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Infolinks 2014

Yanmar marine engines 6LPA series Troubleshooting repair guide

This section contains information and diagnostic troubleshooting charts to accurately diagnose and engine, starter, or alternator problem.

TROUBLESHOOTING CHART

Symptom : Engine does not start or starts with difficulty:

Pinion gear does not engage

Loose terminal of battery / engage magnet Tighten
Poor contact of starting switch Correct with sandpaper or

replace

Open coil of magnet switch Replace
Rough operation of shifter Correct with sandpaper and

apply grease

Burr at gear tooth tip Correct
Poor clearance between pinion and ring gear Correct
Damaged starter bearing Replace

Pinion gear is engaged with ring gear, but does not rotate

Loose battery / starter terminal Tighten
Poor contact of engage magnet switch Correct with sandpaper
Worn brush Replace
Dirty or rough surface of rectifier Correct with sandpaper #500

to #600

Open circuit of starter coil Replace
Worn rectifier Replace
Slippage of starter / clutch Replace
Excessive resistance of cable between battery and starter Increase the cable size or

shorten

Insufficient battery charge Charge

No fuel injection

Incomplete priming of fuel system Carry out sufficient priming
Fuel shut-off by faulty speed adjusting system Re-adjust
Clogged fuel inlet filter Replace
Fuel level in fuel tank is low Add fuel
Closed cock of fuel tank Open cock
Clogged fuel pipe Clean
Failure of fuel feed pump Overhaul or replace

Failure of fuel injection valve

Faulty valve seat Replace
Sticking of nozzle Replace
VVon nozzle Replace
Clogged injection hole Replace
Drop in injection pressure Re-adjust

Failure of fuel injection pump

Probable Cause Measure
Worn plunger Replace both plunger and

barrel (need to be replaced as

a set)

Broken plunger spring Replace
Sticking plunger Overhaul or replace
Oil leak from delivery valve Lap valve
Air trapped in pump Bleed air from pump

Failure in fuel injection system

Incorrect injection timing of fuel injection pump Re-adjust
Loose fuel injection pipe joint Tighten
Broken fuel injection pipe Replace
Air trapped in fuel injection pipe Bleed air from pipe

Engine compressed air leak

Air leak from exhaust valve Carry out fitting of valve and

seat

No valve clearance Re-adjust
Faulty gasket / packing Replace
Worn upper portion of cylinder liner Replace
Worn piston ring Replace
Sticking piston ring Overhaul or replace
Insufficient tightening of head bolt Re-tighten set bolts uniformly
Broken valve spring Replace

Other

Improper thickness of gasket / packing Replace with a part of

appropriate size

Poor mounting of link or lever of speed control system Re-adjust
Location of speed control handle stopping position Move the speed control

handle towards higher speed

Failure of engine starting system Inspect and conduct servicing
Clogged intake or exhaust pipe Clean

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The principle of the engine thermostat and maintenance

A few days ago, a few friends together to eat and talk. One friend said his car thermostat bad, just the weather is hot, ready autumn back a new one. There are cranes and another friend, said he will put every summer season thermostat removed, the cold weather and reloading. My friends are doing is not correct? Today we’ll analyze it.

Analysis of my friends is not the right to do so, we must first understand the principles of the thermostat, the thermostat then what is it? Let’s take a look at the thermostat is what kind of bar.

Wax-type thermostat Appearance

Thermostat generally by the spring, hoses, temperature sensing element, thermostat valves, valve seats, putt, up and down bearing and other components. Its function is to change according to the level of the coolant temperature and the amount of water entering the radiator to automatically adjust, but also to change the scope of the water cycle, that is, we often say “big loop” and “small cycles.” This achieves the regulation of the cooling system cooling capacity, thus ensuring the operation of the engine in the appropriate temperature range.

Wax-type thermostat internal structure

Sales currently on the market, there is a wax-type thermostat and electronic thermostat, but most consumers are still using wax-type thermostat. Wax-type thermostat is to use the principle of paraffin at high temperature deformation state will, in simple terms is the use of the thermal expansion and contraction principle paraffin. When the engine is cold start, the coolant temperature is low, when the coolant temperature is less than the predetermined value, the body temperature was solid paraffin, thermostat valve under the action of the spring is turned off. At this point the pump returns the engine coolant through the cooling system, “small cycles.”

When the temperature of the coolant reaches a predetermined value, the wax begins to melt, then the volume of wax increases also. Volume increases paraffin will oppress hose, hose will shrink, shrink, while the hose will push the center rod, and putting the valve will be a reverse thrust, allowing the valve to open, making the cooling system into the “big loop.”

