Complete service repair manual with Electrical Wiring Diagrams for Hydraulic Excavator PC200, PC200LC, PC220, PC220LC, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200-2, PC200-6, PC200LC-2, PC200LC-6, PC200LC-8, PC220-2, PC220LC-2 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.
TEN00205-00 – Hydraulic Excavator PC200-8, PC200LC-8 Operation & Maintenance Manual.pdf
SEBM010202 – Hydraulic Excavator PC200LC-6 Shop Manual.pdf
SEBM010201 – Hydraulic Excavator PC200-6 Shop Manual.pdf
SEBM0205B04 – Hydraulic Excavator PC200-2, PC200LC-2, PC220-2, PC220LC-2 Shop Manual.pdf
SEAM045200ATH – Hydraulic Excavator GALEO PC200-7, PC200LC-7 Operation & Maintenance Manual.pdf
SEAM023800PT – Hydraulic Excavator PC200-6, PC200LC-6 Operation & Maintenance Manual.pdf
SEAM021701 – Hydraulic Excavator PC200-6 avance Series Operation & Maintenance Manual.pdf
SEAM016301 – Hydraulic Excavator PC200-6 Operation & Maintenance Manual.pdf
CEBM025500 – Hydraulic Excavator PC200LC-8 Shop Manual.pdf
CEAM025700 – Hydraulic Excavator PC200LC-8 Latin America Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,613 pages
File Format: PDF
Language: English
CEAM025700 – Hydraulic Excavator PC200LC-8 Latin America Operation & Maintenance Manual…2
CEBM025500 – Hydraulic Excavator PC200LC-8 Shop Manual…405
CEBM025500 PC200LC-8 LATIN AMERICA…405
CONTENTS…406
GENERAL…409
HOW TO READ THE SHOP MANUAL…410
Volumes…410
Distribution And Updating…410
Filing Method…410
Revised Edition Mark…410
Revisions…410
Symbols…410
HOISTING INSTRUCTIONS…411
Hoisting…411
Wire Ropes…411
PUSH PULL COUPLER…412
Type 1…412
Disconnection…412
Connection…412
Type 2…413
Disconnection…413
Connection…413
Type 3…414
Disconnection…414
Connection…414
COATING MATERIALS…415
STANDARD TIGHTENING TORQUE…418
Standard Tightening Torque Of Bolts And Nuts…418
Tightening Torque Of Hose Nuts…419
Tightening Torque Of Split Flange Bolts…419
Tightening Torque For Flared Nuts…419
Table Of Tightening Torques For O-ring Boss Piping Joints…420
Table Of Tightening Torques For O-ring Boss Plugs…420
Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)…420
ELECTRIC WIRE CODE…421
Classification By Thickness…421
Classification By Color And Code…421
CONVERSION TABLES…422
Method Of Using The Conversion Table…422
01 GENERAL…429
SPECIFICATION AND TECHNICAL DATA…430
Specification Dimension Drawings…430
Working Range Diagram…431
Specifications…432
Weight Table…434
Table Of Fuel, Coolant And Lubricants…436
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil…437
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…439
ENGINE AND COOLING SYSTEM…443
Engine Related Parts…443
Radiator, Oil Cooler, Aftercooler and Fuel Cooler…444
POWER TRAIN…445
Power Train…445
Final Drive…446
Swing Machinery…448
Swing Circle…450
UNDERCARRIAGE AND FRAME…452
Track Frame And Recoil Spring…452
Standard Shoe…453
Idler…454
Carrier Roller…456
Track Roller…458
Track Shoe…460
Triple Grouser Shoe…463
HYDRAULIC SYSTEM…464
Hydraulic Equipment Layout Drawing…464
Hydraulic Tank And Filter…466
Hydraulic Pump…468
Type: HPV95+95…468
Operation of pump…473
Control of delivery…474
LS Valve…475
PC Valve…481
LS (PC)-EPC Valve…488
Pilot Oil Filter…491
For breaker…491
Control Valve…493
Outline…493
General View…494
Sectional View…496
CLSS…506
