equilibrium, the pressure Pi in the drop chamber C to move the
control piston, the lever arm as a fulcrum to swing the servo piston to the right, so that guide
movement of the spool to the right, the slide valve moves the guide loop is cut off between the
hole and a hole b, and c is turned on the excretion hole loop. In addition, b and c hole hole phase,
the oil flow into the servo cylinder chamber A, the servo piston to the right, so that piston tilt
angle becomes smaller, so that the pump flow becomes smaller. At this point, the lever arm is a
pin as the center of rotation in the counterclockwise direction, so that the guide and the spool
moves to the left, and the cutting holes between b and c bore hole and a drain hole. Thus, the
input signal is equivalent to reducing the residual oil discharge.
12, servo valve adjustment screws should be how to adjust?
Servo valve of adjustment screws are adjusted at the factory, and should not be adjusted. A long
time for those machines should be adjusted after each pump and pump the front were. First
inability to walk from the top side of the track, then the servo valve in the pump before the pump
or corresponding. To maintain the side of the track to be kept from the top to rotate, in order to
observe the effect of the adjustment. First unscrew the adjustment screw a half turn, if it is
original to adjust properly, when the screw is screwed out of a half circle, the track speed is
changed. Then the adjustment screws are screwed out within a half circle, you can put both
internal and external adjustment screw spin out some more.
After all, if both internal and external adjustment screw to adjust the rotation of the track is still
very slow. This is the servo arm broken stem or bolt fell out.
13, after the adjustment of the servo valve, on both sides of the track to rotate somewhat faster,
but still not meet the requirements, what reason?
A servo valve orifice chamber and chamber B is increased due to wear, with the servo piston
with a gap caused by too large.
Bore wear generally has appeared obvious steps and out of round, hole boring when repairing
first round, and then grinding, according to the pore size after the repair, go with the Pistons.
After the repair has become larger aperture, while the piston repair set to go with the gap size,
bore and piston about 0.10mm according to the aperture. After repairing the surface of the piston
to be heat treated.
14, after the repair of the piston size has been changed, will affect the driving force of the piston?
Have an impact, but not very obvious, the solution is to reduce the hydraulic pump can be
controlled a little.
15, the pressure is not enough to control the pump has been damaged?
Such a conclusion can not be, because the control pump has a pressure regulating valve, if the
valve is faulty adjustment controls also enhance the pump pressure is not up. After removing the
regulator should carefully check before conclusion. Komatsu excavator pressure regulating valve
structure are the same. This is a pilot operated regulators regulator, the middle of a damping
piston hole, check carefully to check whether the damping orifice blockage. It is the main reason
for the pressure to enhance the impact. There are two well-degree spring spring, cone valve and
poppet valve on the pressure regulator are all affected. Regulator checked debugging can be
installed, if the control of the pump pressure remains less than the required value, you can
determine the control of the pump is damaged.
16, when the control pump pressure reaches a predetermined value while the machine is still
working, fatigue is the reason?
On the above, the following steps can be checked. 58.8MPa with two hydraulic tables were
installed in the two main oil pump outlet pressure taps. Then stepped on the gas, so that the
bucket cylinder rod extension do so overload relief valve in the overflow state, then there should
be a high value a hydraulic table, and see if it reaches a predetermined value. PC200 excavator is
26MPa, PC300 excavator and PC400-2 excavator is 26MPa, PC400-3, PC400-5 and PC400-6
machine is 32MPa, the same way, look at another gauge pressure. If the pressure is less, still not
adjusted in the two pressure regulating valve effect, to remove the main pressure regulator valve
(also called the main valve) for inspection, examination and inspection methods to control the
pump pressure regulating valve same. If the regulator found no fault on the third step further
examination. Ie check whether the internal pump leakage.
17, in the measurement of pressure, to achieve the specified value at the beginning, but soon fell
to 20MPa, is this normal?
Not normal. In general, as long as the overload overflow valve still flow, pointer readings should
not drop down to illustrate the leak.
18, how to check the leak?
There are leaks inside the machine are generally old machine, wear parts is more serious, the gap
is large, and is synchronized wear. Daily work in the machine, we can find that there are leaks
inside the machine, the noise was relatively large, the temperature rises quickly. The leak can be
checked by the following way. The pump in the hydraulic oil exhausted, remove the two high
pressure flowlines, and then poured into the tube in the mouth with a diesel, if the oil level drops
quickly, indicating that the pump has internal leakage; If PC200-1 type and PC200-2 type
