Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM010106 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6 Shop Manual.pdf
SEAM002403 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual.pdf
SEAM002405 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual.pdf
SEAM002406 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual.pdf
SEAM002407 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual.pdf
SEAM002410T – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,665 pages
File Format: PDF
Language: English
SEAM002403 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual….2
1. FOREWORD….4
2. SAFETY INFORMATION….5
3. INTRODUCTION….6
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….7
5. CONTENTS….8
SAFETY….12
6. GENERAL PRECAUTIONS….13
7. PRECAUTIONS DURING OPERATION….19
7.1 BEFORE STARTING ENGINE….19
7.2 OPERATING MACHINE….21
7.3 TRANSPORTATION….26
7.4 BATTERY….27
7.5 TOWING….28
7.6 BUCKET WITH HOOK….29
8. PRECAUTIONS FOR MAINTENANCE….32
8.1 BEFORE CARRYING OUT MAINTENANCE….32
8.2 DURING MAINTENANCE….35
9. POSITION FOR ATTACHING SAFETY LABELS….39
OPERATION….43
10. GENERAL VIEW….44
10.1 GENERAL VIEW OF MACHINE….44
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….45
11. EXPLANATION OF COMPONENTS….46
11.1 MACHINE MONITOR….46
11.2 METER….57
11.3 SWITCHES….58
11.4 CONTROL LEVERS, PEDALS….62
11.5 CEILING WINDOW….67
11.6 FRONT WINDOW….68
11.7 DOOR LOCK….70
11.8 CAP, COVER WITH LOCK….71
11.9 HOT/COOL BOX….72
11.10 LUGGAGE BOX….72
11.11 ASHTRAY….72
11.12 AIR CONDITIONER….73
11.13 CAR RADIO….76
11.14 FUSE….80
11.15 FUSIBLE LINK….81
11.16 CONTROLLERS….81
11.17 TOOL BOX….81
11.18 GREASE PUMP HOLDER….81
11.19 HANDLING ACCUMULATOR….82
12. OPERATION….84
12.1 CHECK BEFORE STARTING ENGINE….84
12.2 STARTING ENGINE….94
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….97
12.4 MOVING MACHINE OFF….103
12.5 STEERING MACHINE….106
12.6 STOPPING MACHINE….108
12.7 SWINGING….109
12.8 OPERATION OF WORK EQUIPMENT….110
12.9 WORKING MODE SELECTION….111
12.10 PROHIBITIONS FOR OPERATION….113
12.11 PRECAUTIONS FOR OPERATION….115
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….116
12.13 HOW TO ESCAPE FROM MUD….118
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….119
12.15 REPLACEMENT AND INVERSION OF BUCKET….120
12.16 PARKING MACHINE….122
12.17 CHECK AFTER FINISHING WORK….123
12.18 STOPPING ENGINE….124
12.19 CHECK AFTER STOPPING ENGINE….125
12.20 LOCKING….125
13. TRANSPORTATION….126
13.1 LOADING, UNLOADING WORK….126
13.2 PRECAUTIONS FOR LOADING….128
13.3 PRECAUTIONS FOR TRANSPORTATION….129
14. COLD WEATHER OPERATION….130
14.1 PRECAUTIONS FOR LOW TEMPERATURE….130
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….132
14.3 AFTER COLD WEATHER….132
15. LONG-TERM STORAGE….133
15.1 BEFORE STORAGE….133
15.2 DURING STORAGE….134
15.3 AFTER STORAGE….134
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….134
16. TROUBLESHOOTING….135
16.1 PHENOMENA THAT ARE NOT FAILURES….135
16.2 METHOD OF TOWING MACHINE….135
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE….135
16.4 PRECAUTIONS ON PARTICULAR JOBSITES….136
16.5 IF BATTERY IS DISCHARGED….136
16.6 OTHER TROUBLE….140
MAINTENANCE….145
17. GUIDES TO MAINTENANCE….146
18. OUTLINES OF SERVICE….149
18.1 OUTLINE OF OIL, FUEL, COOLANT….149
18.2 OUTLINE OF ELECTRIC SYSTEM….152
18.3 OUTLINE OF HYDRAULIC SYSTEM….153
19. WEAR PARTS LIST….154
20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….156
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….160
21.1 INTRODUCTION OF NECESSARY TOOLS….160
21.2 TORQUE LIST….161
23. MAINTENANCE SCHEDULE CHART….164
23.1 MAINTENANCE SCHEDULE CHART….164
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….166
24. SERVICE PROCEDURE….167
24.1 INITIAL 250 HOURS SERVICE….167
24.2 WHEN REQUIRED….168
24.3 CHECK BEFORE STARTING….188
24.4 EVERY 100 HOURS SERVICE….193
24.5 EVERY 250 HOURS SERVICE….196
24.6 EVERY 500 HOURS SERVICE….203
24.7 EVERY 1000 HOURS SERVICE….210
24.8 EVERY 2000 HOURS SERVICE….213
24.9 EVERY 4000 HOURS SERVICE….220
SPECIFICATIONS….221
25. SPECIFICATIONS….222
OPTIONS, ATTACHMENTS….230
26. GENERAL PRECAUTIONS….231
26.1 PRECAUTIONS RELATED TO SAFETY….231
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….232
27. HANDLING BUCKET WITH HOOK….233
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….233
27.2 PROHIBITED OPERATIONS….233
27.3 PRECAUTIONS DURING OPERATIONS….233
28. USING SEAT BELT….234
28.1 SEAT BELT….234
29. HANDLING CAR HEATER….236
29.1 EXPLANATION OF COMPONENTS….236
29.2 PREPARING CAR HEATER….237
30. MACHINES READY FOR ATTACHMENTS….238
30.1 EXPLANATION OF COMPONENTS….238
30.2 HYDRAULIC CIRCUIT….240
31.3 SELECTION OF TRACK SHOES….251
30.4 OPERATION….244
30.5 LONG-TERM STORAGE….245
30.6 SPECIFICATIONS….245
31. INTRODUCTION OF ATTACHMENTS….246
31.1 SPECIFICATION, USE….246
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE….248
31.3 SELECTION OF TRACK SHOES….251
31.4 SELECTION OF BUCKET TEETH….252
31.5 HANDLING RUBBER PAD SHOE….253
31.6 HANDLING TRAPEZOIDAL BUCKET….255
31.7 HANDLING EXTENSION ARM….256
31.8 HANDLING CLAMSHELL BUCKET….257
32. EXTENDING MACHINE SERVICE LIFE….258
32.1 HYDRAULIC BREAKER….258
32.2 POWER RIPPER….261
32.3 FORK GRAB….262
32.4 GRAPPLE BUCKET….263
32.5 SCRAP GRAPPLE….264
32.6 CRUSHER & CUTTER….265
32.7 HYDRAULIC PILE DRIVER….266
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….267
SEAM002405 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual….269
COVER….269
1.FOREWORD….270
2.SAFETY INFORMATION….271
3.INTRODUCTION….272
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….273
5.CONTENTS….274
SAFETY….278
6.GENERAL PRECAUTIONS….279
7.PRECAUTIONS DURING OPERATION….285
7.1 BEFORE STARTING ENGINE….285
7.2 OPERATING MACHINE….287
7.3 TRANSPORTATION….292
7.4 BATTERY….293
7.5 TOWING….294
7.6 BUCKET WITH HOOK….295
8.PRECAUTIONS FOR MAINTENANCE….298
8.1 BEFORE CARRYING OUT MAINTENANCE….298
8.2 DURING MAINTENANCE….301
9.POSITION FOR ATTACHING SAFETY LABELS….305
OPERATION….309
10.GENERAL VIEW….310
10.1 GENERAL VIEW OF MACHINE….310
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….311
11.EXPLANATION OF COMPONENTS….312
11.1 MACHINE MONITOR….312
11.2 SWITCHES….323
11.3 CONTROL LEVERS, PEDALS….327
11.4 CEILING WINDOW….332
11.5 FRONT WINDOW….333
11.6 DOOR LOCK….335
11.7 CAP,COVER WITH LOCK….336
11.8 HOT/COOL BOX….337
11.9 LUGGAGE BOX….337
11.10 ASHTRAY….337
11.11 AIR CONDITIONER….338
11.12 CAR RADIO….341
11.13 FUSE ….346
11.14 FUSIBLE LINK….347
11.15 CONTROLLERS….347
11.16 TOOL BOX….347
11.17 GREASE PUMP HOLDER….347
11.18 HANDLING ACCUMULATOR….348
12.OPERATION….350
12.1 CHECK BEFORE STARTING ENGINE….350
12.2 STARTING ENGINE….360
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….363
12.4 MOVING MACHINE OFF….369
12.5 STEERING MACHINE….372
12.6 STOPPING MACHINE….374
12.7 SWINGING….375
12.8 OPERATION OF WORK EQUIPMENT….376
12.9 HANDLING ACTIVE MODE….377
12.10 WORKING MODE SELECTION….378
12.11 PROHIBITIONS FOR OPERATION….380
12.12 PRECAUTIONS FOR OPERATION….382
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….383
12.14 HOW TO ESCAPE FROM MUD….385
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….386
12.16 REPLACEMENT AND INVERSION OF BUCKET….387
12.17 PARKING MACHINE….389
12.18 CHECK AFTER FINISHING WORK….390
12.19 STOPPING ENGINE….391
12.20 CHECK AFTER STOPPING ENGINE….392
12.21 LOCKING….392
13.TRANSPORTATION….393
13.1 LOADING,UNLOADING WORK….393
13.2 PRECAUTIONS FOR LOADING….395
13.3 PRECAUTIONS FOR TRANSPORTATION….396
14.COLD WEATHER OPERATION….397
14.1 PRECAUTIONS FOR LOW TEMPERATURE….397
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….399
14.3 AFTER COLD WEATHER….399
15.LONG-TERM STORAGE….400
15.1 BEFORE STORAGE….400
15.2 DURING STORAGE….401
15.3 AFTER STORAGE….401
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….401
16.TROUBLESHOOTING….402
16.1 PHENOMENA THAT ARE NOT FAILURES….402
