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KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
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KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
PC200-7 200001 and up
PC200LC-7 200001 and up
PC220-7 60001 and up
PC220LC-7 60001 and up
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Description
KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
Language : English
Pages : 796
Downloadable : Yes
File Type : PDF
MACHINE MODEL SERIAL No.
PC200-7 200001 and up
PC200LC-7 200001 and up
PC220-7 60001 and up
PC220LC-7 60001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
COVER............................................................................................................................... 1
CONTENTS............................................................................................................................ 2
01 GENERAL.......................................................................................................................... 28
SPECIFICATION DIMENSION DRAWINGS ............................................................................................... 29
PC200-7,PC200LC-7........................................................................................................... 29
PC220-7,PC220LC-7........................................................................................................... 31
SPECIFICATIONS.................................................................................................................. 33
PC200-7,PC200LC-7........................................................................................................... 33
PC220-7,PC220LC-7........................................................................................................... 35
WEIGHT TABLE.................................................................................................................... 37
PC200-7,PC200LC-7........................................................................................................... 37
PC220-7,PC220LC-7........................................................................................................... 39
FUEL,COOLANT,AND LUBRICANTS..................................................................................................... 41
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD.................................................................................... 42
ENGINE RELATED PARTS............................................................................................................ 43
RADIATORใปOIL COOLERใปAFTERCOOLER................................................................................................. 44
POWER TRAIN..................................................................................................................... 45
FINAL DRIVE..................................................................................................................... 46
SWING MACHINERY................................................................................................................. 48
PC200-7,PC200LC-7........................................................................................................... 48
PC220-7,PC220LC-7........................................................................................................... 50
SWING CIRCLE.................................................................................................................... 52
PC200-7,PC200LC-7........................................................................................................... 52
PC220-7,PC220LC-7........................................................................................................... 53
TRACK FRAMEใปRECOIL SPRING....................................................................................................... 54
IDLER........................................................................................................................... 56
CARRIER ROLLER.................................................................................................................. 58
TRACK ROLLER.................................................................................................................... 59
TRACK SHOE...................................................................................................................... 60
HYDRAULIC EQUIPMENT LAYOUT DRAWING.............................................................................................. 64
HYDRAULIC TANK.................................................................................................................. 66
HYDRAULIC PUMP.................................................................................................................. 67
CONTROL VALVE................................................................................................................... 88
PC200-7,PC200LC-7........................................................................................................... 88
PC220-7,PC220LC-7...........................................................................................................101
CLSS............................................................................................................................117
SELF PRESSURE REDUCING VALVE....................................................................................................120
SWING MOTOR.....................................................................................................................123
REVERSE PREVENTION VALVE........................................................................................................128
CENTER SWIVEL JOINT.............................................................................................................130
TRAVEL MOTOR....................................................................................................................131
TRAVEL JUNCTION VALVE...........................................................................................................140
STROKE REGULATION WHEN TRAVELLING...............................................................................................142
VALVE CONTROL...................................................................................................................144
WORK EQUIPMENTใปSWING PPC VALVE..................................................................................................145
TRAVEL PPC VALVE................................................................................................................149
SERVICE PPC VALVE...............................................................................................................158
SOLENOID VALVE..................................................................................................................161
PPC ACCUMULATOR.................................................................................................................163
RETURN OIL FILTER ..............................................................................................................164
BOOM HYDRAULIC DRIFT PREVENTION VALVE...........................................................................................165
LIFT CHECK VALVE................................................................................................................168
ATTACHMENT CIRCUIT SELECTOR VALVE...............................................................................................169
HYDRAULIC CYLINDER..............................................................................................................171
PC200-7,PC200LC-7...........................................................................................................171
PC220-7,PC220LC-7...........................................................................................................173
WORK EQUIPMENT..................................................................................................................175
AIR CONDITIONER.................................................................................................................182
ENGINE CONTROL..................................................................................................................183
ELECTRONIC CONTROL SYSTEM ......................................................................................................189
MULTI MONITOR SYSTEM............................................................................................................213
7-SEGMENT MONITOR SYSTEM........................................................................................................233
SENSOR..........................................................................................................................240
20 TESTING AND ADJUSTING............................................................................................................243
STANDARD VALVE TABLE FOR ENGINE RELATED PARTS...................................................................................244
STANDARD VALVE TABLE FOR CHASSIS RELATED PARTS..................................................................................246
TESTING AND ADJUSTING...........................................................................................................261
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING.............................................................................262
INSPECTION AND ADJUSTING OF ENGINE RPM......................................................................................264
MEASUREMENT OF EXHAUST GAS COLOR............................................................................................266
ADJUSTMENT OF VALVE CLEARANCE...............................................................................................267
MEASUREMENT OF COMPRESSION PRESSURE.........................................................................................269