machine, in addition to describing pumps have internal leakage, the pump discharge port and
tubing seals the connection part will have leaks.
19, the number worn piston plunger will produce the leak?
In theory, the gap between the plunger and the plunger hole should not exceed 0.05mm. Due to
the small pore size, difficult to measure, test the following methods generally available, that the
ball head plunger seal the holes with your fingers, hands plunger orifice also sealed, and then
pull back the plunger. If the column Sierra does not move, and there is a strong attraction, with
the gap shows comparatively good, or should be replaced with new parts.
20, Slipper in oblique intraday How does it work?
Ball plunger head and the inner spherical surface contacting the shoe, and can be rotated in any
direction, and the plane of the shoe in contact with the swash plate. In addition, the plunger
through the hole g f holes and put the shoe on the oil pressure lead to the A cavity, so that the
shoe and the formation of a layer of film oblique cross-examination, that the formation of
hydrostatic bearing. When the pump, oil pressure P acting on the piston, to produce a normal
shoe pressing force N, so that the surface of the swash plate slipper pressure, and hydraulic oil
chamber A and P and slipper and swash plate gap the liquid pressure on the shoe a reverse thrust
F, F in the case of the anti-thrust force and the stopper is equal to N, the sliding shoe is in an
equilibrium state.
The shoe is such that the balance of the process, when the pump starts to work close to the shoe
of the swash plate, because the oil in the oil chamber A does not flow, so that in a relatively
quiescent state, then P = P, in this state, under its reverse thrust greater than the pressing force F
N, so that the shoe is gradually pushing the gap h, A chamber oil leakage through the gap and
asked to form a film, this time a chamber of oil in the flow state, so the pressure oil through the
orifice P f and g to A cavity, due to the orifice f and g resistance loss, so P is less than P, until
making reverse thrust and pressing force F N is equal to date, so that the shoe swash plate to
maintain a certain film thickness, and is a new equilibrium state.
21, high pressure hose when excavator working two piston vibration badly what reason?
If the oil pressure gauge installed in the pump outlet pressure taps, you can see the oil pressure
gauge the magnitude of the big swings up and down. This is because the valve plate and cylinder
contact surfaces are not smooth due mostly with grinder mill maintenance or by hand grinding,
grinding quality problems. The key is to check whether the plane perpendicular to the centerline
of the cylinder block and cylinder have changed, whether the center line and valve plate end
vertical valve plate has changed. Another aspect, since the machine is old, pumps repaired
several times, piston cylinder has repeatedly Grinding, as well as the spring force of the cylinder
on the decline, or a little butterfly spring loaded and various other reasons, are inadequate allows
the cylinder and valve plate clamping force. When the oil pressure exceeds the clamping force,
high pressure oil will be from between the valve plate and cylinder leak, causing oil pressure
fluctuations. When the throttle is even greater volatility, tubing will jump more powerful.
Exclusion approach is, if it is flat grinding biased, and to re-grinding; spring force is not enough,
you can add shims; pressing force size, you can use the handle to check that the required two
hands to the pump shaft head twist, pressing force is enough. But also pay attention to the
pressing force can not be too tight, too tight will not be established because the cylinder and
valve plate between a certain thickness of the film, it is easy to overheat the plane burned.
High port plate plane roughness, shape geometry can not be out of tolerance, the best their hand
grinding. Figure 24 is shown on the mill for grinding by hand when the drive shaft can rotate
continuously.
22, when the excavator to work properly, there will be side tracked but suddenly can not move
and digging arm fatigue, is the reason?
The reason is that the majority of hydraulic oil is not clean, tiny dirt clogging the valve piston in
the middle of a small orifice. Remove the valve can be cleaned, remove the orifice clogging it.
23, why the blockage will affect the orifice so big?
This is a common fault, but also a great influence on the hydraulic system failure. To clarify the
truth, the principle should be introduced on a pilot safety valve. Oil pressure P through now
orifice into the cavity C, then C chamber pressure P is equal to the system pressure. Because of
the small spring action, the piston has been pressed to the right seat. When the oil pressure
chamber C up to a certain value. That is up to the cone valve regulator value, the cone valve
open, the oil chamber C through the cone valve back to the tank. In this case, C chamber
pressure plummeted, due to the damping effect of orifice, C chamber and system pressure loss of
balance, so the small piston back to the left, the system pressure by a small piston overflow tank.
When the system pressure falls below a certain value, the poppet valve is reset, followed by a
small piston has the right to reset. So repeatedly performed to adjust the system pressure. If the