16.2 METHOD OF TOWING MACHINE….402
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE….402
16.4 PRECAUTIONS ON PARTICULAR JOBSITES….403
16.5 IF BATTERY IS DISCHARGED….403
16.6 OTHER TROUBLE….407
MAINTENANCE ….412
17.GUIDES TO MAINTENANCE….413
18.OUTLINES OF SERVICE….416
18.1 OUTLINE OF OIL,FUEL,COOLANT….416
18.2 OUTLINE OF ELECTRIC SYSTEM….419
18.3 OUTLINE OF HYDRAULIC SYSTEM….420
19.WEAR PARTS LIST….421
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….423
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….427
21.1 INTRODUCTION OF NECESSARY TOOLS….427
21.2 TORQUE LIST….428
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….429
23.MAINTENANCE SCHEDULE CHART….431
23.1 MAINTENANCE SCHEDULE CHART….431
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….433
24.SERVICE PROCEDURE….434
24.1 INITIAL 250 HOURS SERVICE….434
24.2 WHEN REQUIRED….435
24.3 CHECK BEFORE STARTING….455
24.4 EVERY 100 HOURS SERVICE….460
24.5 EVERY 250 HOURS SERVICE….463
24.6 EVERY 500 HOURS SERVICE….470
24.7 EVERY 1000 HOURS SERVICE….477
24.8 EVERY 2000 HOURS SERVICE….480
24.9 EVERY 4000 HOURS SERVICE….487
SPECIFICATIONS….488
25.SPECIFICATIONS….489
OPTIONS,ATTACHMENTS….497
26.GENERAL PRECAUTIONS….498
26.1 PRECAUTIONS RELATED TO SAFETY….498
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….499
27.HANDLING BUCKET WITH HOOK….500
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….500
27.2 PROHIBITED OPERATIONS….500
27.3 PRECAUTIONS DURING OPERATIONS….500
28.USING SEAT BELT….501
28.1 SEAT BELT….501
29.HANDLING CAR HEATER….503
29.1 EXPLANATION OF COMPONENTS….503
29.2 PREPARING CAR HEATER….504
30.MACHINES READY FOR ATTACHMENT….505
30.1 EXPLANATION OF COMPONENTS….505
30.2 HYDRAULIC CIRCUIT….507
30.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE….509
30.4 OPERATION….511
30.5 LONG-TERM STORAGE….512
30.6 SPECIFICATIONS….512
31.INTRODUCTION OF ATTACHMENTS….513
31.1 SPECIFICATION,USE….513
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE….515
31.3 SELECTION OF TRACK SHOES….518
31.4 SELECTION OF BUCKET TEETH….519
31.5 HANDLING RUBBER PAD SHOE….520
31.6 HANDLING TRAPEZOIDAL BUCKET….522
31.7 HANDLING EXTENSION ARM….523
31.8 HANDLING CLAMSHELL BUCKET….524
31.9 HANDLING VARIABLE 2-PIECE BOOM,ROTATING ARM….525
32.EXTENDING MACHINE SERVICE LIFE….534
32.1 HYDRAULIC BREAKER….534
32.2 POWER RIPPER….537
32.3 FORK GRAB….538
32.4 GRAPPLE BUCKET….539
32.5 SCRAP GRAPPLE….540
32.6 CRUSHER & CUTTER….541
32.7 HYDRAULIC PILE DRIVER….542
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….543
SEAM002406 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual….544
1. FOREWORD….546
2. SAFETY INFORMATION….547
3. INTRODUCTION….548
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….549
5. CONTENTS….550
SAFETY….554
6. GENERAL PRECAUTIONS….555
7. PRECAUTIONS DURING OPERATION….562
7.1 BEFORE STARTING ENGINE….562
7.2 AFTER STARTING ENGINE….564
7.3 TRANSPORTATION….571
7.4 BATTERY….572
7.5 TOWING….574
7.6 LIFTING OPERATIONS….574
8. PRECAUTIONS FOR MAINTENANCE….575
8.1 BEFORE CARRYING OUT MAINTENANCE….575
8.2 DURING MAINTENANCE….579
9. POSITION FOR ATTACHING SAFETY LABELS….584
OPERATION….588
10. GENERAL VIEW….589
10.1 GENERAL VIEW OF MACHINE….589
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….590
11. EXPLANATION OF COMPONENTS….591
11.1 MACHINE MONITOR….591
11.2 SWITCHES….602
11.3 CONTROL LEVERS, PEDALS….606
11.4 CEILING WINDOW….611
11.5 FRONT WINDOW….612
11.6 DOOR LOCK….614
11.7 CAP, COVER WITH LOCK….615
11.8 HOT/COOL BOX….616
11.9 LUGGAGE BOX….616
11.10 ASHTRAY….616
11.11 AIR CONDITIONER….617
11.12 CAR RADIO….620
11.13 FUSE….625
11.14 FUSIBLE LINK….626
11.15 CONTROLLERS….626
11.16 TOOL BOX….626
11.17 GREASE PUMP HOLDER….626
11.18 HANDLING ACCUMULATOR….627
12. OPERATION….629
12.1 CHECK BEFORE STARTING ENGINE….629
12.2 STARTING ENGINE….639
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….642
12.4 MOVING MACHINE OFF….648
12.5 STEERING MACHINE….651
12.6 STOPPING MACHINE….653
12.7 SWINGING….654
12.8 OPERATION OF WORK EQUIPMENT….655
12.9 HANDLING ACTIVE MODE….656
12.10 WORKING MODE SELECTION….658
12.11 PROHIBITIONS FOR OPERATION….660
12.12 PRECAUTIONS FOR OPERATION….662
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….663
12.14 HOW TO ESCAPE FROM MUD….665
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….666
12.16 REPLACEMENT AND INVERSION OF BUCKET….667
12.17 PARKING MACHINE….669
12.18 CHECK AFTER FINISHING WORK….670
12.19 STOPPING ENGINE….671
12.20 CHECK AFTER STOPPING ENGINE….672
12.21 LOCKING….672
13. TRANSPORTATION….673
13.1 LOADING, UNLOADING WORK….673
13.2 PRECAUTIONS FOR LOADING….675
13.3 PRECAUTIONS FOR TRANSPORTATION….676
14. COLD WEATHER OPERATION….677
14.1 PRECAUTIONS FOR LOW TEMPERATURE….677
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….679
14.3 AFTER COLD WEATHER….679
15. LONG-TERM STORAGE….680
15.1 BEFORE STORAGE….680
15.2 DURING STORAGE….681
15.3 AFTER STORAGE….681
15.4 STORING MACHINE AFTER STORAGE….681
16. TROUBLESHOOTING….682
16.1 PHENOMENA THAT ARE NOT FAILURES….682
16.2 METHOD OF TOWING MACHINE….682
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE….682
16.4 PRECAUTIONS ON PARTICULAR JOBSITES….683
16.5 IF BATTERY IS DISCHARGED….683
16.6 OTHER TROUBLE….687
MAINTENANCE….692
17. GUIDES TO MAINTENANCE….693
18. OUTLINES OF SERVICE….696
18.1 OUTLINE OF OIL, FUEL, COOLANT….696
18.2 OUTLINE OF ELECTRIC SYSTEM….699
18.3 OUTLINE OF HYDRAULIC SYSTEM….700
19. WEAR PARTS LIST….701
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….703
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….707
21.1 INTRODUCTION OF NECESSARY TOOLS….707
21.2 TORQUE LIST….708
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….709
23. MAINTENANCE SCHEDULE CHART….713
23.1 MAINTENANCE SCHEDULE CHART….713
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….715
24. SERVICE PROCEDURE….716
24.1 INITIAL 250 HOURS SERVICE….716
24.2 WHEN REQUIRED….717
24.3 CHECK BEFORE STARTING….735
24.4 EVERY 100 HOURS SERVICE….740
24.5 EVERY 250 HOURS SERVICE….743
24.6 EVERY 500 HOURS SERVICE….749
24.7 EVERY 1000 HOURS SERVICE….754
24.8 EVERY 2000 HOURS SERVICE….757
24.9 EVERY 4000 HOURS SERVICE….760
24.10 EVERY 5000 HOURS SERVICE….761
SPECIFICATIONS….766
25. SPECIFICATIONS….767
OPTIONS, ATTACHMENTS….775
26. GENERAL PRECAUTIONS….776
26.1 PRECAUTIONS RELATED TO SAFETY….776
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….777
27. HANDLING BUCKET WITH HOOK….778
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….778
27.2 PROHIBITED OPERATIONS….778
27.3 PRECAUTIONS DURING OPERATIONS….778
28. USING SEAT BELT….779
28.1 SEAT BELT….779
29. HANDLING CAR HEATER….781
29.1 EXPLANATION OF COMPONENTS….781
29.2 PREPARING CAR HEATER….782
30. MACHINES READY FOR ATTACHMENTS….783
30.1 EXPLANATION OF COMPONENTS….783
30.2 HYDRAULIC CIRCUIT….785
30.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE….787
30.4 OPERATION….789
30.5 LONG-TERM STORAGE….790
30.6 SPECIFICATIONS….790
31. INTRODUCTION OF ATTACHMENTS….791
31.1SPECIFICATION, USE….791
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE….793
31.3 SELECTION OF TRACK SHOES….796
31.4 SELECTION OF BUCKET TEETH….797
31.5 HANDLING RUBBER PAD SHOE….798
31.6 HANDLING TRAPEZOIDAL BUCKET….800
31.7 HANDLING EXTENSION ARM….801
31.8 HANDLING CLAMSHELL BUCKET….802
31.9 HANDLING VARIABLE 2-PIECE BOOM, ROTATING ARM….803
32. EXTENDING MACHINE SERVICE LIFE….812
32.1 HYDRAULIC BREAKER….812
32.2 POWER RIPPER….815
32.3 FORK GRAB….816
32.4 GRAPPLE BUCKET….817
32.5 SCRAP GRAPPLE….818
32.6 CRUSHER & CUTTER….819
32.7 HYDRAULIC PILE DRIVER….820
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….821
SEAM002407 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual….823
COVER….823
1. FOREWORD….824
2. SAFETY INFORMATION….825
3. INTRODUCTION….826
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….827
5. CONTENTS….828
SAFETY….832
6. GENERAL PRECAUTIONS….833