MEASUREMENT OF BLOW-BY PRESSURE.............................................................................................270
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING..........................................................................271
MEASUREMENT OF ENGINE OIL PRESSURE..........................................................................................273
ADJUSTMENT OF ENGINE SPEED SENSOR...........................................................................................274
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION....................................................................274
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM.......................................................................275
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...........................................................................276
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION.............................................................................277
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT,SWING AND TRAVEL................278
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE...................................................................282
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE...........................................................283
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE...........................................................286
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE...............................................................................291
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE....................................................................................294
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE............................................................................295
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................296
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................297
MEASUREMENT OF OIL LEAKAGE AMOUNT...........................................................................................298
AIR BLEEDING OF VARIOUS PARTS...............................................................................................300
INSPECTION PROCEDURES FOR DIODE.............................................................................................302
SPECIAL FUNCTION OF MULTI-MONITOR PANEL.....................................................................................303
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT MONITOR PANEL.............................................................328
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM..........................................................................345
TROUBLESHOOTING.................................................................................................................355
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................356
SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................357
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................358
CHECKS BEFORE TROUBLESHOOTING ..............................................................................................366
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................................367
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...........................................................371
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................405
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE...................................................................................430
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED....................437
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................439
SERVICE CODE IN ELECTRICAL SYSTEM[E101](ABNORMAL DATA IN ERROR HISTORY).................................................441
SERVICE CODE IN ELECTRICAL SYSTEM[E112](SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....443
SERVICE CODE IN ELECTRICAL SYSTEM[E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....445
SERVICE CODE IN ELECTRICAL SYSTEM[E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................447
SERVICE CODE IN ELECTRICAL SYSTEM[E115](ABNORMAL WINDSHIELD WIPER MOTION)...............................................451
SERVICE CODE IN ELECTRICAL SYSTEM[E116](ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................453
SERVICE CODE IN ELECTRICAL SYSTEM[E201](SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................455
SERVICE CODE IN ELECTRICAL SYSTEM[E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................459
SERVICE CODE IN ELECTRICAL SYSTEM[E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................463
SERVICE CODE IN ELECTRICAL SYSTEM[E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................467
SERVICE CODE IN ELECTRICAL SYSTEM[E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................471
SERVICE CODE IN ELECTRICAL SYSTEM[E211](DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................475
SERVICE CODE IN ELECTRICAL SYSTEM[E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................479
SERVICE CODE IN ELECTRICAL SYSTEM[E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID).........................................483
SERVICE CODE IN ELECTRICAL SYSTEM[E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................487
SERVICE CODE IN ELECTRICAL SYSTEM[E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................491
SERVICE CODE IN ELECTRICAL SYSTEM[E217](ABNORMALITY IN INPUTTING MODEL CODE)............................................495
SERVICE CODE IN ELECTRICAL SYSTEM[E218](DISCONNECTION OF S-NET SIGNAL)..................................................499
SERVICE CODE IN ELECTRICAL SYSTEM[E222](SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................501
SERVICE CODE IN ELECTRICAL SYSTEM[E223](DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................502
SERVICE CODE IN ELECTRICAL SYSTEM[E224](ABNORMALITY IN F PUMP PRESSURE SENSOR)..........................................503
SERVICE CODE IN ELECTRICAL SYSTEM[E225](ABNORMALITY IN R PUMP PRESSURE SENSOR)..........................................505
SERVICE CODE IN ELECTRICAL SYSTEM[E226](ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)....................................507
SERVICE CODE IN ELECTRICAL SYSTEM[E227](ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................509
SERVICE CODE IN ELECTRICAL SYSTEM[E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................510
SERVICE CODE IN ELECTRICAL SYSTEM[E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................511
SERVICE CODE IN ELECTRICAL SYSTEM[E233](DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................513
SERVICE CODE IN ELECTRICAL SYSTEM[E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................515
SERVICE CODE IN ELECTRICAL SYSTEM[E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................517
SERVICE CODE IN ELECTRICAL SYSTEM[E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY)....518
SERVICE CODE IN ELECTRICAL SYSTEM[E256](INCORRECT NONVOLATILE MEMORY DATA)..............................................519
SERVICE CODE IN ELECTRICAL SYSTEM[E306](ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................520
SERVICE CODE IN ELECTRICAL SYSTEM[E308](ABNORMALITY IN FULE DIAL).......................................................522
SERVICE CODE IN ELECTRICAL SYSTEM[E315](SHORT-CIRCUITING IN BATTERY RELAY)..............................................524
SERVICE CODE IN ELECTRICAL SYSTEM[E316](STEP-OUT IN GOVERNOR MOTOR).....................................................526
SERVICE CODE IN ELECTRICAL SYSTEM[E317](DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................527
SERVICE CODE IN ELECTRICAL SYSTEM[E318](SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B).........................529
SERVICE CODE IN ELECTRICAL SYSTEM[E501]("MODEL SELECTION" FUNCTION NOT PROVIDED YET)....................................531
SERVICE CODE IN ELECTRICAL SYSTEM[E502](MODEL SELECTING SIGNAL FAULT)...................................................532
FAILURE CODE IN MECHANICAL SYSTEM[A000N1](OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING)...................................533
FAILURE CODE IN MECHANICAL SYSTEM[A000N2](OUT-OF-RATE ENGINE ROTATION AT LOW IDLING)....................................533
FAILURE CODE IN MECHANICAL SYSTEM[AA10NX](AIR CLEANER CLOGGING).........................................................534
FAILURE CODE IN MECHANICAL SYSTEM[ABOOKE](ABNORMALLY LOWERED CHARGING VOLTAGE)..........................................535
FAILURE CODE IN MECHANICAL SYSTEM[B@BAZG](ABNORMALLY LOWERED ENGINE OIL PRESSURE).......................................538
FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED ENGINE OIL LEVEL)..........................................539
FAILURE CODE IN MECHANICAL SYSTEM[B@BCNS](ENGINE COOLING WATER OVERHEATING).............................................540
FAILURE CODE IN MECHANICAL SYSTEM[B@BCZK](ABNORMALLY LOWERED RADIATOR WATER LEVEL)......................................541
FAILURE CODE IN MECHANICAL SYSTEM[B@HANS](HYDRAULIC OIL OVERHEATING)....................................................542
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)................................................................................543
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................544
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE...........................................................................545
E-1 ENGINE DOES NOT START(ENGINE DOES NOT ROTATE).......................................................................546