Under different cycle thermostat open the way

Electronic thermostat works with the wax-type thermostat works largely the same. Only electronic thermostat is an electronic thermostat built thermistor, when the water temperature, the thermistor signal will be transmitted to the control unit, and a control unit and then send a signal to the execution unit, the execution unit based on the sensor signal the calculated value of the temperature control unit load voltage, turn heat resistance, and then depending on the resistance temperature characteristic diagram of the paraffin is heated paraffin expansion, in order to achieve the “big loop” cooling system. Advantages of electronic thermostat is relatively high accuracy, the disadvantage is the high cost of maintenance is too much trouble.

Electronic Thermostat Appearance

It says the “big loop” and “small cycles”, where it is necessary to explain what is meant by “big loop”, what is “small cycles.” “Big loop” is the cooling flow through the heat sink body and the process, and “small loop” is the engine body, the cooling process does not go through the radiator.

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Husqvarna Chain Saws Trouble shooting repair guide

Trouble shooting schematic Faults that can develop on the chain saw are divided into four groups as follows. In each category, possible malfunctions are shown on the left, with a list of possible faults on the right. The most probable fault is given first and so on.

1. Starting

Difficult starting

  • Adjust L-screw
  • Air filter blocked
  • Choke not working correctly
  • Worn choke shaft
  • Worn choke plate
  • Fuel filter blocked
  • Fuel line blocked
  • Piston ring seized
  • Blocked impulse channel

Carburettor leaking fuel

  • Loose or faulty fuel pipe
  • Hole in diaphragm
  • Worn needle valve/needle
  • Control system sticking
  • Control system set too high
  • Leak in control system (air or fuel)
  • Loose cover on carburettor
  • pump side

Flooding when the engine is not running

  • Worn needle valve
  • Control system set too high
  • Control system sticking

2. Idling (low rpm) (cont.)

Idles when L-screw closed

  • Worn needle valve/needle
  • Leaking control diaphragm/
  • cover plate
  • Control system sticking
  • Worn throttle lever
  • Faulty diffuser jet

Idling uneven

  • Fuel filter blocked
  • Fuel line blocked
  • Leaking manifold
  • Loose carburettor mounting
  • Worn throttle valve shaft
  • Loose throttle valve screw
  • Worn throttle valve
  • Control system sticking
  • Leak in throttle system (air or fuel)
  • Control diaphragm centre knob is worn
  • Hole in diaphragm
  • Leaking control diaphragm/cover plate
  • Crankcase leaking

L-screw requires constant adjustment

  • Fuel line blocked
  • Control system set too high
  • Control system sticking
  • Control system (air or fuel)
  • Leaking control diaphragm/
  • cover plate
  • Faulty diffuser jet
  • Crankcase leaking

Too much fuel at idling

  • Control system set too high
  • Control system sticking
  • Control system damaged
  • Worn needle valve
  • Leaking control diaphragm/
  • cover plate
  • Control system incorrectly
  • assembled

3. Idling (low rpm)

Will not idle

  • Adjust L-screw
  • Leaking manifold (intermediate)
  • Loose carburettor mounting
  • Loose or faulty fuel pipe
  • Fuel filter blocked
  • Fuel line blocked
  • Fuel tank breather blocked
  • Throttle shaft and lever stiff
  • Throttle cable sticking
  • Defective throttle return spring
  • Bent throttle lever shaft stop
  • Faulty diffuser jet

Idling too rich

  • Adjust L-screw
  • Worn needle valve/needle
  • Control system set too high
  • Worn throttle lever
  • Leaking control diaphragm/cover plate
  • Control system sticking

4. High rpm

Will not run at full throttle

  • Adjust H-screw
  • Blocked air filter
  • Blocked fuel tankbreather
  • Blocked fuel filter
  • Fuel line blocked
  • Loose or damaged fuel line
  • Impulse channel leaking
  • Impulse channel blocked
  • Loose cover on carburettor
  • pump side
  • Faulty pump diaphragm
  • Leaking manifold
  • Loose carburettor mounting
  • Control system set too low
  • Control system damaged
  • Control system incorrectly
  • assembled
  • Leaking control diaphragm/cover
  • Control system sticking
  • Blocked silencer