7. PRECAUTIONS DURING OPERATION….840
7.1 BEFORE STARTING ENGINE….840
7.2 AFTER STARTING ENGINE….842
7.3 TRANSPORTATION….849
7.4 BATTERY….850
7.5 TOWING….852
7.6 LIFTING OPERATIONS….852
8. PRECAUTIONS FOR MAINTENANCE….853
8.1 BEFORE CARRYING OUT MAINTENANCE….853
8.2 DURING MAINTENANCE….857
9. POSITION FOR ATTACHING SAFETY LABELS….863
OPERATION….868
10. GENERAL VIEW….869
10.1 GENERAL VIEW OF MACHINE….869
10.2 GENERAL VIEW OF CONTROL AND GAUGES….870
11. EXPLANATION OF COMPONENTS….871
11.1 MACHINE MONITOR….871
11.2 SWITCHES….882
11.3 CONTROL LEVERS, PEDALS….886
11.4 CEILING WINDOW….891
11.5 FRONT WINDOW….892
11.6 DOOR LOCK….894
11.7 CAP, COVER WITH LOCK….895
11.8 HOT/COOL BOX….896
11.9 LUGGAGE BOX….896
11.10 ASHTRAY….896
11.11 AIR CONDITIONER….897
11.12 CAR RADIO….900
11.13 FUSE….905
11.14 FUSIBLE LINK….906
11.15 CONTROLLERS….906
11.16 TOOL BOX….906
11.17 GREASE PUMP HOLDER….906
11.18 HANDLING ACCUMULATOR….907
12. OPERATION….909
12.1 CHECK BEFORE STARTING ENGINE….909
12.2 STARTING ENGINE….919
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….922
12.4 MOVING MACHINE OFF….928
12.5 STEERING MACHINE….931
12.6 STOPPING MACHINE….933
12.7 SWINGING….934
12.8 OPERATION OF WORK EQUIPMENT….935
12.9 HANDLING ACTIVE MODE….936
12.10 WORKING MODE SELECTION….938
12.11 PROHIBITIONS FOR OPERATION….940
12.12 PRECAUTIONS FOR OPERATION….942
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….943
12.14 HOW TO ESCAPE FROM MUD….945
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….946
12.16 REPLACEMENT AND INVERSION OF BUCKET….947
12.17 PARKING MACHINE….949
12.18 CHECK AFTER FINISHING WORK….950
121.9 STOPPING ENGINE….951
12.20 CHECK AFTER STOPPING ENGINE….952
12.21 LOCKING….952
13. TRANSPORTATION….953
13.1 LOADING, UNLOADING WORK….953
13.2 PRECAUTIONS FOR LOADING….955
13.3 PRECAUTIONS FOR TRANSPORTATION….956
14. COLD WEATHER OPERATION….957
14.1 PRECAUTIONS FOR LOW TEMPERATURE….957
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….959
14.3 AFTER COLD WEATHER….959
15. LONG-TERM STORAGE….960
15.1 BEFORE STORAGE….960
15.2 DURING STORAGE….961
15.3 AFTER STORAGE….961
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….961
16. TROUBLESHOOTING….962
16.1 PHENOMENA THAT ARE NOT FAILURES….962
16.2 METHOD OF TOWING MACHINE….962
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE….962
16.4 PRECAUTIONS ON PARTICULAR JOBSITES….963
16.5 IF BATTERY IS DISCHARGED….963
16.6 OTHER TROUBLE….967
MAINTENANCE….972
17. GUIDES TO MAINTENANCE….973
18. OUTLINES OF SERVICE….976
18.1 OUTLINE OF OIL, FUEL, COOLANT….976
18.2 OUTLINE OF ELECTRIC SYSTEM….979
18.3 OUTLINE OF HYDRAULIC SYSTEM….980
19. WEAR PARTS LIST….981
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….983
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….987
21.1 INTRODUCTION OF NECESSARY TOOLS….987
21.2 TORQUE LIST….988
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….989
23. MAINTENANCE SCHEDULE CHART….993
23.1 MAINTENANCE SCHEDULE CHART….993
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….995
24. SERVICE PROCEDURE….996
24.1 INITIAL 250 HOURS SERVICE….996
24.2 WHEN REQUIRED….997
24.3 CHECK BEFORE STARTING….1015
24.4 EVERY 100 HOURS SERVICE….1020
24.5 EVERY 250 HOURS SERVICE….1023
24.6 EVERY 500 HOURS SERVICE….1029
24.7 EVERY 1000 HOURS SERVICE….1034
24.8 EVERY 2000 HOURS SERVICE….1037
24.9 EVERY 4000 HOURS SERVICE….1040
24.10 EVERY 5000 HOURS SERVICE….1041
SPECIFICATIONS….1046
25. SPECIFICATIONS….1047
OPTIONS, ATTACHMENTS….1056
26. GENERAL PRECAUTIONS….1057
26.1 PRECAUTIONS RELATED TO SAFETY….1057
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….1058
27. HANDLING BUCKET WITH HOOK….1059
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….1059
27.2 PROHIBITED OPERATIONS….1059
27.3 PRECAUTIONS DURING OPERATIONS….1059
28. USING SEAT BELT….1060
28.1 SEAT BELT….1060
29. HANDLING CAR HEATER….1062
29.1 EXPLANATION OF COMPONENTS….1062
29.2 PREPARING CAR HEATER….1063
30. MACHINES READY FOR ATTACHMENTS….1064
30.1 EXPLANATION OF COMPONENTS….1064
30.2 HYDRAULIC CIRCUIT….1066
30.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE….1068
30.4 OPERATION….1070
30.5 LONG-TERM STORAGE….1071
30.6 SPECIFICATIONS….1071
31. INTRODUCTION TO ATTACHMENTS….1072
31.1 SPECIFICATION, USE….1072
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE….1074
31.3 SELECTION OF TRACK SHOES….1077
31.4 SELECTION OF BUCKET TEETH….1078
31.5 HANDLING RUBBER PAD SHOE….1079
31.6 HANDLING TRAPEZOIDAL BUCKET….1081
31.7 HANDLING EXTENSION ARM….1082
31.8 HANDLING CLAMSHELL BUCKET….1083
31.9 HANDLING VARIABLE 2-PIECE BOOM, ROTATING ARM….1084
32. EXTENDING MACHINE SERVICE LIFE….1093
32.1 HYDRAULIC BREAKER….1093
32.2 POWER RIPPER….1097
32.3 FORK GRAB….1098
32.4 GRAPPLE BUCKET….1099
32.5 SCRAP GRAPPLE….1100
32.6 CRUSHER & CUTTER….1101
32.7 HYDRAULIC PILE DRIVER….1102
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….1103
SEAM002410T – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6 Mighty, PC210LC-6 Mighty, PC220-6, PC220LC-6, PC230-6 Mighty, PC230LC-6 Mighty Operation & Maintenance Manual….1106
COVER….1106
1.FOREWORD….1107
2.SAFETY INFORMATION….1110
3.INTRODUCTION….1111
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….1112
5.CONTENTS….1113
SAFETY….1117
6.GENERAL PRECAUTIONS….1118
7.PRECAUTIONS DURING OPERATION….1125
7.1 BEFORE STARTING ENGINE….1125
7.2 AFTER STARTING ENGINE….1127
7.3 TRANSPORTATION….1134
7.4 BATTERY….1135
7.5 TOWING….1137
7.6 LIFTING OPERATIONS….1137
8.PRECAUTIONS FOR MAINTENANCE….1138
8.1 BEFORE CARRYING OUT MAINTENANCE….1138
8.2 DURING MAINTENANCE….1142
9.POSITION FOR ATTACHING SAFETY LABELS….1148
OPERATION….1153
10.GENERAL VIEW….1154
10.1 GENERAL VIEW OF MACHINE….1154
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….1155
11.EXPLANATION OF COMPONENTS….1156
11.1 MACHINE MONITOR….1156
11.2 SWITCHES….1167
11.3 CONTROL LEVERS, PEDALS….1171
11.4 CEILING WINDOW….1176
11.5 FRONT WINDOW….1177
11.6 DOOR LOCK….1179
11.7 CAP,COVER WITH LOCK….1180
11.8 HOT/COOL BOX….1181
11.9 LUGGAGE BOX….1181
11.10 ASHTRAY….1181
11.11 AIR CONDITIONER….1182
11.12 CAR RADIO….1185
11.13 FUSE ….1190
11.14 FUSIBLE LINK….1191
11.15 CONTROLLERS….1191
11.16 TOOL BOX….1191
11.17 GREASE PUMP HOLDER….1191
11.18 HANDLING ACCUMULATOR….1192
12.OPERATION….1194
12.1 CHECK BEFORE STARTING ENGINE….1194
12.2 STARTING ENGINE….1204
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….1207
12.4 MOVING MACHINE OFF….1213
12.5 STEERING MACHINE….1216
12.6 STOPPING MACHINE….1218
12.7 SWINGING….1219
12.8 OPERATION OF WORK EQUIPMENT….1220
12.9 HANDLING ACTIVE MODE….1221
12.10 WORKING MODE SELECTION….1223
12.11 PROHIBITIONS FOR OPERATION….1225
12.12 PRECAUTIONS FOR OPERATION….1227
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….1228
12.14 HOW TO ESCAPE FROM MUD….1230
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR….1231
12.16 REPLACEMENT AND INVERSION OF BUCKET….1232
12.17 PARKING MACHINE….1234
12.18 CHECK AFTER FINISHING WORK….1235
12.19 STOPPING ENGINE….1236
12.20 CHECK AFTER STOPPING ENGINE….1237
12.21 LOCKING….1237
13.TRANSPORTATION….1238
13.1 LOADING,UNLOADING WORK….1238
13.2 PRECAUTIONS FOR LOADING….1240
13.3 PRECAUTIONS FOR TRANSPORTATION….1241
14.COLD WEATHER OPERATION….1242
14.1 PRECAUTIONS FOR LOW TEMPERATURE….1242
14.2 PRECAUTIONS AFTER COMPLETION OF WORK….1244
14.3 AFTER COLD WEATHER….1244
15.LONG-TERM STORAGE….1245
15.1 BEFORE STORAGE….1245
15.2 DURING STORAGE….1246
15.3 AFTER STORAGE….1246
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE….1246
16.TROUBLESHOOTING….1247
16.1 PHENOMENA THAT ARE NOT FAILURES….1247
16.2 METHOD OF TOWING MACHINE….1247
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE….1247
16.4 PRECAUTIONS ON PARTICULAR JOBSITES….1248
16.5 IF BATTERY IS DISCHARGED….1248
16.6 OTHER TROUBLE….1252
MAINTENANCE ….1257
17.GUIDES TO MAINTENANCE….1258
18.OUTLINES OF SERVICE….1261
18.1 OUTLINE OF OIL,FUEL,COOLANT….1261