small piston in the middle of damping holes are blocked, not pressure oil, C C chamber cavity
pressure is much lower than the system pressure, so the small piston has been in the left position.
System pressure regardless of the level, also are in the overflow state. So when the tiny orifice
Once blocked, the impact will be great. Therefore, a hydraulic oil
24, upon inspection orifices are not blocked, the pressure relief valve why still tune it up?
Most such cases are closed due to lax cone valve and valve seat, so that the hydraulic chamber C
not be established.
25, grinding gear end pay attention to what?
Gear pump gear worn, use high precision grinding machine for grinding, strong sense of
responsibility to find the master operation. For example, bench grinder to be absolutely clean,
dust is not allowed on the platform. Because the table is slightly unclean, will make a vertical
line plane bearing hole grind shifted.
26, how to know the gear plane bearing hole grind verticality changed?
Only found in assembling the gear pump, because the end face of the gap is very small, generally
about 0.05mm. If the face and the bearing hole verticality changed, after the pump gear shaft
assembly is not active. If the locking screw is loose a little, but still turn Debu smooth, and then
dismantling the gear pump, end there scratching marks. This is not the end face of a plane
perpendicular to the bearing hole caused.
27, when assembling the gear pump pay attention to what?
Wear in the pump casing into the oil chamber would be more a little more, if the pump housing
is symmetrical, can flip 180. Re-use. For passive gear, two can not be swapped, do mark when
removed. Because the side of the gear wear will occur. Driving gear is integral with the rotation
shaft, not inverted; passive gear flip line contact points can meshing gears change. Pump
assembly is completed, to add a little oil before hand to slightly rotate, touch to flow.
28, the end surface of the bearing assembly are also at the same time to replace?
Must be replaced. Since the end face of the pump wear, the main bearing clearance is too large,
so that the swing gears resulting in rotation.
29, while the crawler can only move forward not backwards. What is the reason?
Is walking in the motor overload relief valve core is stuck due to death. Travel motor for safety
protection system, set up two overload relief valve in the system, if there was an overload relief
valve stuck in the overflow location, the system pressure is lost.
30, while the track go very slow, but you can get up if the track while doing a rotation action,
what reason?
This failure will occur on many excavator. This is because the supply shortage walking piston
motor traffic. When the excavator to do another action the same time, it means another plus a
piston flow. 2 pump flow at Komatsu 200-2 excavator control valve will be merging, Komatsu
200-3 type to PC200-6 excavator, will merge in a straight line with a valve.
Piston flow shortage, not necessarily the pump has been damaged, the majority of the flow
control valve is not adjusted good reasons.
31, pulled walking excavator joystick feel very heavy (almost pull does not move) is the reason?
Walking assign different distribution valves and other valves. Most machines assigned to walk
hydraulic control valve is not, but by a mechanical lever pulled directly by hand. Because the
machine obsolete, or distribution slide valve had worn so with slip valve hole gap becomes
larger, high-pressure oil will leak from the oil path through the slide valve clearance to the end of
spring, the spring but also have a spring cover tightly cover forward, so that the formation of
high pressure inside the hood, resulting in dispensing valve springs here to go there when the
shift lever is very heavy (the other direction is less).
32, simultaneous operation of two crawler excavators walking joystick makes the start, the
engine speed will drop in an instant, or even turn off, why?
This failure is more common. This is mainly a problem with piston variable agency. Machine in
idle state, the piston is still a lot of traffic.
33, walking oil repaired, small throttle when the track go faster, but will not go when the
throttle is what causes and what remedy?
This is because the repair milled valve plate and excessive amount of grinding, so that the
pressing force plane and the cylinder valve plate is not enough. When small throttle hydraulic
small, easy to leak between the plane and the plane; oil pressure when the throttle is increased,
resulting in an overflow room flat, resulting in a large throttle when the track but could not
move.
The remedy can be added in the spring washer, if it is butterfly spring, can pay a butterfly spring.
34, failure is what makes excavators can not walk a straight line?
Is usually caused by a hydraulic motor oil on both sides to enter different sizes, large side
hydraulic, naturally go faster. Available 2 oil pressure gauge checks were installed on both sides
of the pressure taps running motor oil, if the pressure difference is large, the safety valve will be
raised a little less stressful side. If the pressure on both sides are the same, and that is different
from the two piston sent the oil flow rate (how to adjust the pump flow, devoted in part 2). If you
are type 3 and 5 machines can not walk a straight line, you should check its linear control valves.
35, why can not stop excavator slopes?