Low power

  • Adjust H-screw
  • Blocked fuel tankbreather
  • Blocked fuel filter
  • Impulse channel leaking
  • Impulse channel blocked
  • Loose cover on carburettor
  • pump side
  • Faulty pump diaphragm
  • Blocked air filter
  • Control system sticking
  • Leak in throttle system (air or
  • fuel)
  • Control system incorrectly
  • assembled
  • Loose diaphragm
  • Hole in diaphragm
  • Leaking control diaphragm/cover
  • Blocked fuel tank breather
  • Blocked fuel filter

Will not ”four-stroke”

  • Fuel line blocked
  • Loose or damaged fuel line
  • Impulse channel leaking
  • Impulse channel blocked
  • Loose cover on carburettor
  • pump side
  • Faulty pump diaphragm
  • Leaking manifold
  • Loose carburettor mounting
  • bolts
  • Control system set too low
  • Leak in throttle system (air or
  • fuel)
  • Control system incorrectly
  • assembled
  • Loose diaphragm
  • Hole in diaphragm
  • Leaking control diaphragm/cover

5. Acceleration and retardation

Does not accelerate

  • Adjust L-screw
  • Adjust H-screw
  • Blocked air filter
  • Blocked fuel tankbreather
  • Blocked fuel filter
  • Fuel line blocked
  • Loose or damaged fuel line
  • Impulse channel blocked
  • Loose cover on carburettor
  • pump side
  • Faulty pump diaphragm
  • Leaking manifold
  • Loose carburettor mounting
  • Throttle set too low
  • Control system incorrectly
  • assembled
  • Control system sticking
  • Faulty diffuser jet
  • Blocked silencer

Motor stalls when throttle released

  • Adjust L-screw
  • Adjust H-screw
  • Faulty pump diaphragm
  • Control system set too high
  • Control system sticking
  • Faulty diffuser jet

Over rich acceleration

  • Adjust L-screw
  • Adjust H-screw
  • Blocked air filter
  • Faulty pump diaphragm
  • Faulty diffuser jet

Trouble shooting methods
In addition to faults given in the above schematic, trouble shooting can be carried out on a specific component or sub-system of the chain saw. The different testing procedures are described in respective sections and are as follows:
1. Pressure testing the carburettor.
See page 100.-
2. Pressure testing the crankcase and cylinder.
See page 114. -
3. Pressure testing the decompression valve.
See page 114. -
4. Checking the operation of the chain brake.
See page 47. -

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Excavator engine deposits causes and hazards

Engine in use will produce carbon, then these carbon generation and harm, what does?

Excavator engine deposits causes and hazards

The reason for the production of coke

Fuel is not pure
In fact be 100% pure are possible, a filter will filter limit, so some small impurities in the fuel after the combustion is deposited in the cylinder carbonization.

Intake is not pure
Two filters (coarse filter, fine filter) can not guarantee 100% filtered air waste. The fine dust into the combustion chamber with the gas, after the deposition of combustion in the cylinder carbonization.

Moving parts to wear
Moving parts inside the cylinder, cylinder, valve, piston, piston rings and other high-speed motion process will MITI wear debris that is deposited through the burning mix in the cylinder.

Hazard coke
Said carbon harm, we must first know at the coke deposition. Coke combustion, explosion after the impact, and ultimately will be deposited into the piston ring groove, Injector port, valve place.

Deposited piston ring groove
Burning carbonized deposits accumulate in the piston ring groove, will piled up, stick piston rings, piston rings eventually deform, highlighting, scratches cylinder, causing pull cylinders, seizures. Cylinder piston causing the piston rings all scrapped.
Deposited Injector mouth
The end result is clogged injector port, and now the technology base can not repair EFI car fuel injection port. Only replace the fuel injector

Deposited at the valve
Accumulate more uneven force will cause the valve, the valve stem fracture, fracture of the situation valve chassis. The results will cause the valve, locking plate, seat ring, piston, all the damage.

Through the above can be learned, engine deposits can cause very serious consequences, so be careful to understand the situation of the machine, especially a long year, hours and more machines. Watch the power is stable, there is no decline. Once the problems should be promptly repair, replace four matching.

YAMAHA repair fault code ERROR MESSAGES LIST

Es00001:CODE ERROR! Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board., Check voltage of 5V power supply.

Es00002:INTERNAEs00 ERROR! Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board., Check voltage of 5V power supply.

Es00003:FEEDBACK ERR 0! Servo-motor not responding to commands from servo-board. — CAUSE — Mechanical locking., The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective., Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking., Wire the encoder or the motor cable correctly., Replace motor,cable,servo-board,or driver-board., Check voltage or capacity of power supply.

Es00004:FEEDBACK ERR 1! Cannot receive signal of the encoder correctly. — CAUSE — The encoder cable wiring is incorrect or disconnected., The servo-motor is defective., The servo- board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,encoder cable,or servo-board.