18.2 OUTLINE OF ELECTRIC SYSTEM….1264
18.3 OUTLINE OF HYDRAULIC SYSTEM….1265
19.WEAR PARTS LIST….1266
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….1268
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1272
21.1 INTRODUCTION OF NECESSARY TOOLS….1272
21.2 TORQUE LIST….1273
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1274
23.MAINTENANCE SCHEDULE CHART….1278
23.1 MAINTENANCE SCHEDULE CHART….1278
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER….1280
24.SERVICE PROCEDURE….1281
24.1 INITIAL 250 HOURS SERVICE….1281
24.2 WHEN REQUIRED….1282
24.3 CHECK BEFORE STARTING….1300
24.4 EVERY 100 HOURS SERVICE….1305
24.5 EVERY 250 HOURS SERVICE….1308
24.6 EVERY 500 HOURS SERVICE….1314
24.7 EVERY 1000 HOURS SERVICE….1319
24.8 EVERY 2000 HOURS SERVICE….1322
24.9 EVERY 4000 HOURS SERVICE….1325
24.10 EVERY 5000 HOURS SERVICE….1326
SPECIFICATIONS….1331
25.SPECIFICATIONS….1332
OPTIONS,ATTACHMENTS….1340
26.GENERAL PRECAUTIONS….1341
26.1 PRECAUTIONS RELATED TO SAFETY….1341
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS….1342
27.HANDLING BUCKET WITH HOOK….1343
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK….1343
27.2 PROHIBITED OPERATIONS….1343
27.3 PRECAUTIONS DURING OPERATIONS….1343
28.USING SEAT BELT….1344
28.1 SEAT BELT….1344
29.HANDLING CAR HEATER….1346
29.1 EXPLANATION OF COMPONENTS….1346
29.2 PREPARING CAR HEATER….1347
30.MACHINES READY FOR ATTACHMENT….1348
30.1 EXPLANATION OF COMPONENTS….1348
30.2 HYDRAULIC CIRCUIT….1350
30.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE….1352
30.4 OPERATION….1354
30.5 LONG-TERM STORAGE….1355
30.6 SPECIFICATIONS….1355
31.INTRODUCTION OF ATTACHMENTS….1356
31.1 SPECIFICATION,USE….1356
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE….1358
31.3 SELECTION OF TRACK SHOES….1361
31.4 SELECTION OF BUCKET TEETH….1362
31.5 HANDLING RUBBER PAD SHOE….1363
31.6 HANDLING TRAPEZOIDAL BUCKET….1365
31.7 HANDLING EXTENSION ARM….1366
31.8 HANDLING CLAMSHELL BUCKET….1367
31.9 HANDLING VARIABLE 2-PIECE BOOM,ROTATING ARM….1368
32.EXTENDING MACHINE SERVICE LIFE….1377
32.1 HYDRAULIC BREAKER….1377
32.2 POWER RIPPER….1381
32.3 FORK GRAB….1382
32.4 GRAPPLE BUCKET….1383
32.5 SCRAP GRAPPLE….1384
32.6 CRUSHER & CUTTER….1385
32.7 HYDRAULIC PILE DRIVER….1386
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE….1387
SEBM010106 – Hydraulic Excavator PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6 Shop Manual….1389
COVER….1389
CONTENTS….1390
SAFETY….1399
Safety Notice….1399
FOREWORD….1401
General….1401
How to Read the Shop Manual….1402
Hoisting Instructions….1403
Method of Disassembling, Connecting Push-Pull Type Coupler….1404
Coating Materials….1406
Standard Tightening Torque….1408
Electric Wire Code….1411
Conversion Table….1412
Units….1418
01 GENERAL….1419
Specification Dimension Drawings….1420
Specifications….1428
Weight Table….1450
Fuel, Coolant and Lubricants….1470
10 STRUCTURE AND FUNCTION….1473
Engine Related Parts….1474
Radiator, Oil Cooler, Aftercooler….1476
Power Train….1479
Final Drive….1480
Swing Circle….1481
Swing Machinery….1482
Track Frame, Recoil Spring….1483
Track Shoe….1484
Hydraulic Piping Drawing….1486
Hydraulic Circuit Diagram….1490
Hydraulic Tank….1494
Hydraulic Pump….1495
Line Oil Filter….1527
Control Valve….1528
Self-reducing Pressure Valve….1542
CLSS….1547
Swing Motor….1610
Center Swivel Joint….1616
Travel Motor….1618
Valve Control….1626
Work Equipment, Swing PPC Valve….1628
Travel PPC Valve….1636
Service PPC Valve….1640
Safety Lock Valve….1644
PPC Accumulator….1644
Straight-Travel System….1645
Solenoid Valve….1646
Boom Holding Valve….1648
Additional Filter for Breaker….1651
Swivel Joint for Arm Rotation….1653
Arm Rotation Motor….1654
Work Equipment….1656
Air Conditioner….1657
Actual Electric Wiring Diagram….1658
Electrical Circuit Diagram….1666
PC220-6 STD Serial No.: 96514 – 102228….1666
PC210-6 STD Serial No.: 30980 – 31424….1666
PC220-6 STD Serial No.: 52852 – 53561….1666
PC230-6 STD Serial No.: 10177 – 10246….1666
Engine Control System….1680
Electronic Control System for STD….1689
Electronic Control System for Hyper GX….1729
Machine Monitor System….1788
Sensors….1799
Front Window Auto Pull-up System….1802
20 TESTING AND ADJUSTING….1805
TABLE OF JUDGEMENT STANDARD VALUE….1808
TESTING AND ADJUSTING….1833
Tools for Testing, Adjusting, and Troubleshooting….1833
Measuring Engine Speed….1834
Measuring Exhaust Gas Color….1835
Adjusting Valve Clearance….1836
Measuring Compression Pressure….1837
Measuring Blow-by Pressure….1837
Testing and Adjusting Fuel Injection Timing….1838
Measuring Engine Oil Pressure….1839
Testing and Adjusting Alternator Belt Tension….1840
Testing and Adjusting Belt Tension for Air Conditioner Compressor….1840
Measuring Speed Sensor….1841
Testing and Adjusting Governor Motor Lever Stroke….1842
Testing and Adjusting Hydraulic Pressure in Work Equipment, Swing, Travel Circuit….1843
Testing and Adjusting PC Valve Output Pressure (Servo Piston Input Pressure)….1846
Testing and Adjusting LS Valve Output Pressure (Servo Piston Input Pressure) and LS Differential Pressure….1848
Testing and Adjusting Control Circuit Oil Pressure….1851
Testing Solenoid Valve Output Pressure….1853
Measuring PPC Valve Output Pressure….1855
Measuring EPC Solenoid Valve Output Pressure and Checking EPC Shuttle Valve….1857
Adjusting Work Equipment, Swing PPC Valve….1859
Testing Travel Deviation….1860
Testing Locations Causing Hydraulic Drift of Work Equipment….1861
Measuring Oil Leakage….1863
Releasing Remaining Pressure in Hydraulic Circuit….1865
Testing Clearance of Swing Circle Bearing….1866
Testing and Adjusting Track Shoe Tension….1867
Bleeding Air….1868
Input/Output Structure of GX Controller….1871
Basic Operation and GX Function….1872
Special Functions on GX Panel (Background Mode)….1874
Check Procedure when Operation of GX Automatic Function is Defective….1897
Adjusting Swing Back Prevention Function (Swing Teaching Mode)….1899
Bucket Dimension Input Mode when Using Custom Bucket….1901
Procedure for Replacing Sensor….1904
TROUBLESHOOTING….1910
Points to Remember When Troubleshooting….1911
Sequence of Events in Troubleshooting….1912
Precautions When Carrying Out Maintenance….1913
Checks Before Troubleshooting….1921
Connector Types and Mounting Locations….1923
Connection Table for Connector Pin Numbers….1931
Explanation of Control Mechanism for Electrical System….1943
Display Method and Special Functions of Monitor Panel….1945
Method of Using Judgement Table….1955
Method of Using Troubleshooting Charts….1957
Details of Troubleshooting and Troubleshooting Procedure….1959
Troubleshooting of Communication Abnormality System ( N Mode)….1966
N-1 (E218) Communications Abnormality….1967
Troubleshooting of Engine Throttle – Pump Controller (Govenor Control System) (E Mode)….1970
Points to Remember When Carrying Out Troubleshooting of Engine Throttle – Pump Controller System….1971
Action Taken by Controller When Abnormality Occurs and Problems on Machine….1973
Judgement Table for Engine Throttle – Pump Controller (Govenor Control System) and Engine Related Parts….1977
Electrical Circuit Diagram for E Mode System….1979
E-1 Abnormality in Engine Throttle – Pump Controller Power Source (controller LED is OFF)….1981
E-2 (E308) Abnormality in Fuel Control Dial Imput Value is Displayed….1982
E-3 (E317) Abnormality (disconnection) in Motor Drive System is Displayed….1983
E-4 (E318) Abnormality (short circuit) in Motor Drive System is Displayed….1984
E-5 (E306) Abnormality in Feedback Potentionmeter System is Displayed….1985
E-6 (E315) Abnormality (short circuit) in Battery Relay Output System is Displayed….1986
E-7 (E316) Abnormality (step-out) in Motor is Displayed….1987
E-8 Engine Does Not Start….1989
E-9 Engine Speed is Irregular….1993
a) Idling Speed is Irregular….1993
b) There is Hunting….1995