Generally excavator can be stopped at the ramp because excavator pump itself with brakes, just
do not give a solution
Oil pressure motor, the brake device from the braking action, and in the system there is a
reciprocating valve of the motor 2 are mounted on the circuit. Hydraulic oil P before entering the
travel motors, oil all the way into the A-side first shuttle valve, the reciprocating valve to B shift;
oil pressure P oil all the way through to reach the brake shuttle valve spool, the spool to the
spring brake shifting the direction of the hydraulic oil to the motor brake, the motor starts to
rotate. The brakes are loose brake, it is almost synchronized. When the oil supply to the motor is
stopped, the shuttle valve and brake is automatically reset, motor brakes while braking, the
shuttle valve has broken pipeline flow of oil. Since oil can not flow from the shuttle valve is a
braking action. Excavators slope not stop, it must be checked for leaks reciprocating valve.
36, PCA00-3 excavators why there is no quick stop?
Skating valve control oil change is coming from the control pump, controlled speed in the cab of
the electromagnetic switch, this switch controls the oil to go through to get to the solenoid valve
control valve variable speed skating. If the solenoid valve is broken, it can not shift. When you
open a fast stop, two four-way solenoid valve to the right to control oil through the solenoid
valve spool to reach the lower end of the slide valve moves into the servo valve on the high
pressure oil chamber is cut off, in the meantime the solenoid valve to control oil also entered the
lower chamber of the servo valve, the servo valve piston pushed, the motor variables.
37, the rotation of the motor can not rotate the turntable is the reason?
From Komatsu excavator type 3 to 6, the turntable has a parking brake, if the brake solenoid
valve is faulty or the control line failure, can lead to not open the motor brake.
46, if the turntable rotation speed brake solenoid valve is broken. What emergency measures?
The main function of the solenoid valve is to make two 3-way valve and move around to cut off
or turn control of the oil. We can put the hose directly to the hose A B connectors, temporarily
without solenoid valves, motors can be rotated.
38, when the rotary dial is difficult to stop in position to stop what reason?
This is a rotary motor lock function deteriorated.
39, the structure and working principle of rotary motor and travel motor are the same?
Basically the same, just walking motor with automatic brake device and the rotary motor did not.
40, the back wheel rely stopped?
Stop to motor oil, motor gave out the oil distribution valve foreclosed. Then the motor will not
turn to no matter which side. Only two have problems or overload pressure regulating valve is
too low, the hydraulic oil will overload valve in case of overflow, the motor will not stop failure
occurs.
41, the turntable can not turn a full circle is enough for what reason?
Turntable ring gear off two or more teeth.
42, turntable hydraulic oil filler rushed to what reason?
Is a rotary motor shaft seal head is damaged.
43, the lifting arm while rotating turntable excavators appear weak, why?
This situation only occurs in type 1 and type 2 Komatsu machines. When the machine to swing,
it will give a signal to the two hydraulic piston total power regulator, to reduce the number of
piston flow, so that power can be compensated. If the control valve is faulty, can not pass the
signal sensitively, thus causing difficult and turntable arm linkage.
44, the operation dial why one direction fast and slow in the other direction?
Not with liquid dug models This phenomenon is generally slow side overload valve is faulty, or
different rod length distribution valves caused.
45, the excavator Komatsu, the variable mechanism of type 1, type 2, type 3, and 5 is the same
type of machine it?
An excavator is the use of early PNC system structure is relatively simple, if you mention the big
arm black smoke, to remove the variable mechanism to be checked.
Check the focus is on the piston bore, 2, 3 and 4 small piston inside. Check whether the piston
stuck in the piston bore.
46, why the above four small piston is stuck after. Make the engine load increase?
Because the high-pressure and high-pressure oil pump oil before the pump holes respectively 1,3
and 2,4 into the hole, push the small piston hole 4 right, the small piston to the right time and the
right to push the piston, the piston the journal and piston swing frame connection, thus boosting
the swing frame to the right, swing frame and front and rear pump is mechanically connected, so
they drive swing frame when the right front and right swing pump, pump swing angle decreases,
the pump discharge a small amount of the engine load increase.
47, the piston can check four small events, the engine still smoky how failure should be
excluded?
You can put the right end of the adjustment screws gradually relaxed, until able to unload so far.
48, Komatsu PC300-3 type, PC400-5 excavator boom when promoted. Engine black smoke is
the reason?
Is out of control due to the variable agency. Variable agency Komatsu three machines and five
type machine is more complex, with OLSS systems, post-added products in the computer
system, called electronic control OLSS system (Chinese name is open-center load sensing