Es00005:OVEREs00OAD! Too much load has been detected on servo-motor. — CAUSE — Mechanical action is not smooth., The electromagnetic break is defective. — COUNTERMEASURE — Check load on motor., Check the electromagnetic break.

Es00006:Tr.OVER CURRENT Power module in driver-board detected excessive current etc. — CAUSE — The motor cable wiring is incorrect., Power module in driver-board is defective., The motor or servo-board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,servo-board,or driver-board.

Es00007:OVER CURRENT! Electric current of servo-motor is over limit. — CAUSE — Mechanical locking, The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective., Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking., Wire the encoder or the motor cable correctly., Replace motor,cable,servo-board,or driver-board., Check voltage of power supply.

Es00008:MOTOR OVERHEAT Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00009:Tr. OVERHEAT Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00010:WATCHDOG ERR 0! Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00011:WATCHDOG ERR 1! Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00012:DIVISION ERROR! Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00013:2nd Es00IMIT EXCEEDED! Axis of servo is beyond mechanical limit. — COUNTERMEASURE — Move relevant axis to center of axis range.

Es00014:EMERGENCY STOP! “Emergency Stop” switch is “ON”. — COUNTERMEASURE — Check “Emergency Stop” switches. Es00015:M.POWER DOWN! Failure of “Servo-ON”. — COUNTERMEASURE — Power ON again., Check the circuit-protector., Check voltage of power supply.
Es00016:PI1 CON. OFF! Controller front panel connector is not connected properly. — CAUSE — Connector is out of socket. — COUNTERMEASURE — Connect controller front panel correctly.

Es00017:PI2 CON. OFF! Controller front panel connector is not connected properly. — CAUSE — Connector is out of socket. — COUNTERMEASURE — Connect controller front panel correctly.

Es00018:I/O CMU. ERROR! Fatal error occurred in I/O board. — COUNTERMEASURE — Power ON again, Check earth line or condition of connector, Change I/O board.

Es00019:WRITE PROTECT! Fatal error occurred in I/O board. — COUNTERMEASURE — Power ON again., Check ground line or condition of connector., Replace I/O board.

Es00020:SERVO NO ACK. No response from servo-board. — CAUSE — The connection of servo-board to mother-board is bad., The servo-board is defective. — COUNTERMEASURE — Check the connection of servo-board to mother-board., Power ON again., Replace servo-board. Es00021:SRV NOT INSTAEs00Es00ED The servo-board is not installed. — COUNTERMEASURE — Check the connection of servo-board to mother-board., Replace servo-board.

Es00022:ENCODER ZERO ER Cannot receive C phase signal of the encoder correctly. — CAUSE — The encoder cable wiring is incorrect or disconnected., The servo-motor is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,encoder cable. Es00023:BAD POSITION Cannot count the encoder pulses correctly. — CAUSE — The encoder cable wiring is incorrect or disconnected., The servo-motor is defective., The servo- board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,encoder cable,or servo-board., Power ON again.

Es00024:MOTORPOWER FAIEs00 Voltage of DRIVERPOWER is out from DC186V-414V — CAUSE — The driver-power cable wiring is disconnected., The driver-power cable wiring has a ground leak. The motor,servo-board,or driver-board is defective. — COUNTERMEASURE — Check QF30/31 circuit-protector, Wire the motor cable correctly., Replace motor,servo-board,or driver-board.

Es00025:PHASE Es00OSS Phase loss in three phase power source — CAUSE — Three phase power source in factory is defective., The cable in machine is disconnected or contact-fail. — COUNTERMEASURE — Check power source in factory, Wire the cable in machine correctly. Es00026:SERVO-ON FAIEs00 MOTORPOWER FAIEs00 and PHASE Es00OSS during servo-on — CAUSE — The driver-power cable wiring is disconnected., The driver-power cable wiring has a ground leak., The motor,servo-board,or driver-board is defective., Three phase power source in factory is defective., The cable in machine is disconnected or contact-fail., Driver-power-board is defec- tive., Temp. in controller is higher than 65degrees. — COUNTERMEASURE — Check QF30/31 circuit-protector., Wire the motor cable correctly., Replace motor,servo-board,or driver-board., Check power source in factory., Wire the cable in machine correctly., Check temp. around controller., Check input-voltage., Replace driver-power-board.

Es00030:SRV PARAM.ERR Parameter data of servo-motor has been destroyed. — CAUSE — Parameter data file is destroyed., Servo-board is defective. — COUNTERMEASURE — Power ON again., Install software again., Replace servo-board.