E-10 Lack of Output (engine high idling speed is too low)….1997
E-11 Engine Does Not Stop….1999
E-12 Defective Operation of Battery Relay System (engine does not stop)….2001
Troubleshooting of Engine System (S Mode)….2004
Method of Using Troubleshooting Charts….2005
S-1 Starting Performance is Poor (starting always takes time)….2009
S-2 Engine Does Not Start….2010
(1) Engine Does Not Turn….2010
(2) Engine Turns But no Exhaust Smoke Comes Out (fuel is not being injected)….2011
(3) Exhaust Smoke Comes Out but Engine Does Not Start (fuel is being injected)….2012
S-3 Engine Does Not Pick Up Smoothly (follow-up is poor)….2013
S-4 Engine Stops During Operation….2014
S-5 Engine Does Not Rotate Smoothly (hunting)….2015
S-6 Engine Lacks Output ( no power)….2016
S-7 Exhaust Smoke is Black (incomplete combustion)….2017
S-8 Oil Consumption is Excessive (or exhaust smoke is blue)….2018
S-9 Oil Becomes Contaminated Quickly….2019
S-10 Fuel Consumption is Excessive….2020
S-11 Oil is in Cooling Water, or Water Spurts Back, or Water Level Goes Down….2021
S-12 Oil Pressure Caution Lamp Lights Up (drop in oil pressure)….2022
S-13 Oil Level Rises (water, fuel in oil)….2023
S-14 Water Temperature Becomes Too High (overheating)….2024
S-15 Abnormal Noise is Made….2025
S-16 Vibration is Excessive….2026
Troubleshooting of Engine Throttle – Pump Controller (Pump Control System) (C Mode)….2028
Points to Remember When Troubleshooting Pump Controller System….2029
Action Taken by Controller When Abnormality Occurs and Problems on Machine….2031
Judgement Table for Engine Throttle – Pump Controller (pump control system) and Hydraulic Related Parts….2039
Electrical Circuit Diagram for C Mode….2041
C-1 Abnormality in Controller Power Source System (controller LED is OFF)….2045
C-2 (E232) Short Circuit in PC-EPC Solenoid System is Displayed….2046
C-3 (E233) Disconnection in PC-EPC Solenoid System is Displayed….2047
C-4 (E203) Short Circuit in Swing Brake Solenoid System is Displayed….2048
C-5 (E213) Disconnection in Swing Brake Solenoid System is Displayed….2050
C-6 (E204) Short Circuit in Pump Merge/Divider Solenoid System is Displayed….2052
C-7 (E214) Disconnection in Pump Merge/Divider Solenoid System is Displayed….2053
C-8 (E207) Short Circuit In Active Mode Solenoid System is Displayed….2054
C-9 (E208) Disconnection in Active Mode Solenoid System is Displayed….2055
C-10 (E206) Short Circuit in Travel Speed Solenoid System is Displayed….2056
C-11 (E216) Disconnection in Travel Speed Solenoid System is Displayed….2057
C-12 (E205) Short Circuit in 2-Stage Relief Solenoid System is Displayed….2058
C-13 (E215) Disconnection in 2-State Relief Solenoid System is Displayed….2059
C-14 (E217) Model Selection Input Error is Displayed….2060
C-15 (E222) Short Circuit in LS-EPC Solenoid System is Displayed….2062
C-16 (E223) Disconnection in LS-EPC Solenoid System is Displayed….2063
C-17 (E224) Abnormality in Front Pump Pressure Sensor System is Displayed….2064
C-18 (E225) Abnormality in Rear Pump Pressure Sensor System is Displayed….2065
C-19 (E226) Abnormality in Pressure Sensor Power Source System is Displayed….2066
C-20 (E227) Abnormality in Engine Speed Sensor System is Displayed….2067
C-21 (E302) Short Circuit in Swing Stroke Limit Solenoid System is Displayed….2068
C-22 (E303) Disconnection in Swing Stroke Limit Solenoid System is Displayed….2069
Troubleshooting of Engine throttle – Pump Controller (Input Signal System) (F Mode)….2070
Electrical Circuit Diagram for F Mode….2071
F-1 Bit Pattern 20-(1) Swing Oil Pressure Switch Does Not Light Up….2075
F-2 Bit Pattern 20-(2) Travel Oil Pressure Switch Does Not Light Up….2076
F-3 Bit Pattern 20-(3) Boom LOWER Oil Pressure Switch Does Not Light Up….2077
F-4 Bit Pattern 20-(4) Boom RAISE Oil Pressure Switch Does Not Light Up….2078
F-5 Bit Pattern 20-(5) Arm IN Oil Pressure Switch Does Not Light Up….2079
F-6 Bit Pattern 20-(6) Arm OUT Oil Pressure Switch Does Not Light Up….2080
F-7 Bit Pattern 21-(1) Bucket CURL Oil Pressure Switch Does Not Light Up….2081
F-8 Bit Pattern 21-(2) Bucket DUMP Oil Pressure Switch Does Not Light Up….2082
F-9 Bit Pattern 21-(3) Swing Lock Switch Does Not Light Up….2083
F-10 Bit Pattern 22-(5) Kerosene Mode Connection Does Not Light Up….2084
F-11 Bit Pattern 22 (6) L.H. Knob Switch Does Not Light Up….2085
Troubleshooting of Hydraulic and Mechanical system (H Mode)….2086
Table of Failure Modes and Causes for Hydraulic and Mechnaical Systems ….2087
Pump Merge/Divider Logic….2091
Solenoid Actuation Table….2092
Troubleshooting Flow Charts for Each Failure Mode….2093
All Work Equipment, Travel, Swing….2093
H-1 Speeds of All Work Equipment, Swing, Travel Are Slow or Lack Power….2093
H-2 There is Excessive Drop in Engine Speed, or Engine Stalls….2095
H-3 No Work Equipment, Travel, Swing Move….2096
H-4 Abnormal Noise Generated (around pump)….2096
H-5 Auto-Deceleration Does Not work (PPC shuttle valve is euqipped only in travel PPC valve)….2097
H-6 Fine Control Ability is Poor or Response is Poor….2097
Work Equipment….2099
H-7 Boom is Slow or Lacks Power….2099
H-8 Arm is Slow or Lacks Power….2101
H-9 Bucket is Slow or Lacks Power….2103
H10- Work Equipment (boom, arm, bucket) Does Not Move (but travel and swing are normal)….2104
H-11 Excessive Hydraulic Drift….2104
H-12 Excessive Time Lag (engine at low idling)….2105
H-13 Other Equipment Moves When Single Circuit is Relieved….2105
H-14 Lack of Power When Pressure Rises….2106
H-15 In L/O, F/O Modes, Work Equipment Speed is Faster Than Specified Speed….2107
Compound Operations….2107
H-16 In Compound Operations, Work Equipment with Larger Load is Slow….2107
H-17 In Swing + Boom RAISE, Boom RAISE is Slow….2108
H-18 In Swing + Travel, Travel Speed Drops Excessively….2108
Travel System….2109
H-19 Travel Deviation….2109
H-20 Travel Speed is Slow….2111
H-21 Steering Does Not Turn Easily or Lacks Power….2113
H-22 Travel Speed Does Not Switch or is Faster than Specified Speed….2115
H-23 Travel Does Not Move (one side only)….2115
Swing System….2116
H-24 Does Not Swing….2116
H-25 Swing Acceleration is Poor or Swing Speed is Slow….2117
H-26 Excessive Overrun When Stopping Swing….2119
H-27 Excessive Shock When Stopping Swing (one direction only)….2120
H-28 Excessive Abnormal Noise When Stopping Swing….2120
H-29 Excessive Hydraulic Drift of Swing….2121
H-30 Swing Speed is Faster than Specified Speed in L/O and F/O Modes….2122
H-31 Operation of Automatic Mode is Defective (HYPER specification)….2122
Troubleshooting of Machine Monitor System (M Mode)….2124
Action Taken by Monitor Panel When Abnormality Occurs and Problems on Machine….2127
Electrical Circuit Diagram for M Mode System….2129
M-1 (E101) Abnormality in Error Data is Displayed….2131
M-1 (E102) Error in Clock Data is Displayed….2131
M-2 (E103) Short Circuit in Buzzer Output or Contact of 24V Wiring Harness with Buzzer Drive Harness is Displayed….2132
M-3 (E104) Air Cleaner Clogging Detected is Displayed….2133
M-4 (E108) Engine Water Temperature 105 degrees C Detected is Displayed….2133
M-5 When Starting Switch is Turned ON, None of Lamps on Monitor Panel Light Up for 3 Seconds….2134
a) None of Lamps on Monitor Panel Light Up….2134
b) Some of Lamps on Monitor Panel Do Not Light Up….2134
M-6 When Starting Switch is Turned ON, Monitor Panel Lamps All Stay Lighted Up and Do Not Go Out….2136
M-7 When Starting Switch is Turned ON, Items Lighted Up on Monitor Palen are Different from Actual Machine (Model)….2136
M-8 When Starting Switch is Turned ON (engine stopped), Basic Check Items Flash….2137
a) Coolant Level Flashes….2137
b) Engine Oil Level Flashes….2138
c) Hydraulic Oil Level Flashes….2139
M-9 Preheating is Not Being Used But Preheating Monitor Lights Up….2140
M-10 When Starting Switch is Turned ON and Engine is Started, Basic Check Items Flash….2141