system). In addition to adjustments should also check OLSS system is faulty.
49, what should pay attention to the cylinder repair?
In addition to the length must be accurate, the cylinder flange when welding flange centerline
and cylinder bore diameter must be aligned, otherwise it would go the wrong rod.
50, down to the position of the arm perpendicular to the ground when, why will stay for a while?
This is less than the arm cylinder due to the large oil chamber when the vertical position of the
arm down, the large cylinder chamber has been lack of oil. Maintenance to check whether the
installed anti throttle arm or plunger pump flow is adequate.
51, PO400-3 excavator why not flip the lever, there will be automatic arm outstretched
phenomenon?
This is to accelerate the distribution of the arm due to stuck valve spool in one direction. PCA00-
3 excavator arm distribution valve spool has two, one on another valve, not easy to find.
52, has confirmed that the boom cylinder seal is damaged, but how specifically confirm what a
seal?
Cylinder seal is damaged, the temperature higher than undamaged, can be judged to touch.
Another method is to two cylinders are down, the tubing two small cavities on the cylinder
removed, and then into the large chamber oil. Go to the extreme when the piston, the cylinder
tubing head good stop out of oil, and seal the damaged cylinder, tube head will continue to have
the oil flow.
53, Komatsu excavator why PCA00-2 flip lever arm when the boom is raised, or when walking
lever pulled, turntable will automatically rotate in one direction?
To rotate the turntable, turntable distribution valve must be not in neutral position, which is the
first to confirm the clear, but to confirm the distribution valve slide properly. Secondly then
check in P. 0. The case of C pilot control valve does not work, there is not a lot of pilot oil into
the ends of the distribution valves. Inspection findings normal, we can identify the fault is with
the rotary flow control valve. Rotary flow control valve A. When there is no manipulation of the
rotation, A in the middle of the valve body, the valve case from the jet out of the mouth rather Pd
zero pressure oil through hydraulic pump 1 N. C and then flows through the upper valve A valve,
then to the fuel tank. Once A valve stuck, A spool is not in the middle position, Pd pressure oil
can not be returned to the fuel tank, hydraulic rising possible. A spool is not because the middle
position, the pump 1, pump 2 and the rotary control oil distribution valve opening is opened, Pd
Pd hydraulic valve from the jet out of the mouth that flows into the rotary distribution valve
control circuit, push the dispensing valve to a mobile side. Lead to automatic rotary turntable
will happen.
54, Komatsu PC200-5, PC200-6 excavator boom cylinder piston rod and the cylinder piston rod
arm flange discoloration phenomenon occurs (local oil temperature is too high phenomenon).
What is the reason?
Because between the distribution valve PC200-5 and PC200-6 excavator boom cylinder to the
bottom, there is a boom installed to keep the valve prevents the arm moving down automatically.
PC200-6 excavator boom cylinder rod side in between the dispensing valve is also installed one
in the arm to keep the valve. Prevent the arm down automatically.
Since the holding valve is provided in the oil passage, so that the hydraulic oil out of the cylinder
increases drag, especially in the case where there is no back pressure of the slide valve is
released out of the well, is not enough to open the slide valve, so that a greater fluid flow
resistance. Resistance, the temperature of friction is large, resulting in a local high oil
temperature. Komatsu other models do not have this phenomenon.
55, Komatsu excavator PCA00-3 plunger, piston body and the valve plate to replace a new piece
of work after less than half a day, and plunger valve plate contact surface is burned, is the
reason?
There are many reasons, there may be purchased substandard parts, fuel tanks and piping does
not clean well, excluding the above reasons, the key is to not put the plunger body and the valve
plate were run-in. Are cambered contact (PC400-3 and PC400-5 type) between the body and buy
a new plunger valve plate, the contact surface to go through in order to put a good run-in to
work. The method can be manually run-run-in, and then installed before running the run, the first
run-in with a small throttle for about 4h, use the throttle run-4h.
56, PC400-3 Komatsu excavator working pressure is normal. Control the pump output pressure
and jet valve pressure is also normal. Why work fatigue?
This should carefully check the servo valve. Check from two aspects: First decomposition valve
parts, colors, check valve and slide valve where there is a black site, indicating that this part of a
string of oil, to be replaced with new parts. Second, check for abnormal color, if the slide valve
adjustment is likely to be improper to make inlet ports B and C have the phenomenon of
communication.
57, overload valve and dispensing valve is damaged, how to judge?
Overload valve failure of judgment Methods: Walking distribution valve plug removed and
overload valve on the dress, if the arm is no longer declining, indicating overload valve is faulty;
distribution valve failure of judgment method: Pull out the distribution valve, observe the color,
black is a spool leakage has occurred.