Es00031:SERVO CPU ERR0 Type0 error occured in the CPU of servo-board. — CAUSE — The servo-board is defective. — COUNTERMEASURE — Power ON again., Replace servo-board.

Es00032:SERVO CPU ERR1 Type1 error occured in the CPU in servo-board. — CAUSE — The servo-board is defective. — COUNTERMEASURE — Power ON again., Replace servo-board.

Es00033:SERVO CPU ERR2 Type2 error occured in the CPU in servo-board. — CAUSE — The servo-board is defective. — COUNTERMEASURE — Power ON again., Replace servo-board.

Es00034:SERVO CPU ERR3 Type3 error occured in the CPU in servo-board. — CAUSE — The servo-board is defective. — COUNTERMEASURE — Power ON again., Replace servo-board.

Es00035:POS DEV. EXCESS Servo-motor not responding to commands from servo-board. — CAUSE — Mechanical locking., The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective., Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking., Wire the encoder or the motor cable correctly., Replace motor,cable,servo-board,or driver-board., Check voltage or capacity of power supply.

Es00036:SPD DETECT. ERR Too much speed has been detected on servo-motor when holding. — CAUSE — The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective. — COUNTERMEASURE — Wire the encoder or the motor cable correctly., Replace motor,servo-board,or cable. Es00037:OVREs00OAD PROTECT Too much load has been detected on servo-motor. — CAUSE — Mechanical action is not smooth., The electromagnetic break is defective. — COUNTERMEASURE — Check load on motor., Check the electromagnetic break.

Es00038:OVRCUR. PROTECT Power module in driver-board detected excessive current etc. — CAUSE — The motor cable wiring is incorrect., Power module in driver-board is defective., The motor or servo-board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,servo-board,or driver-board.

Es00039:SPD DEV. EXCESS Electric current of servo-motor is over limit. — CAUSE — Mechanical locking, The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective., Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking., Wire the encoder or the motor cable correctly., Replace motor,cable,servo-board,or driver-board., Check voltage of power supply.

Es00040:SERVO ERROR 0 Undefined error occured in servo-board.

Es00041:SERVO ERROR 1 Undefined error occured in servo-board.

Es00042:SERVO ERROR 2 Undefined error occured in servo-board.

Es00043:SERVO ERROR 3 Undefined error occured in servo-board.

Es00044:SERVO ERROR 4 Undefined error occured in servo-board.

Es00045:SERVO ERROR 5 Undefined error occured in servo-board.

Es00046:SERVO ERROR 6 Undefined error occured in servo-board.

Es00047:SERVO ERROR 7 Undefined error occured in servo-board.
Es00048:HOEs00D SPEED ERR Too much speed has been detected on servo-motor when holding. — CAUSE — The encoder cable wiring is incorrect or disconnected., The motor cable wiring is incorrect or disconnected., The motor is defective., The servo-board or the driver-board is defective. — COUNTERMEASURE — Wire the encoder or the motor cable correctly., Replace motor,servo-board,or cable.

Es00049:POWER MODUEs00E ER Power module in driver-board detected excessive current etc. — CAUSE — The motor cable wiring is incorrect., Power module in driver-board is defective., The motor or servo-board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,servo-board,or driver-board.

Es00050:POWER DETECT ER Motor current has been detected on servo-motor abnormally. — CAUSE — The motor cable wiring is incorrect., Current detector in driver-board is defective., The servo- board or the driver-board is defective. — COUNTERMEASURE — Wire the motor cable correctly., Replace servo-board or driver-board.

Es00051:Es00ACK OF CURRENT Cannot supply sufficient current to servo-motor. — CAUSE — The motor cable wiring is incorrect or disconnected., Driver-board is defective. — COUNTERMEASURE — Wire the motor cable correctly., Replace the motor cable., Replace driver-board.

Es00052:CPU TIMER0 ERR Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00053:CPU TIMER1 ERR Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00054:CPU TIMER2 ERR Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again., Replace servo-board. Es00055:SRV VERSION ERR A mismatch between servo-board and software. — COUNTERMEASURE — Power ON again., Install software again., Replace servo-board.

Es00056:POS DETECT ERR Cannot receive signal of the encoder correctly. a. A position difference between two axes of dual drive. b. A position difference between two encoders. — CAUSE — The encoder cable wiring is incorrect or disconnected., The servo-motor is defective., The servo- board is defective. — COUNTERMEASURE — Wire the encoder cable correctly., Replace motor,encoder cable,or servo-board.