Outline of CLSS…506
LS Differential Pressure and Pump Swash Plate Angle…507
Functions and Operation by Valve…510
Hydraulic Circuit Diagram and the Name of Valves…510
Unload Valve…512
Introduction Of LS Pressure…514
LS Bypass Plug…515
Pressure Compensation Valve…516
Integrated Pressure Compensation Valve…517
Pressure Compensation Valve Inner Shuttle Valve…519
Boom Regeneration Circuit…521
Arm Regeneration Circuit…523
Merge-divider Valve…525
LS Select Valve…528
Self Pressure Reducing Valve…529
Travel Junction Valve…532
Travel PPC Shuttle Valve…534
Boom Drift Prevention Valve…537
Arm Drift Prevention Valve (if equipped)…540
Quick Return Valve…544
Lift Check Valve…547
Main Relief Valve…548
2-stage Safety-suction Valve…549
Swing Motor…552
Torque Values…553
Specifications…553
Swing Holding Brake…556
Relief Valve Portion…557
Outline…557
Reverse Prevention Valve…558
Center Swivel Joint…562
Travel Motor…564
Operation Of Motor…568
Operation of Parking Brake…570
Brake Valve…572
Operation When Pressurized Oil is Supplied…572
Operation of Brake During Traveling Downhill…573
PPC Valve…576
Work Equipment and Swing PPC Valve…576
Travel PPC Valve…582
Pressure reducing valve function…586
Travel Signal/steering Function…588
Service PPC Valve (With EPC Valve)…594
EPC valve…596
When Signal Current Is 0…598
When Signal Current is Very Small…598
When Signal Current Is Maximum…599
Service PPC Valve…600
Valve Control…602
Lever Positions…603
Solenoid Valve…604
When Solenoid is De-energized…605
When Solenoid is Energized…606
PPC Accumulator…607
Specifications…607
CRN (Canadian certified) PPC Accumulator…607
Return Oil Filter…608
Attachment Circuit Selector Valve…609
When Attachment Other Than Breaker is Installed…610
When Breaker is Installed…610
Hydraulic Cylinder…612
PC200LC-8…612
WORK EQUIPMENT…614
Dimensions of Components…614
PC200LC-8…615
CAB AND ITS ATTACHMENTS…621
Air Conditioner Piping…621
ELECTRICAL SYSTEM…622
Engine Control…622
Operation of system…622
Component…623
Fuel Control Dial…623
Engine Controller…624
Coolant Temperature Sensor…627
Oil Pressure Switch…627
Rotation Sensor…628
Boost Pressure and Temperature Sensor…628
WIF (Water-in-fuel Detection) Sensor…629
Engine Oil Level Sensor…629
Electrical Control System…631
Machine Control System Diagram…631
MONITOR SYSTEM…655
Machine Monitor…656
Input And Output Signals…657
Monitor Control, Display Portion…659
Precautions on the Machine Monitor Display…660
Monitor Items and Display…661
Switches…665
Buzzer Cancel Switch…665
Auto-deceleration Switch…665
Guidance Icon And Function Switch…665
Working Mode Selector Switch…667
Travel Speed Selector Switch…667
Window Washer Switch…668
Wiper Switch…668
Air Conditioner Control Switch…668
Camera Screen Display Function…669
Service Meter/Time Selector Function…670
Maintenance Function…670
User Mode…672
Breaker/Attachment Setting…672
Changing Breaker Mode Setting…673
Changing Attachment Mode Setting…675
Message Display…676
Screen Adjustment…677
Clock Adjustment…677
Language Setting…678
Economy Mode Adjustment…678
Idle Stop Guidance Function…679
Service Meter Check Function…679
Display LCD Check Function…679
User Code/Failure Code Display Function…680
SENSOR…681
Fuel Level Sensor…681
Air Cleaner Clogging Sensor…682
Coolant Level Sensor…682
