COMPONENT CODE K1

PARTS & SERVICE REF NO. AA03037

DATE Mar. 7, 2003
NEWS Page 1 of 4

SUBJECT: REPAIR OF PUMP LOAD SENSING VALVE

PURPOSE: To introduce modification procedure to prevent occurrence of malfunctioning of
the pump load sensing (LS) valve
APPLICATION: PC200-7 and PC200LC-7 Hydraulic Excavator, S/N 200397, 200398, 200400,
200403, 200405, 200407, 200410, 200412, 200413, 200415, 200417 thru
200428, 200430 thru 200457, 200467 thru 200477, 200479, 200480, 200482 thru
200497, 200499 thru 200501, 200504 thru 200527, 200529 thru 200614, 200617
thru 200634, 200626 thru 200638, 200641 thru 200652, 200654, 200657, 200660
thru 200673, 200678, 200682, 200684 thru 200687, 200691, 200692, 200696
thru 200701, 200703 thru 200711, 200714 thru 200719, 200722, 200723, 200725
thru 200728, 200730, 200731, 200733, 200736 thru 200740, 200743, 200744,
200746 thru 200749, 200751, 200754, 200755, 200760, 200764 thru 200766,
200768, 200771 thru 200774, 200776 thru 200778, 200780, 200783, 200784,
200788, 200789, 200794, 200798 thru 200805, 200808, 200819 and 200822
PC200LC-7B Hydraulic Excavator, S/N C50001 and up
PC200LC-7L Hydraulic Excavator, S/N A86001 and up
PC210-7 Hydraulic Excavator, S/N 40029 thru 40044, 40047 and 40048
PC220LC-7 Hydraulic Excavator, S/N 60001 and up
PC220LC-7L Hydraulic Excavator, S/N A86001 and up
PC270LC-7L Hydraulic Excavator, S/N A86001 and up
PC228US-3 and PC228USLC-3 Hydraulic Excavator, S/N 20893 thru 20895,
20900 thru 20902, 20904 thru 20915, 20917 thru 20922, 20924 and 20925
BR120T-1 Mobile Crusher, S/N 1070 thru 1074 and 1076
FAILURE CODE: K1G1PM
DESCRIPTION:

There is a possibility of a malfunction of the pump load sensing (LS) valve resulting in slower work
equipment moving speed and slower travel speed. When the aforementioned phenomenon occurs, con-
duct (1) checking and confirming the phenomenon, (2) checking and determining if the LS valve is func-
tioning or malfunctioning and (3) carrying out the modification listed in this PARTS & SERVICE
NEWS.

AA03037
Page 2 of 4
.
Purpose of
Part No. Part Name Qty Remarks
Part
This part number should be used for overseas
markets (2 assemblies for F and R). The stock
708-2L-06710 Valve A 2
in the Parts Supply Center was inspected on
October 29th and returned the old valve stock.
Replacement
708-2L-00300 Pump A 1 PC200-7, PC210-7
708-2L-00103 Pump A 1 PC228US-3
708-2L-00860 Pump A 1 BR120T-1

3. Details of the failure

Because of a machining error for the sleeve of the LS valve ( machining was made by the cutting
tools of which chipping was overlooked) the inner diameter of the excape section of some sleeves is
smaller than the specification. In this case, the piston may be caught by the subect section and the LS
valve spool will keep outputting the min. swash plate signals to decrease the discharge flow rate of
the pump, thus retarding the work equipment speed and the machine travel speed.

Cause for malfunctioning of the LS valve (stays at the min. swash plate angle).

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 Page 3 of 4
4. Checking and confirming the phenomenon.
(1) Hydraulic Excavators:
1) Make the following settings:
•Mode: L mode
•Engine revolution: Full
•Merging - dividing condition: Dividing condition
2) Check items
1) Operate the work equipment independently to check if the speed is not extremely slow. When
the work equipment is operated repetitvely, the speed may become slow once in awhile.
2) At the same time, measure the pump discharge pressure, PFC, PRC and pump control pressure,
PENF and PENR.

(2) Mobile Crushers:

1) Set the engine revelation to
"FULL".
2) Check items:
1) Repeat start/stop of the ham-
mer mill only to check if the
speed is not extremely slow.
2) After starting all the other
motors than the hammer mill
motor, repeat start/stop of
the tab motor to check if rev-
eloution of other motors may
not become extremly slow
while the tab motor is in
rotation.
3) At the same time, measure
the pump discharge pressure,
PF, PR and pump control
pressure, PENF and PENR.

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Page 4 of 4

5. Determining the LS valve if it is in good condition or not.

1) Combinations of the work equipment and the pump:
Hydraulic Excavators Mobile Crushers
Arm Tab motor
F. Pump Swing Fan Motor
R.H. traveling Belt conveyor, etc.
Boom
R. Pump Bucket Hammer Mill
L.H.traveling
2) Determination
1) Hydraulic Excavators:
When the arm dumping speed and swing speed are slow, it is assumed that the LS valve for the F.
pump is malfunctioning. When the boom raising speed and bucket moving speed are slow, it is
assumed that the LS valve for the R. pump is malfunctioning.
2) Mobile Crushers:
When the hammer mill speed is slow, it is assumed that the LS valve for the R pump is
malfunctioning. When other motos other than the hammer mill motor are slow, it is assumed
that the LS valve for the F. pump is malfunctioning.

6. Modification:

If the LS valve has malfunctioned as a result of this determination process described in Section 5,
replace the corresponding LS valve.

Mounting position of the LS valve: Refer to the outline drawing showing in the preceeding section.

LS valve tightening torque: 13.5 - 16 kg.m

Shape of the tightening section: width across flat = 27mm, Hexagon head shape (Use a 27mm box
wrench)

Precatuion: The LS valve has a structure that the tip end section can be separated. Although it
does not come out easily, be careful not to let it fall.

AA03037