E-2 ENGINE STOPS WHILE IN OPERATION.....................................................................................550
E-3 ENGINE SPEED IS IRREGULAR,OR THERE IS HUNTING.......................................................................551
E-4 ENGINE DOES NOT STOP................................................................................................554
E-5 AUTO-DECELERATOR DOES NOT WORK......................................................................................557
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK............................................................................558
E-7 PREHEATER DOES NOT WORK.............................................................................................559
E-8 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE.....................................................................561
E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK............................................................................563
E-10 NO DISPLAY IN MONITOR PANEL AT ALL ................................................................................564
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING........................................................................565
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL............................................................565
E-13 FULE LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING......................................................566
E-14 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.................................................567
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................................568
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..............................................................................569
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY......................................................................570
E-18 WHEN THE MONITOR SWITCH IS OPERATED,NO DISPLAY APPEARS.............................................................572
E-19 WINDSHIELD WIPER DOES NOT WORK.....................................................................................573
E-20 ALARMING BUZZER CANNOT BE CANCELLED................................................................................575
E-21 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................................576
E-22 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................................577
E-23 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................578
E-24 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................579
E-25 "BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....................................................580
E-26 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....................................................581
E-27 "SWING" IS NOT CORRECTLY DISPLAYED IS MONITOR FUNCTION.............................................................582
E-28 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION ...........................................................584
E-29 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................586
E-30 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................................588
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.........................................................................590
E-32 TRAVEL ALARM DOES NOT SOUND........................................................................................602
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).................................................................603
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS.......................................................................604
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................606
H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW...................................................607
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS.........................................................................608
H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE .............................................................................609
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP..................................................................609
H-5 AUTO-DECELERATOR DOES NOT WORK......................................................................................610
H-6 FINE CONTROL MODE DOES NOT FUNCTION.................................................................................610
H-7 BOOM MOVES SLOWLY OR LACKS POWER....................................................................................611
H-8 ARM MOVES SLOWLY OR LACKS POWER.....................................................................................612
H-9 BUCKET MOVES SLOWLY OR LACKS POWER..................................................................................613
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION...............................................................613
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT..................................................................614
H-12 WORK EQUIPMENT HAS BIG TIME LAG ...................................................................................615
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...........................................................615
H-14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE.......................................................................615
H-15 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGE LOAD MOVES SLOWLY..................................................616
H-16 IN SWING+BOOM RAISE OPERATION,BOOM MOVES SLOWLY....................................................................616
H-17 IN SWING+TRAVEL TRAVEL SPEED DROPS SHARPLY.........................................................................616
H-18 MACHINE SWERVES IN TRAVEL..........................................................................................617
H-19 MACHINE TRAVELS SLOWLY.............................................................................................618
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER....................................................................619
H-21 TRAVEL SPEED DOES NOT SHIFT,OR IT IS TOO SLOW OR FAST..............................................................620
H-22 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY).........................................................................621
H-23 MACHINE DOES NOT SWING.............................................................................................622
H-24 SWING ACCELERATION IS POOR ,OR SWING SPEED IS SLOW.................................................................623
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING..............................................................................624
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING.............................................................................625
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING.............................................................625
H-28 SWING NATURAL DRIFT IS TOO BIG.....................................................................................626
TROUBLESHOOTING OF ENGINE (S-MODE)..........................................................................................627
METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................628
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)............................................................632
S-2 ENGINE DOES NOT START...............................................................................................634
(1) ENGINE DOES NOT TURN............................................................................................634
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)........................................635
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).......................................636
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................637
S-4 ENGIEN STOPS DURING OPERATIONS ....................................................................................638
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)............................................................................639
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................640
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................641
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................642
S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................643
S-10 FUEL CONSUMPTION IS EXCESSIVE .....................................................................................644
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..............................................645
S-12 OIL PRESSURE MONITOR LIGHTS UP(DROP IN OIL PRESSURE)...............................................................646
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)................................................................................647
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)....................................................................648
S-15 ABNORMAL NOISE IS MADE.............................................................................................649
S-16 VIBRATION IS EXCESSIVE.............................................................................................650
30 DISASSEMBLY AND ASSEMBLY.........................................................................................................651
HOW TO READ THIS MANUAL ........................................................................................................653
REMOVEL AND INSTALLATION OF ASSEMBLIES......................................................................................653