KOMTRAX TERMINAL SYSTEM…683
KOMTRAX Communication ORBCOMM…684
TH300…684
Input And Output Signals…684
20 STANDARD VALUE TABLES…685
STANDARD SERVICE VALUE TABLE…687
Standard Service Value Table for Engine…687
Standard Value Table for Chassis Related Parts…688
Machine Position for Measurement…695
Control Valve: Spool Stroke…695
Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing…695
Swing 2: Hydraulic Drift Of Swing…695
Travel 1: Travel Speed (Without Load)…695
Travel 2: Travel Speed (Actual Run), Travel Deviation…696
Travel 3: Travel Deviation…696
Travel 4: Hydraulic Drift Of Travel…696
Work Equipment 1: Hydraulic Drift Of Work Equipment…696
Work Equipment 2: Boom Speed…697
Work Equipment 3: Arm Speed…697
Work Equipment 4: Bucket Speed…697
Work Equipment 5: Boom Time Lag…697
Work Equipment 6: Arm Time Lag…698
Work Equipment 7: Bucket Time Lag…698
Work Equipment 8: Characteristics Of PC Flow Control Valve…698
30 TESTING AND ADJUSTING…699
SPECIAL TOOL LIST…702
Sketch Of Special Tool…705
ENGINE COMPONENTS…706
Determining A Defective Cylinder…706
Procedures…706
Determining Cylinder Group…706
Isolating the Defective Cylinder…706
Water Pump Leakage…707
Engine Speed…712
Intake Air Pressure (Boost Pressure)…714
Exhaust Gas Color…715
Valve Clearance…717
Compression Pressure…719
Blow-by Pressure…721
Engine Oil Pressure…722
Handling Fuel System Parts…723
Releasing Residual Pressure From Fuel System…723
Fuel Pressure…724
Fuel Return Rate And Leakage…727
Bleeding Air From Fuel Circuit…732
Fuel Circuit – Checking For Leakage…733
AIR CONDITIONER COMPRESSOR BELT TENSION…734
Checking…734
Adjusting…734
FAN BELT…735
SWING CIRCLE BEARING CLEARANCE…736
TRACK SHOE TENSION…738
Checking…738
Adjusting…738
OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…740
Measuring…740
Adjusting…743
CONTROL CIRCUIT BASIC PRESSURE…745
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…747
Measuring…747
Adjusting…749
Pump PC Valve…749
OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…750
Measuring…750
Adjusting…754
LS valve…754
SOLENOID VALVE OUTPUT PRESSURE…755
PPC VALVE OUTPUT PRESSURE…758
Connecting Points Of PPC Piping…758
Adjusting Play of Work Equipment and Swing PPC Valves…760
WORK EQUIPMENT HYDRAULIC DRIFT…761
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…763
OIL LEAKAGE…764
BLEEDING AIR FROM EACH PART…767
CAB TIPPING STOPPER…769
MIRRORS…770
REAR VIEW CAMERA…773
Angle Adjustment…773
MACHINE MONITOR SPECIAL FUNCTIONS…775
Air Conditioner Specification…775
Upper Section of Machine Monitor…776
Display Section…776
Switch Section…776
Lower Section Of Machine Monitor…776
Switch Section…776
Ordinary Functions and Special Functions of Machine Monitor…777
Operator Mode (Outline)…779
Display of KOMATSU Logo…780
Display of Inputting Password…780
Display of Check of Breaker Mode…780
Display of Check Before Starting…781
Display of Warning After Check Before Starting…781
Display of Ending of Maintenance Interval…781
Display of Check of Working Mode and Travel Speed…781
Display of Ordinary Screen…782
Display of End Screen…782
Selection of Auto-Deceleration…782
Selection of Working Mode…782
Selection of Travel Speed…784
Operation to Stop Alarm Buzzer…784
Operation of Windshield Wiper…784
Operation of Window Washer…784
Operation of Air Conditioner/heater…784