a) Alternator System….2141
b) Engine Oil Pressure System….2142
M-11 When Starting Switch is Turned ON (engine stopped), Caution Items, Emergency Items Flash (battery, engine oil pressure l….2143
a) Alternator System….2143
b) Engine Oil Pressure Sensor System….2144
M-12 When Starting Switch is Turned ON and Engine is Started, Caution Items, Emergency Items Flash (when there is no abnormal….2145
a) Engine Oil Pressure Flashes….2145
b) Coolant Level Flashes….2145
c) Battery Charge Flashes….2145
d) Coolant Temperature Flashes….2146
e) Fuel Level Flashes….2146
f) Air Cleaner Clogging Flashes….2147
M-13 When Starting Switch is Turned ON (engine stopped), Buzzer Does Not Sound for 1 Second; Caution Item Flashes but Buzzer ….2148
M-14 No Abnormality is Displayed on Monitor but Buzzer Sounds….2148
M-15 Night Lighting on Monitor Panel Does Not Light Up (liquid crystal display is normal)….2149
M-16 Coolant Temperature Gauge Does Not Rise….2150
M-17 Coolant Temperature Gauge Does Not Give Any Display (none of gauge lamps light up during operation)….2150
M-18 Fuel Level Gauge Always Displays FULL….2151
M-19 Fuel Level Gauge Does Not Give Display….2151
M-20 Swing Lock Switch is Turned ON (LOCK) but Swing Lock Monitor Does Not Light Up….2152
M-21 Swing Prolix Switch is Turned ON (prolix), but Swing Lock Monitor Does Not Flash….2152
M-22 Service Meter Does Not Advance While Engine is Running….2153
M-23 When Starting Switch is at OFF and Time Switch is Pressed, Time and Service Meter Are Not Displayed….2153
M-24 Defective Fuel Level Sensor System….2154
M-25 Defective Coolant Temperature Sensor System….2155
M-26 Defective Engine Oil Level Sensor System….2156
M-27 Defective Coolant Level Sensor System….2157
M-28 Defective Hydraulic Oil Level Sensor System….2158
M-29 Wiper Does Not Work, or Switch is Not Being Used but Wiper is Actuated….2159
a) Wiper Does Not Work….2159
b) Wiper Switch is Not Being Operated but Wiper is Actuated….2162
M-30 Washer Motor Does Not Work, or Switch is Not Being Used but Washer Motor is Actuated….2164
a) Washer Motor Does Not Work….2164
b) Switch is Not Being Operated but Washer is Actuated….2165
Troubleshooting of GX Controller System (A Mode)….2166
Points to Remember When Troubleshooting GX Controller System….2168
Procedure for Troubleshooting Hyper GX….2169
Operation of GX Error Code Display Mode and Content of Display….2172
Action Taken by Controller When Abnormality Occurs, and Problems on Machine….2175
Electrical Wiring Diagram for GX Controller….2183
A-1 E6:01, E6:02, E6:03, and E6:04 are Displayed at the Same Time….2185
A-2 E6:01 (GX panel 011, 012) [Abnormality in Boom (RAISE) Pressure Sensor System] is Displayed….2187
A-3 E6:01 (GX panel 013, 014) [Abnormality in Boom (LOWER) Pressure Sensor System] is Displayed….2189
A-4 E6:02 (GX panel 021, 022) [Abnormality in Arm (IN) Pressure Sensor System] is Displayed….2191
A-5 E6:02 (GX panel 023, 024) [Abnormality in Arm (OUT) Pressure Sensor System] is Displayed….2193
A-6 E6:03 (GX panel 031, 032) [Abnormality in Bucket (CURL) Pressure Sensor System] is Displayed….2195
A-7 E6:03 (GX panel 033, 034) [Abnormality in Bucket (DUMP) Pressure Sensor System] is Displayed….2197
A-8 E6:04 (GX panel 041, 042) [Abnormality in Swing (RIGHT) Pressure Sensor System] is Displayed….2199
A-9 E6:04 (GX panel 043, 044) [Abnormality in Swing (LEFT) Pressure Sensor System] is Displayed….2201
A-10 E6:06 (GX panel 061, 063) [Abnormality in Clinometer Input Valve] is Displayed….2203
A-11 E6:07 and E6:08 [Abnormality in Potentiometer Power Source] are Displayed at the Same Time….2205
A-12 E6:07 (GX panel 071, 072) [Abnormality in Boom Potentionmeter System] is Displayed….2207
A-13 E6:08 (GX panel 081, 082) [Abnormality in Arm Potentiometer System] is Displayed….2209
A-14 E6:11 (GX panel 111, 112) [Abnormality in Boom Variable Angle] is Displayed….2211
A-15 E6:12 (GX panel 121, 122) [Abnormality in Arm Variable Angle] is Displayed….2213
A-16 E6:13 (GX panel 131, 132) [Abnormality in Bucket Variable Angle] is Displayed….2216
A-17 E6:14 (GX panel 141) [Abnormality in Comparision of Two Boom Sensor Signals] is Displayed….2217
A-18 E6:15 (GX panel 151) [Abnormality in Comparision of Two Arm Sensor Singals] is Displayed….2218
A-19 E6:16 (GX panel 163) [No Change in Signal When Work Equipment Should Move] is Displayed….2219
A-20 E6:17 (GX panel 171, 172) [Cutting Edge Position Out of Range] is Displayed….2220
A-21 E6:18 (GX panel 181, 182) [Abnormality in Data ROM] is Displayed….2220
A-22 E6:21 (GX panel 211, 212, 213, 214) [Abnromality in Engine Pick-up] is Displayed….2221
A-23 E6:22 (GX panel 221) [Change in Wiring Harness After Engine Picks up] is Displayed….2225
A-23 E6:22 (GX panel 222) [Automatic Operation Disconnection Switch Signal Does Not Match in Valve Controller and GX Control….2225
A-23 E6:22 (GX panel 223) [Abnormality in Controller Power Source] is Displayed….2225
A-24 E6:23 (GX panel 231) [Abnormality in Remote Singal] is Displayed….2229
A-24 E6:23 (GX panel 235) [Abnormality in 12V Power Source (overcurrent detection)] is Displayed….2229
A-24 E6:23 (GX panel 236) [Abnormality in 24V Power Source (overcurrent detection)] is Displayed….2229
A-25 E6:24 (GX panel 241) [Abnormality in Buzzer Drive System] is Diaplayed….2232
A-26 E6:25 (GX panel 251, 252) [Impossible to Receive Network (S-NET) Signal] is Displayed….2233
A-26 E6:25 (GX panel 253) [Impossible to Receive Network (HS-NET) Signal] is Displayed….2235
A-27 E6:26 (GX panel 261, 262, 263, 264) [Abnormality in Non-Volatile Memory Data Range] is Displayed….2238
A-28 E6:27 [Non-Volatile Read Error] is Displayed….2239
A-29 E6:28 [Non-Volatile Write Error] is Displayed….2239
A-30 Buzzer Does Not Sound (when there is no abnormal display)….2240
A-31 Automatic Mode is Not Actuated When Knob Switch is Pressed (when there is no abnormal display….2241
Troubleshooting of Valve Controller System (K Mode)….2242
Points to Remember When Troubleshooting Valve Controller System….2244
Action Taken by Controller When Abnormality Occurs and Problems on Machine….2245
Judgement Table for Valve Controller System….2263
Electrical Circuit Diagram of Valve Controller System….2265
K-1 [LED OFF] Controller Power Source System….2268
K-2 [E4:02] L.H. Knob Switch OFF System is Displayed….2269
K-3 [E4:07] Abnormality in Model Code Input is Displayed….2270
K-4 [E4:51] Abnormality in S-NET Communication is Displayed….2271
1. Disconnection Related….2271
2. Short Circuit Related….2273
K-5 [E4:56] Abnormality in Teaching, Playback RAM Data is Displayed….2273
K-6 [E4:57] Abnormality in Knob Switch is Displayed….2274
K-7 [E4:01] Abnormality in Control Lever Neutral System is Displayed….2275
K-8 [E4:04] Abnormality in Control Lever Potentiometer Power Source System is Displayed….2277
K-9 [E4:11) Short Circuit in EPC Relay 1 Drive Power Source System is Displayed….2278
K-10 [E4:12] Contact Between Chassis Power Source and EPC Relay 1 Drive Power Source System is Displayed….2279
K-11 [E4:13] Short Circuit in EPC Relay 2 Drive Power Source System is Displayed….2280
K-12 [E4:14] Contact Between Chassis Power Source and EPC Relay 2 Drive Power Source System is Displayed….2281
K-13 [E4:15] Disconnection in EPC Relay 1,2 Solenoid Power Source System is Displayed….2282
K-14 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed….2284
K-14 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed….2284
1) When E4:16 is Displayed Independently….2284
2) When E4:16, E4:17 are Displayed Simultaneously….2284
K-15 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed….2286
K-15 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed….2286
1) When E4:17 is Displayed Independently….2286
2) When E4:16, E4:17 are Displayed Simultaneously….2286
K-16 [E4:18] Abnormality in Lever Signal Input Delay Circuit System is Displayed….2288