Troubleshooting

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[Troubleshooting] Kobelco excavator fault

code fault code

Kobelco excavator repair SK200-2 SK200-3 fault code:

Kobelco SK200-6 fault code:

Switches, relays, system fault codes:

Fuel pump system failure code:

Fuel injection system fault codes:

Turbine system fault code:

Kobelco excavator @ // SK200-6 fault code Description

Fault code Fault grounds

Fault code Fault grounds

Kobelco SK-8] [fault code, the code following meanings:

A Kobelco SK-8 (engine systems) sensor systems:

5 Kobelco SK-8 turbo system:

[Troubleshooting] Hitachi excavator fault

Hitachi 200-3 240-3270-3 fault code:

636-2 camshaft angle sensor error (no signal)

723-2 crank speed sensor abnormality (no signal)

110-3 coolant temperature sensor is abnormal (high pressure anomaly)

110-4 coolant temperature sensor abnormality (low pressure anomaly)

174-3 fuel temperature sensor abnormality (abnormal high pressure)

157-3 rail pressure sensor anomaly (high pressure anomaly)

157-4 rail pressure sensor anomaly (low pressure anomaly)

100-4 oil pressure sensor abnormality (abnormal high pressure)

2, fault code: 11301-4

(1) Excavators one cylinder injector fault, fault code 0001-11

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Hitachi (HLTACHL) explain in detail excavator fault code troubleshooting steps:

[Troubleshooting] hyundai excavator fault

hyundai-9 series excavators fault code:

1080 Walking (idling) higher than normal pressure sensor data

1220 pressure sensor data overload higher than normal

1230 a negative feedback pressure sensor data is higher than normal

1240 Negative feedback data is higher than normal pressure sensor 2

Several common fault codes DOOSAN excavator Case

This article from the SF excavator repair plant consolidation Share

(1) Excavators fault code 0091-08: throttle position signal anomalies

main diesel engine shutdown or failure phenomenon is not running.

Cause: ECM detects all of the following conditions:

a.ECM read signal voltage higher than 4.8V continued 8s;

. b has at least the power supply of the ECM 2s;

(3) fault code 0094-04: Fuel pressure sensor shorted to ground

main diesel engine shutdown or failure phenomenon is not running.

Cause ECM detects all of the following conditions:

. b has at least the power supply of the ECM 2s;

a. diesel low power operation.

b. diesel engine speed is reduced.

Cause ECM detects all of the following conditions:

. b has at least the power supply of the ECM 2s;

e. diesel engine is not running.

(5) fault code 0100-04: oil pressure sensor shorted to ground

a. diesel low power operation.

b. diesel engine speed is reduced.

Cause ECM detects all of the following conditions:

a.ECM read signal voltage higher than 0.2V continued 18s;

e. diesel engine is not running.

a. diesel will not go into cold mode.

b. diesel engine does not fire.

c. diesel low power operation.

d. diesel engine speed is reduced.

Cause ECM detects all of the following conditions:

a ECM reads the signal voltage continues to 4.92V or more 8s;

b. supply of power to at least the existing ECM 2s.