Operation to Display Camera Mode (If Camera is Installed)…785
Operation to Display Clock and Service Meter…786
Check of Maintenance Information…786
Setting and Display of User Mode (Including KOMTRAX Messages for User)…787
KOMTRAX Message…788
Display of Energy-Saving Guidance…788
Display of Caution Monitor…788
Display of Automatic Judgment of Breaker…788
Display of User Code and Failure Code…789
Function of Checking Display of LCD (Liquid Crystal Display)…790
Function of Checking Service Meter…790
Function of Changing Attachment/Maintenance Password…790
Service Mode…792
Monitoring…793
Monitoring Items Table…796
Abnormality Record (Mechanical Systems)…799
Abnormality Record (Electrical Systems)…800
Failure Codes Table…802
Abnormality Record (Air-Conditioning System/ Heater System)…806
Maintenance Record…807
Maintenance Mode Change…808
Phone Number Entry…810
Default (Key-on Mode)…811
Default (Unit)…812
Default (With/Without Attachment)…813
Default (Attachment/Maintenance Password)…814
Default (Camera)…815
Default (ECO Display)…816
Default (Breaker Detect)…818
Adjustment (Pump Absorption Torque (F))…819
Adjustment (Pump Absorption Torque (R))…820
Adjustment (Low Speed)…821
Adjustment (Attachment Flow Adjustment)…822
Cylinder Cut-Out…823
No Injection…824
Fuel Consumption…826
KOMTRAX Settings (Terminal Status)…827
KOMTRAX Settings (GPS & Communication Status)…828
KOMTRAX Setting (MODEM S/N: TH300)…829
Display of KOMTRAX message…830
Long Distance Transport Mode…831
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…833
PREPARING FOR ELECTRICAL SYSTEM TROUBLESHOOTING…833
PROCEDURE FOR TESTING DIODES…838
PM CLINIC SERVICE…840
40 TROUBLESHOOTING…849
GENERAL INFORMATION…853
Points To Remember…853
Sequence Of Events In Troubleshooting…855
Handling Electric Equipment and Hydraulic Components…856
New Connectors for Tier 3 Engines…864
Check Before Troubleshooting…868
Classification And Troubleshooting Steps…869
Troubleshooting Classification…869
Troubleshooting steps…869
Information In Troubleshooting Table…870
Related Circuit Diagram…871
Possible Problems and Troubleshooting No…872
How To Read Electric Wire Code…875
Connection Table For Connector Pin Numbers…878
T-boxes and T-adapters Table…911
FAILURE CODE (DISPLAY OF CODE)…914
Failure Codes Table…914
Before Troubleshooting With Failure Code Displayed…919
Fuse Box Connection Table…919
Locations Of Fusible Links…920
Location Of Fuse Box And Fuse Nos…920
Trouble That Occurs When Power Supply Of Pump Controller Is Defective…921
989L00 Engine Controller Lock Caution 1…923
989M00 Engine Controller Lock Caution 2…923
989N00 Engine Controller Lock Caution 3…924
AA10NX Air Cleaner Clogging…924
AB00KE Charge Voltage Low…926
B@BAZG Eng Oil Press. Low…928
B@BAZK Eng Oil Level Low…928
B@BCNS Eng Water Overheat…929
B@BCZK Eng Water Level Low…929
B@HANS Hydr Oil Overheat…930
CA111 EMC Critical Internal Failure…930
CA115 Eng Ne and Bkup Speed Sens Error…931
CA122 Chg Air Press Sensor High Error…932
CA123 Chg Air Press Sensor Low Error…934
CA131 Throttle Sensor High Error…936
CA132 Throttle Sensor Low Error…938
CA144 Coolant Temp Sens High Error…940
CA145 Coolant Temp Sens Low Error…942
CA153 Chg Air Temp Sensor High Error…944
CA154 Chg Air Temp Sensor Low Error…946