Es00101:Disk write-protected — CAUSE — This is a DOS error, This floppy disk is write-protected. — COUNTERMEASURE — Cancel write-protect on this floppy disk.

Es00102:Drive not available — CAUSE — This is a DOS error.

Es00103:Drive not ready — CAUSE — This is a DOS error, There is no floppy disk in the drive which you selected. — COUNTERMEASURE — Insert a floppy disk in the drive which you selected.

Es00104:Invalid disk command This is a DOS error.

Es00105:CRC error This is a DOS error.

Es00106:Invalid length This is a DOS error.

Es00107:Seek error — CAUSE — This is a DOS error. Files were read or written from the middle of the files. — COUNTERMEASURE — Process files again.

Es00108:Not an MS-DOS disk — CAUSE — This is a DOS error. Floppy disk which you used is not 1.4M format disk. — COUNTERMEASURE — Use 1.4M format disk.

Es00109:Sector not found — CAUSE — This is a DOS error, Floppy disk which you used is not normal, Floppy disk which you used is not formatted, Floppy disk which you used is not 1.4M format disk. — COUNTERMEASURE — Use new floppy disk, Use 1.4M format disk.

Es00110:Out of paper This is a DOS error.

Es00111:Write fault — CAUSE — This is a DOS error, Floppy disk which you used is not normal, Floppy disk which you used is not 1.4M format disk. — COUNTERMEASURE — Use new floppy disk, Use 1.4M format disk.

Es00112:Read fault — CAUSE — This is a DOS error, Floppy disk which you used is not normal, Floppy disk which you used is not 1.4M format disk. — COUNTERMEASURE — Use new floppy disk, Use 1.4M format disk.

Es00113:General failure This is a DOS error.

Es00114:unknown error This is a DOS error.

Es00115:No such file — CAUSE — This is a DOS error. The file you selected does not exist. — COUNTERMEASURE — Check the file name which you selected.

Es00116:Arg list too long This is a DOS error.

Es00117:Exec format error This is a DOS error.

Es00118:Bad file number This is a DOS error.

Es00119:Not enough core This is a DOS error.

Es00120:Permission denied This is a DOS error.

Es00121:File exists — CAUSE — This is a DOS error. A file with the name you selected already exists. — COUNTERMEASURE — Select a new file name.

Es00122:Cross-device link This is a DOS error.

Es00123:Invalid argument This is a DOS error.

Es00124:Too many open files This is a DOS error.

Es00125:Disk full — CAUSE — This is a DOS error. This floppy disk is full and cannot be written to. — COUNTERMEASURE — Use a new floppy disk.

Es00126:Math argument This is a DOS error.

Es00127:Result too large This is a DOS error.

Es00128:Resource deadlock This is a DOS error.

Es00129:Unable to change dir This is a DOS error.

Es00130:Unable to change drv This is a DOS error.

Es00131:Directory exists — CAUSE — This is a DOS error. A directory with the name you selected already exists. — COUNTERMEASURE — Select a new directory name.

Es00132:Unable to make dir This is a DOS error.

Es00133:Unable to remove dir — CAUSE — This is a DOS error. Files exist in the directory which you selected. — COUNTERMEASURE — Delete files from the directory which you selected.

Es00134:Unable to rename This is a DOS error.

Es00201:KG2-42S9 File Open Error”

Es00202:KG2-42S8 File Open Error”
Es00203:KG2-42S7 File Open Error

Es00204:KG2-58D9 File Open Error

Es00205:KG2-58D9 File Open Error

Es00206:KG2-42S7 File Open Error

Es00207:KG2-42S9 File Close Error

Es00208:KG2-42S8 File Close Error

Es00209:KG2-42S7 File Close Error

Es00210:KG2-42S7 File Close Error

Es00211:KG2-58D9 File Close Error

Es00212:CPU8344 retry — COUNTERMEASURE — Power ON again.

Es00212:APPL CPU Handshake Error

Es00213:Servo HEX Data Error

Es00214:Servo HEX Address Error

Es00215:ENB/DIS before D.L.”