DISASSEMBLY AND ASSEMBLY OF ASSEMBLES.......................................................................................654
PRECAUTION WHEN PERFORMING OPERATION............................................................................................655
SPECIAL TOOL LIST...............................................................................................................657
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY.............................................................................661
REMOVAL.....................................................................................................................661
INSTALLATION................................................................................................................661
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY........................................................................662
SPECIALTOOLS................................................................................................................662
REMOVAL.....................................................................................................................662
INSTALLATION................................................................................................................664
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...................................................................................666
SPECIAL TOOLS...............................................................................................................666
REMOVAL.....................................................................................................................666
INSTALLATION................................................................................................................666
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL....................................................................................668
REMOVAL.....................................................................................................................668
INSTALLATION................................................................................................................669
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..............................................................................670
SPECIAL TOOLS...............................................................................................................670
REMOVAL.....................................................................................................................670
INSTALLATION................................................................................................................673
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...................................................................................676
REMOVAL.....................................................................................................................676
INSTALLATION................................................................................................................677
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.......................................................................678
REMOVAL.....................................................................................................................678
INSTALLATION................................................................................................................679
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES................................................................680
SPECIAL TOOLS...............................................................................................................680
REMOVAL.....................................................................................................................680
INSTALLATION................................................................................................................684
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY................................................................................686
REMOVAL.....................................................................................................................686
INSTALLATION................................................................................................................686
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY...................................................................................687
SPECIAL TOOLS...............................................................................................................687
DISASSEMBLY.................................................................................................................687
ASSEMBLY....................................................................................................................689
SKETCHES OF SPECIAL TOOLS.......................................................................................................694
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................695
REMOVAL.....................................................................................................................695
INSTALLATION................................................................................................................695
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................696
SPECIAL TOOLS...............................................................................................................696
DISASSEMBLY.................................................................................................................696
ASSEMBLY....................................................................................................................698
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................703
SPECIAL TOOLS...............................................................................................................703
DISASSEMBLY.................................................................................................................703
ASSEMBLY....................................................................................................................705
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.............................................................................710
SPECIAL TOOLS...............................................................................................................710
ASSEMBLY....................................................................................................................710
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...............................................................................711
SPECIAL TOOLS...............................................................................................................711
ASSEMBLY....................................................................................................................711
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY......................................................................................712
SPECIAL TOOLS...............................................................................................................712
DISASSEMBLY.................................................................................................................712
ASSEMBLY....................................................................................................................713
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY..............................................................................715
SPECIAL TOOLS...............................................................................................................715
DISASSEMBLY.................................................................................................................715
ASSEMBLY....................................................................................................................716
REMOVAL AND INSTALLATION OF SPROCKET............................................................................................717
REMOVAL.....................................................................................................................717
INSTALLATION................................................................................................................717
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.................................................................................718
SPECIAL TOOLS...............................................................................................................718
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY(IRON)..........................................................................718
INSTALLATION................................................................................................................719
REMOVAL AND EXPANSION OF ROAD LINERS........................................................................................720
INSTALLATION OF ROAD LINERS.................................................................................................721
REMOVAL AND INSTALLATION OF SWING CIRCUIT ASSEMBLY..............................................................................722
REMOVAL.....................................................................................................................722
INSTALLATION................................................................................................................722
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY............................................................................723
REMOVAL.....................................................................................................................723
INSTALLATION................................................................................................................724