CA155 Chg Air Temp High Speed Derate…948
CA187 Sens Supply 2 Volt Low Error…950
CA221 Ambient Press Sens High Error…952
CA222 Ambient Press Sens Low Error…954
CA227 Sens Supply 2 Volt High Error…956
CA234 Eng Overspeed…957
CA238 Ne Speed Sens Supply Volt Error…958
CA271 IMV/PCV1 Short Error…959
CA272 IMV/PCV1 Open Error…960
CA322 Inj #1 Open/Short Error…962
CA323 Inj #5 Open/Short Error…964
CA324 Inj #3 Open/Short Error…966
CA325 Inj #6 Open/Short Error…968
CA331 Inj #2 Open/Short Error…970
CA332 Inj #4 Open/Short Error…972
CA342 Calibration Code Incompatibility…974
CA351 Injectors Drive Circuit Error…976
CA352 Sens Supply 1 Volt Low Error…978
CA386 Sens Supply 1 Volt High Error…980
CA428 Water in Fuel Sensor High Error…982
CA429 Water in Fuel Sensor Low Error…984
CA435 Eng Oil Press Sw Error…986
CA441 Battery Voltage Low Error…987
CA442 Battery Voltage High Error…990
CA449 Rail Press Very High Error…992
CA451 Rail Press Sensor High Error…994
CA452 Rail Press Sensor Low Error…996
CA488 Chg Air Temp High Torque Derate…998
CA553 Rail Press High Error…999
CA559 Rail Press Low Error…1000
CA689 Eng Ne Speed Sensor Error…1002
CA731 Eng Bkup Speed Sens Phase Error…1004
CA757 All Continuous Data Lost Error…1006
CA778 Eng Bkup Speed Sensor Error…1008
CA2185 Throt Sens Sup Volt High Error…1011
CA2186 Throt Sens Sup Volt Low Error…1012
CA2249 Rail Press Very Low Error…1013
CA2311 IMV Solenoid Error…1014
CA2555 Grid Htr Relay Volt High Error…1016
CA2556 Grid Htr Relay Volt Low Error…1018
D19JKZ Personal Code Relay Abnormality…1020
D862KA GPS Antenna Discon…1022
DA22KK Pump Solenoid Power Low Error…1024
DA25KP 5V Sensor 1 Power Abnormality…1026
DA29KQ Model Selection Abnormality…1032
DA2RMC CAN Discon (Pump Con Detected)…1034
DAF8KB Short Circuit In Camera Power Supply…1042
DAFGMC GPS Module Error…1044
DAFRMC CAN Discon (Monitor Detected)…1045
DGH2KB Hyd Oil Sensor Short…1052
DHPAMA F Pump Press Sensor Abnormality…1054
DHPBMA R Pump Press Sensor Abnormality…1056
DHS3MA Arm Curl PPC Press Sensor Abnormality…1058
DHS4MA Bucket Curl PPC Press Sensor Abnormality…1060
DHS8MA Boom Raise PPC Press Sensor Abnormality…1062
DHSAMA Swing RH PPC Press Sensor Abnormality…1064
DHSBMA Swing LH PPC Press Sensor Abnormality…1066
DHSDMA Bucket Dump PPC Press Sensor Abnormality…1068
DHX1MA Overload Sensor Abnormality (Analog)…1070
DW43KA Travel Speed Sol Discon…1074
DW43KB Travel Speed Sol Short…1076
DW45KA Swing Brake Sol Discon…1078
DW45KB Swing Brake Sol Short…1080
DW91KA Travel Junction Sol Discon…1082
DW91KB Travel Junction Sol Short…1084
DWA2KA Service Sol Discon…1086
DWA2KB Service Sol Short…1087
DWK0KA 2-Stage Relief Sol Discon…1088
DWK0KB 2-Stage Relief Sol Short…1090
DXA8KA PC-EPC (F) Sol Discon…1092
DXA8KB PC-EPC (F) Sol Short…1094
DXA9KA PC-EPC (R) Sol Discon…1096
DXA9KB PC-EPC (R) Sol Short…1098
DXE0KA LS-EPC Sol Discon…1100
DXE0KB LS-EPC Sol Short…1102
DXE4KA Service Current EPC Discon…1104
DXE4KB Service Current EPC Short…1106
DXE5KA Merge-divider Main Sol Discon…1108
DXE5KB Merge-divider Main Sol Short…1110
DXE6KA Merge-divider LS Sol Discon…1112
DXE6KB Merge-divider LS Sol Short…1114
DY20KA Wiper Working Abnormality…1116
DY20MA Wiper Parking Abnormality…1118
DY2CKA Washer Drive Discon…1120
DY2CKB Washer Drive Short…1122