Es00216:KG2-42S7 File Read Errror”

Es00217:KG2-42S9 File Write Error

Es00218:KG2-42S8 File Write Error

Es00219:KG2-42S7 File Write Error Es00220:KG2-58D9 File Write Error

Es00221:KG2-42S8 File Read Erorr

Es00222:KG2-42S7 File Read Erorr

Es00223:KG2-42S7 File Read Erorr Es00224:Servo Card Not Found

Es00225:KG2-58D9 File Read Erorr Es00226:KG2-58D9 File Read Erorr

Es00227:BadSRAM/DC srv#1 Es00228:BadSRAM/DC srv#2

Es00229:BadSRAM/AC srv

Es00230:Servo Card1 Data Write Error

Es00231:Servo Card2 Data Write Error Es00232:Servo Card3 Data Write Error

Es00233:Servo Card4 Data Write Error

Es00234:Binary File Over 32KB

Es00235:Illegal PLC Function

Es00236:I/O Already Down Loaded

Es00237:No answer from servo This is an error in the servo card.

Es00238:KM5-42S8 File Open Error

Es00239:KM5-42S8 File Close Error

Es00240:KM5-42S8 File Write Error

Es00241:KM5-42S8 File Read Errror

Es00301:Read File Error This is a DOS error.

Es00302:Seek File Error This is a DOS error.

Es00303:Open File Error This is a DOS error.

Es00304:WriteFile Error This is a DOS error.

Es00305:Soft Es00imit Exceeded — CAUSE — Axis of servo is outside “Soft Es00imit” . — COUNTERMEASURE — Move relevant axis to center of axis range.

Es00306:Watch Cat Error This is an error in the VISION card.

Es00307:Invalid Axis This is an error of communication between the system board and servo card.

Es00308:InterEs00ock Error — CAUSE — “InterEs00ock” occurred. — COUNTERMEASURE — Remove “InterEs00ock” shown in error message.
PAGE 4
ERROR MESSAGES LIST
Es
Es00309:Mainte.SW.is ON — CAUSE — Machine speed is slowed by “NJ13″ switch. — COUNTERMEASURE — Turn “NJ13″ switch “ON” or “OFF”.

Es00310:Visin No Answer

Es00311:No Such Video Image

Es00312:No Triger Pulse

Es00313: Current Position SoftLimit Over

Es00314: Target Position Dangerous Limit1 Over

Es00315: Target Position Dangerous Limit2 Over

Es00316: Target Position Dangerous Limit3 Over

Es00401:Feed Back Error Servo-motor not responding to commands from servo-board. — CAUSE — Mechanical locking. The motor cable wiring is incorrect or disconnected. The motor is defective. The servo-board or the driver-board is defective. Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking. Wire the motor cable correctly. Replace motor,cable,or servo-unit. Check voltage or capacity of power supply.

Es00402:Over Load Too much load has been detected on servo-motor. — CAUSE — Mechanical action is not smooth. The electromagnetic break is defective. — COUNTERMEASURE — Check load on motor. Check the electromagnetic break.

Es00403:Over Current Electric current of servo-motor is over limit. — CAUSE — Mechanical locking The motor cable wiring is incorrect or disconnected. The motor is defective. The servo-board or the driver-board is defective. Shortage of current capacity. — COUNTERMEASURE — Check mechanical locking. Wire the motor cable correctly. Replace motor,cable,or servo-unit. Check voltage of power supply.

Es00404:Servo Watch Dog Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00445:Slave CPU Error4 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00446:Slave CPU Error5 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00447:Slave CPU Error6 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.
Es00448:Slave CPU Error7 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00449:Slave CPU Error8 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00450:Slave CPU Error9 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00451:Slave CPU Error10 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00452:Slave CPU Error11 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00460:Controller Error0 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00461:Controller Error1 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00462:Controller Error2 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00463:Controller Error3 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00464:Controller Error4 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again.Replace servo-unit. Es00465:Controller Error5 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00466:Controller Error6 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00467:Controller Error7 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit. Es00468:Controller Error8 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00470:MasterCPU Error0 Command number data from APPL-board has been destroyed. — CAUSE — APPL-board is defective. Servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected. — COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

Es00471:MasterCPU Error1 Axis number data from APPL-board has been destroyed. — CAUSE — APPL-board is defective. Servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected. — COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

Es00472:MasterCPU Error2 Fatal error occurred in servo-board — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00473:MasterCPU Error3 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00474:MasterCPU Error4 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00475:MasterCPU Error5 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00476:MasterCPU Error6 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00477:MasterCPU Error7 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00478:MasterCPU Error8 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00479:MasterCPU Error9 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00480:MasterCPU Error10 Fatal error occurred in servo-board. — COUNTERMEASURE — Power ON again. Replace servo-unit.

Es00481:MasterCPU Error11 Cannot receive data from APPL-board correctly. — CAUSE — APPL-board is defective. Servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected. — COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

Es00520:Servo CPU Error0 Undefined error occurred in servo-board.