K-17 [E4:21] Abnormality 1 in Drive Circuit System for Boom LOWER EPC Valve is Displayed….2289
K-17 [E4:25] Abnormality 1 in Drive Circuit System for Boom RAISE EPC Valve is Displayed….2289
K-17 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed….2291
K-17 [E4:25] [E4:35] Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed….2291
K-18 [E4:31 Abnormality 2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed….2293
K-18 [E4:35] Abnormality 2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed….2293
K-18 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed….2295
K-18 [E4:25] [E4:35} Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed….2295
K-19 [E4:32} Abnormality 2 in Drive Circuit System for Arm IN EPC Valve is Displayed….2297
K-19 [E4:33] Abnormality 2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed….2297
K-19 [E4:34] Abnormality 2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed….2297
K-19 [E4:36] Abnormality 2 in Drive Circuit System for Arm OUT LEFT EPC Valve is Displayed….2297
K-19 [E4:37] Abnormality 2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed….2297
K-19 [E4:38] Abnormality 2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed….2297
K-19 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed….2299
K-19 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed….2299
K-19 [E4: 24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed….2299
K-19 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed….2299
K-19 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed….2299
K-19 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed….2299
K-20 [E4:41] [E4:42] [E4:43] [E4:44} Over-range in Control Lever Potentiometer Signal System is Displayed….2301
K-21 [E4:45] [E4:46] [E4:47] [E4:48] Excessive Error in Signal SIG and Switch SIG of Control Lever Potentiometer is Displayed….2303
K-22 [E4:55] Abnormality in ROM, RAM of CPU is Displayed….2305
K-23 [E4:58] Abnormality in Interlock PLD is Displayed….2305
K-24 [E4:22] Abnormality 1 in Drive Circuit System for Arm IN EPC Valve is Displayed….2306
K-24 [E4:23] Abnormality 1 in Drive Circuit System for Bucket CURL EPC Valve is Displayed….2306
K-24 [E4:24] Abnormality 1 in Drive Circuit System for Swing LEFT EPC Valve is Displayed….2306
K-24 [E4:26] Abnormality 1 in Drive Circuit System for Arm OUT EPC Valve is Displayed….2306
K-24 [E4:27] Abnormality 1 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed….2306
K-24 [E4:28] Abnormality 1 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed….2306
K-24 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed….2308
K-24 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed….2308
K-24 [E4:24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed….2308
K-24 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed….2308
K-24 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed….2308
K-24 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed….2308
30 DISASSEMBLY AND ASSEMBLY….2310
Method of Using Manual….2312
Precautions When Carrying Out Operation….2313
Special Tool List….2315
Sketches of Special Tools….2323
Starting Motor….2326
Removal of Starting Motor Assembly….2326
Installation of Starting Motor Assembly….2326
Alternator….2327
Removal of Alternator Assembly….2327
Installation of Alternator Assembly….2328
Air Conditioner Compressor….2330
Removal of Air Conditioner Compressor Assembly….2330
Installation of Air Conditioner Compressor Assembly….2330
Condenser….2331
Removal of Condenser Assembly….2331
Installation of Condenser Assembly….2331
Air Conditioner Condenser ….2332
Removal of Air Conditioner Condenser Assembly….2332
Installation of Air Conditioner Condenser Assembly….2332
Dry Receiver….2333
Removal of Dry Receiver Assembly….2333
Installation of Dry Receiver Assembly….2333
Engine Oil Cooler Core….2334
Removal of Engine Oil Cooler Core Assembly….2334
Installation of Engine Oil Cooler Core Assembly….2334
Fuel Injection Pump….2335
Removal of Fuel Injection Pump Assembly….2335
Installation of Fuel Injection Pump Assembly….2338
Water Pump….2345
Removal of Water Pump Assembly….2345
Installation of Water Pump Assembly….2346
Nozzle Holder….2347
Removal of Nozzle Holder Assembly….2347
Installation of Nozzle Holder Assembly….2347
Turbocharger….2348
Removal of Turbocharger Assembly….2348
Installation of Turbocharger Assembly….2348
Thermostat….2349
Removal of Thermostat Assembly….2349
Installation of Thermostat Assembly….2350
Govenor Motor….2351
Removal of Govenor Motor Assembly….2351
Installation of Governor Motor Assembly….2351
Cylinder Head….2352
Removal of Cylinder Head Assembly….2352
Installation of Cylinder Head Assembly….2358
Hydraulic Oil Cooler….2369
Removal of Hydraulic Oil Cooler Assembly….2369
Installation of Hydraulic Oil Cooler Assembly….2369
Radiator – Hydraulic Oil Cooler….2371
Removal of Radiator, Hydraulic Oil Cooler Assembly….2371
Installation of Radiator, Hydraulic Oil Cooler Assembly….2373
Engine – Main Pump….2377
Removal of Engine, Main Pump Assembly….2377
Installation of Engine, Main Pump Assembly….2381
Damper….2382
Removal of Damper Assembly….2382
Installation of Damper Assembly….2382
Fuel Tank….2383
Removal of Fuel Tank Assembly….2383
Installation of Fuel Tank Assembly….2383
Center Swivel Joint….2384
Removal of Center Swivel Joint Assembly….2384
Installation of Center Swivel Joint Assembly….2385
Disassembly of Center Swivel Joint Assembly….2386
Assembly of Center Swivel Joint Assembly….2386
Final Drive….2387
Removal of Final Drive Assembly….2387
Installation of Final Drive Assembly….2387
Disassembly of Final Drive Assembly….2388
Assembly of Final Drive Assembly….2391
Travel Motor….2396
Disassembly of Travel Motor Assembly….2396
Assembly of Travel Motor Assembly….2402
Sprocket….2410
Removal of Sproket….2410
Installation of Sprocket….2410
Swing Motor and Swing Machinery….2411
Removal of Swing Motor, Swing Machinery Assembly….2411
Installation of Swing Motor, Swing Machinery Assembly….2412
Disassembly of Swing Machinery Assembly….2413
Assembly of Swing Machinery Assembly….2417
Swing Motor….2422
Disassembly of Swing Motor Assembly….2422
Assembly of Swing Motor Assembly….2426
Revolving Frame….2434
Removal of Revolving Frame Assembly….2434
Installation of Revolving Frame Assembly….2435
Swing Circle….2436
Removal of Swing Circle Assembly….2436
Installation of Swing Circle Assembly….2437
Idler – Recoil Spring….2438
Removal of Idler – Recoil Spring Assembly….2438
Installation of Idler – Recoil Spring Assembly….2438
Recoil Spring….2439
Disassembly of Recoil Spring Assembly….2439
Assembly of Recoil Spring Assembly….2440
Idler….2441
Disassembly of Idler Assembly….2441
Assembly of Idler Assembly….2442
Track Roller….2444
Removal of Track Roller Assembly….2444
Installation of Track Roller Assembly….2444
Disassembly of Track Roller Assembly….2445
Assembly of Track Roller Assembly….2447
Carrier Roller….2449
Removal of Carrier Roller Assembly….2449
Installation of Carrier Roller Assembly….2449
Disassembly of Carrier Roller Assembly….2450
Assembly of Carrier Roller Assembly….2452
Track Shoe….2454
Removal of Track Shoe Assembly….2454
Installation of Track Shoe Assembly….2454
Hydraulic Tank….2455
Removal of Hydraulic Tank Assembly….2455
Installation of Hydraulic Tank Assembly….2456
Main Pump….2457
Removal of Main Pump Assembly….2457
Installation of Main Pump Assembly….2459
Disassembly of Main Pump Assembly….2461
Assembly of Main Pump Assembly….2474
Main Pump Input Shaft Oil Seal….2490
Removal of Main Pump Input Shaft Oil Seal….2490
Installation of Main Pump Input Shaft Oil Seal….2490
Control Valve….2491
Removal of Control Valve Assembly….2491
Installation of Control Valve Assembly….2493
Disassembly of Control Valve Assembly….2494
Assembly of Control Valve Assembly….2499
Pump Merge-Divider Valve….2505