REMOVAL AND INSTALLATION OF CENTER SWIVEL JIONT ASSEMBLY........................................................................725
REMOVAL.....................................................................................................................725
INSTALLATION................................................................................................................726
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY........................................................................727
SPECIAL TOOLS...............................................................................................................727
DISASSEMBLY.................................................................................................................727
ASSEMBLY....................................................................................................................727
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............................................................................728
REMOVAL.....................................................................................................................728
INSTALLATION................................................................................................................729
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY..............................................................................730
REMOVAL.....................................................................................................................730
INSTALLATION................................................................................................................732
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY..............................................................................733
SPECIAL TOOLS...............................................................................................................733
ASSEMBLY....................................................................................................................734
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.............................................................................736
SPECIAL TOOLS...............................................................................................................736
REMOVAL.....................................................................................................................736
INSTALLATION................................................................................................................738
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT..............................................................739
SPECIAL TOOLS...............................................................................................................739
REMOVAL.....................................................................................................................739
INSTALLATION................................................................................................................739
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...................................................................740
ASSEMBLY....................................................................................................................740
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...................................................................741
ASSEMBLY....................................................................................................................741
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...........................................................................742
ASSEMBLY....................................................................................................................742
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.........................................................................743
SPECIAL TOOLS...............................................................................................................743
DISASSEMBLY.................................................................................................................743
ASSEMBLY....................................................................................................................745
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.............................................................................749
SPECIAL TOOLS...............................................................................................................749
REMOVAL.....................................................................................................................749
INSTALLATION................................................................................................................750
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.......................................................................752
SPECIAL TOOLS...............................................................................................................752
REMOVAL.....................................................................................................................752
INSTALLATION................................................................................................................754
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.......................................................................755
SPECIAL TOOLS...............................................................................................................755
REMOVAL.....................................................................................................................755
INSTALLATION................................................................................................................756
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY..............................................................................757
REMOVAL.....................................................................................................................757
INSTALLATION................................................................................................................757
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.............................................................................758
REMOVAL.....................................................................................................................758
INSTALLATION................................................................................................................759
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.............................................................................760
REMOVAL.....................................................................................................................760
INSTALLATION................................................................................................................762
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...................................................................763
SPECIAL TOOLS...............................................................................................................764
REMOVAL.....................................................................................................................764
INSTALLATION................................................................................................................765
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...............................................................................773
REMOVAL.....................................................................................................................773
INSTALLATION................................................................................................................775
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY....................................................................................778
REMOVAL.....................................................................................................................778
REMOVAL AND INSTALLATION OF GOVERNOR,PUMP CONTROLLER ASSEMBLY...................................................................779
REMOVAL.....................................................................................................................779
INSTALLATION................................................................................................................779
90 OTHERS...........................................................................................................................780
HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................781
PC200-7,PC200LC-7...........................................................................................................781
PC220-7,PC220LC-7...........................................................................................................782
ELECTRICAL CIRCUIT DIAGRAM .....................................................................................................783
PC200-7,PC200LC-7(SERIAL NO. 200001-250000) PC220-7,PC220LC-7(SERIAL NO. 60001-65000).......................................783
FOR MULTI MONITOR.......................................................................................................783
FOR 7-SEGMENT MONITOR...................................................................................................787
PC200-7,PC200LC-7 (SERIAL NO. 250001 AND UP) PC220-7,PC220LC-7 (SERIAL NO. 65001 AND UP)....................................791
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER..................................................................................795DESCRIPTION:
KOMATSU PC200, 200LC-7 PC220, 220LC-7 SHOP MANUAL SEBM024310 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