Es00521:Servo CPU Error1 Undefined error occurred in servo-board.

Es00522:Servo CPU Error2 Undefined error occurred in servo-board.

Es00523:Servo CPU Error3 Undefined error occurred in servo-board.

Es00524:Servo CPU Error4 Undefined error occurred in servo-board.

Es00525:Servo CPU Error5 Undefined error occurred in servo-board.

Es00526:Servo CPU Error6 Undefined error occurred in servo-board.

Es00527:Servo CPU Error7 Undefined error occurred in servo-board.

Es00530:EMERGENCY STOP “Emergency Stop” switch is “ON”. — COUNTERMEASURE — Check “Emergency Stop” switches or cover etc. Push “READY” button on YPU.

Es00531:Second Limit Over Axis of servo is beyond mechanical limit. — COUNTERMEASURE — Move relevant axis to center of axis range.

Es00532:I/O Cmmunication Error Fatal error occurred in I/O board. — COUNTERMEASURE — Power ON again. Check ground line or condition of connector. Replace I/O board.

Es00533:System WatchDog Undefined error occurred in controller.

Es00534:Servo No Answer No response from servo-board. — CAUSE — The APPL-board is defective. The servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected.
— COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

Es00535:Servo Not Installed The servo-board is not installed. — CAUSE — The APPL-board is defective. The servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected.
— COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

Es00536:Encoder Zero Error Cannot receive C phase signal of the encoder correctly. — CAUSE — The servo-motor is defective. The servo-board is defective. — COUNTERMEASURE — Replace motor, servo-unit.

Es00537:Bad Position Cannot count the encoder pulses correctly. — CAUSE — The servo-motor is defective. The servo-board is defective. — COUNTERMEASURE — Replace motor, servo-unit. Power ON again.

Es00538:Motor Power Failure Voltage of DRIVERPOWER is out from DC186V-414V. — CAUSE — The driver-power cable wiring is disconnected. The driver-power cable wiring has a ground leak. The motor,servo-board,or driver-board is defective. — COUNTERMEASURE — Check QF31 circuit-protector Wire the motor cable correctly. Replace motor,servo-unit.

Es00539:Phase Loss Phase loss in three phase power source — CAUSE — Three phase power source in factory is defective. The cable in machine is disconnected or contact-fail. — COUNTERMEASURE — Check power source in factory Wire the cable in machine correctly.

Es00540:Servo On Error MOTORPOWER FAIL and PHASE LOSS during servo-on — CAUSE — The driver-power cable wiring is disconnected. The driver-power cable wiring has a ground leak. The motor,servo-board,or driver-board is defective. Three phase power source in factory is defective. The cable in machine is disconnected or contact-fail. Driver-power-board is defective. Temp. in controller is higher than 65degrees. — COUNTERMEASURE — Check QF31 circuit-protector. Wire the motor cable correctly. Replace motor,servo-unit. Check power source in factory. Wire the cable in machine correctly. Check temp. around controller. Check input-voltage. Replace driver-power-board. Es00541: Voltage of DRIVERPOWER is higher than DC414V, or temp. in controller is higher than Over Voltage Or High Temperature 65degrees. — CAUSE — Shortage of current capacity. Driver-power-board is defective. Temp. in controller is higher than 65degrees. — COUNTERMEASURE — Check voltage or capacity of power supply. Replace driver-power-board. Check temp. around controller.

Es00542:12V Power Supply Error Voltage of 12V power supply in controller is out from 10.2V-13.8V. — CAUSE — SW power supply is defective. The cable in controller is disconnected or contact-fail. Driver-power-board is defective. Servo-board is defective. — COUNTERMEASURE — Replace SW power supply. Wire the cable in controller correctly. Replace driver-power-board. Replace servo-unit.

Es00543:5V Power Supply Error Voltage of 5V power supply in controller is out from 4.75V-6V. — CAUSE — SW power supply is defective. The cable in controller is disconnected or contact-fail. Driver-power-board is defective. Servo-board is defective. — COUNTERMEASURE — Replace SW power supply. Wire the cable in controller correctly. Replace driver-power-board. Replace servo-unit.

Es00544:Data Error Error number is out of bounds. — CAUSE — APPL-board is defective. Servo-board is defective. The cable between APPL-board and servo-board wiring is incorrect or disconnected.
— COUNTERMEASURE — Power ON again. Replace APPL-board. Replace servo-unit. Wire the cable between APPL-board and servo-board correctly.

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 it’s 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 regulator’s 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 马达刚 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.

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