Disassembly of Pump Merge-Divider Valve Assembly….2505
Assembly of Pump Merge-Divider Valve Assembly….2505
Main Relief Valve….2506
Disassembly of Main Relief Valve Assembly….2506
Assmebly of Main Relief Valve Assembly….2506
Work Equipment EPC Valve….2507
Removal of Work Equipment EPC Valve Assembly….2507
Installation of work Equipment EPC Valve Assembly….2507
PC Valve….2508
Removal of PC Valve Assembly….2508
Installation of PC Valve Assembly….2509
LS Valve ….2510
Removal of LS Valve Assembly….2510
Installation of LS Valve Assembly….2510
PC, LS-EPC Valve….2511
Removal of PC, LS-EPC Valve Assembly….2511
Installation of PC, LS-EPC Valve Assembly….2511
Solenoid Valve….2512
Removal of Solenoid Valve Assembly….2512
Installation of Solenoid Valve Assembly….2512
Work Equipment – Swing PPC Valve….2513
Removal of Work Equipment – Swing PPC Valve Assembly….2513
Installation of Work Equipment – Swing PPC Valve Assembly….2513
Disassembly of Work Equipment – Swing PPC Valve Assembly….2514
Assembly of Work Equipment – Swing PPC Valve Assembly….2515
Travel PPC Valve….2516
Removal of Travel PPC Valve Assembly….2516
Installation of Travel PPC Valve Assembly….2516
Disassembly of Travel PPC Valve Assembly….2517
Assembly of Travel PPC Valve Assembly….2518
Boom Lock Valve….2519
Removal of Boom Lock Valve Assembly….2519
Installation of Boom Lock Valve Assembly….2519
Boom Cylinder….2520
Removal of Boom Cylinder Assembly….2520
Installation of Boom Cylinder Assembly….2521
Arm Cylinder….2522
Removal of Arm Cylinder Assembly….2522
Installation of Arm Cylinder Assembly….2523
Bucket Cylinder….2524
Removal of Bucket Cylinder Assembly….2524
Installation of Bucket Cylinder Assembly….2525
Hydraulic Cylinder….2526
Disassembly of Hydraulic Cylinder Assembly….2526
Assembly of Hydraulic Cylinder Assembly….2529
Work Equipment….2533
Removal of Work Equipment Assembly….2533
Installation of Work Equipment Assembly….2534
Bucket….2535
Removal of Bucket Assembly….2535
Installation of Bucket Assembly….2536
Arm….2537
Removal of Arm Assembly….2537
Installation of Arm Assembly….2538
Bucket – Arm….2539
Removal of Bucket – Arm Assembly….2539
Installation of Bucket – Arm Assmebly….2540
Boom….2541
Removal of Boom Assembly….2541
Installation of Boom Assembly….2542
Opeator's Cab….2543
Removal of Operator's Cab Assembly….2543
Installation of Operator's Cab Assembly….2544
Counterweight….2545
Removal of Counterweight Assembly….2545
Installation of Counterweight Assembly….2545
Work Equipment Electric Lever Unit….2547
Removal of Work Equipment Electric Lever Unit Assembly….2547
Installation of Work Equipment Electric Lever Unit Assembly….2547
Engine Throttle – Pump Controller….2548
Removal of Engine Throttle – Pump Controller Assembly….2548
Installation of Engine Throttle – Pump Controller Assembly….2548
Control Stand Case….2549
Removal of Control Stand Case….2549
Installation of Control Stand Case….2550
Valve Controller….2551
Removal of Valve Controller Assembly….2551
Installation of Valve Controller Assembly….2551
Monitor….2552
Removal of Monitor Assembly….2552
Installation of Monitor Assembly….2552
ITERMS FOR HYPER GX….2553
Swing Motor….2553
Removal of Swing Motor Assembly….2553
Installation of Swing Motor Assembly….2553
Control Valve….2554
Removal of Control Valve Assembly….2554
Installation of Control Valve Assembly….2555
Work Equipment EPC Valve….2556
Removal of Work Equipment EPC Valve Assembly….2556
Installation of Work Equipment EPC Valve Asembly….2556
Boom Cylinder….2557
Removal of Boom Cylinder Assembly….2557
Installation of Boom Cylinder Assembly….2558
Arm Cylinder….2559
Removal of Arm Cylinder Assembly….2559
Installation of Arm Cylinder Assembly….2560
Bucket Cylinder….2561
Removal of Bucket Cylinder Assembly….2561
Installation of Bucket Cylinder Assembly….2562
Disassembly of Bucket Cylinder Assembly….2563
Assembly of Bucket Cylinder Assembly….2565
Work Equipment….2569
Removal of Work Equipment Assembly….2569
Installation of Work Equipment Assembly….2571
Bucket….2572
Removal of Bucket Assembly….2572
Installation of Bucket Assembly….2573
Arm….2574
Removal of Arm Assembly….2574
Installation of Arm Assembly….2575
Bucket – Arm….2576
Removal of Bucket – Arm Assembly….2576
Installation of Bucket – Arm Assembly….2577
Boom….2578
Removal of Boom Assembly….2578
Installation of Boom Assembly….2580
Valve Controller….2581
Removal of Valve Controller Assembly….2581
Installation of Valve Controller Assembly….2581
GX Controller….2582
Removal of GX Controller Assembly….2582
Installation of GX Controller Assembly….2582
GX Panel….2583
Removal of GX Panel Assembly….2583
Installation of GX Panel Assembly….2583
40 MAINTENANCE STANDARD….2584
Swing Machinery….2585
Swing Circle….2587
Final Drive….2589
Track Frame – Recoil Spring….2591
Idler….2593
Carrier Roller….2595
Track Roller….2596
Track Shoe….2597
Hydraulic Pump….2603
Control Valve….2604
Safety-Suction Valve (for Service Valve)….2617
Self-Reducing Pressure Valve….2618
Swing Motor….2619
Travel Motor….2620
Work Equipment – Swing PPC Valve….2621
Work Equipment – Swing EPC Valve….2622
Tavel PPC Valve….2623
Service PPC Valve….2624
EPC Solenoid Valve….2625
Center Swivel Joint….2626
Boom Holding Valve….2628
Hydraulic Cylinder….2629
Work Equipment….2635
Dimension of Work Equipment….2641
90 OTHER….2648
Hydraulic Circuit Diagram (pg. 90-3)….2649
PC200-6 STD Serial No.: 96514 – 102228….2649
PC210-6 STD Serial No.: 30980 – 31424….2649
PC220-6 STD Serial No.: 52852 – 53561….2649
PC230-6 STD Serial No.: 10177 – 10246….2649
Hydraulic Circuit Diagram (pg. 90-5)….2650
PC200-6 STD Serial No.: 102229 and UP….2650
PC210-6 STD Serial NO.: 31425 and UP….2650
PC220-6 STD Serial No.: 53562 and UP….2650
PC230-6 STD Serial NO.: 10247 and UP….2650
Hydraulic Circuit Diagram (pg. 90-7)….2651
PC200-6 HYPER GX Serial No.: 96514 – 102228….2651
Hydraulic Circuit Diagram (pg. 90-9)….2652
PC200-6 HYPER GX Serial No.: 102229 and UP….2652
Hydraulic Circuit Diagram (pg. 90-10-1)….2653
For Rotary Arm = PC200, 200LC-6….2653
Electrical Circuit Diagram [ 1/2 ] (pg. 90-11)….2654
PC200-6 STD Serial No.: 96514 – 102228….2654
PC210-6 STD Serial No.: 30980 – 31424….2654
PC220-6 STD Serial No.: 52852 – 53561….2654
PC230-6 STD Serial No.: 10177 – 10246 ….2654
Electrical Circuit Diagram [ 2/2 ] (pg. 90-13)….2655
PC200-6 STD Serial No.: 96514 – 102228….2655
PC210-6 STD Serial No.: 30980 – 31424….2655
PC220-6 STD Serial NO.: 52852 – 53561….2655
PC230-6 STD Serial No.: 10177 – 10246….2655
Electrical Circuit Diagram [1/2 ] (pg. 90-15)….2656
PC200-6 STD Serial No.: 102229 and UP….2656
PC210-6 STD Serial No.: 31425 and UP….2656
PC220-6 STD Serial No.: 53562 and UP….2656
PC230-6 STD Serial No.: 10247 and UP….2656
Electrical Circuit Diagram [ 2/2 ] (pg. 90-17)….2657
PC200-6 STD Serial No.: 102229 and UP….2657
PC210-6 STD Serial No.: 31425 and UP….2657
PC220-6 STD Serial No.: 53562 and UP….2657
PC230-6 STD Serial No.: 10247 and UP….2657
Electrical Circuit Diagram [ 1/3 ] (pg. 90-19)….2658
PC200-6 HYPER GX Serial No.: 94999 – 102228….2658
Electrical Circuit Diagram [ 2/3 ] (pg. 90-21)….2659
PC200-6 HYPER GX Serial No.: 94999 – 102228….2659
Electrical Circuit Diagram [ 3/3 ] (pg. 90-23)….2660
PC200-6 HYPER GX Serial No.: 94999 – 102228….2660
Electrical Circuit Diagram (pg. 90-25)….2661
PC200-6 HYPER GX Serial No.: 94999 – 102228….2661
Electrical Circuit Diagram [ 1/3 ] (pg. 90-27)….2662
PC200-6 HYPER GX Serial No.: 102229 and UP….2662
Electrical Circuit Diagram [ 2/3 ] (pg. 90-29)….2663
PC200-6 HYPER GX Serial No.: 102229 and UP….2663
Electrical Circuit Diagram [ 3/3 ] (pg. 90-31)….2664
PC200-6 HYPER GX Serial No.: 102229 and UP….2664
Electrical Circuit Diagram (pg 90-33)….2665
PC200-6 HYPER GX Serial No.: 102229 and UP….2665
Komatsu Hydraulic Excavator PC200, PC200LC, PC210, PC210LC, PC220, PC220LC, PC230, PC230LC Repair Service Manuals