DY2DKB Wiper Drive (For) Short…1124
DY2EKB Wiper Drive (Rev) Short…1126
ELECTRICAL SYSTEM (E-MODE)…1128
Troubleshooting Table…1128
E-1 No Machine Monitor Display When Starting Switch Is Turned On…1130
E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)…1132
E-3 Engine Does Not Start…1135
E-4 Preheater Does Not Operate…1140
E-5 Automatic Warm-up System Does Not Operate (In Cold Season)…1144
E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked…1146
E-7 Precaution Lights Up While Engine Is Running…1148
E-8 Emergency Stop Item Lights Up While Engine Is Running…1153
E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally…1154
E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally…1155
E-11 Fuel Level Gauge Does Not Indicate Normally…1158
E-12 Machine Monitor Content Displays Are Different From Applicable Machine…1160
E-13 Machine Monitor Does Not Display Some Items…1160
E-14 Function Switch Does Not Work…1160
E-15 Auto-decelerator Does Not Operate Normally…1161
E-16 Working Mode Does Not Change…1162
E-17 Travel Speed Does Not Change…1163
E-18 Alarm Buzzer Cannot be Stopped…1164
E-19 Windshield Wiper and Window Washer Do Not Operate…1166
E-20 Power Maximizing Function Does Not Operate Normally…1168
E-21 Swing Holding Brake Does Not Operate Normally…1170
E-22 Travel Alarm Does Not Sound or Does Not Stop…1172
E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)…1174
E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position…1196
E-25 Machine Monitor Cannot Be Set In Service Mode…1196
E-26 Monitoring Function Does Not Display Lever Control Signal Normally…1197
E-27 Komtrax System Does Not Operate Normally…1206
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1208
System Diagram of Hydraulic and Mechanical System…1208
Information In Troubleshooting Table…1210
H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow…1211
H-2 Engine Speed Drops Sharply or Engine Stalls…1213
H-3 Work Equipment, Swing, and Travel Systems Do Not Work…1214
H-4 Abnormal Noise Is Heard Around Hydraulic Pump…1214
H-5 Auto-decelerator Does Not Work…1215
H-6 Fine Control Mode Does Not Function or Responds Slow…1215
H-7 Boom Moves Slowly or Lacks Power…1216
H-8 Arm Moves Slowly or Lacks Power…1217
H-9 Bucket Moves Slowly or Lacks Power…1218
H-10 Work Equipment Does Not Move In Its Single Operation…1218
H-11 Work Equipment Hydraulic Drift Is Too Fast…1219
H-12 Work Equipment Has Big Time Lag…1221
H-13 Other Work Equipment Moves When Relieving Single Circuit…1221
H-14 Power Maximizing Function Does Not Work…1222
H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly…1222
H-16 In Swing and Boom Raise Operation, Boom Moves Slowly…1223
H-17 In Swing and Travel Operation, Travel Speed Drops Sharply…1223
H-18 Machine Swerves In Travel…1224
H-19 Machine Travels Slowly…1225
H-20 Machine Steers With Difficulty or Lacks Power…1226
H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast…1227
H-22 Track Shoe Does Not Turn (On One Side Only)…1228
H-23 Machine Does Not Swing…1229
H-24 Swing Acceleration Is Poor or Swing Speed Is Slow…1231
H-25 Excessive Overrun When Stopping Swing…1233
H-26 There Is a Big Jolt When Stopping Swing…1234
H-27 Large Sound Is Made When Upper Structure Stops Swinging…1234
H-28 Swing Hydraulic Drift Is Too Big…1235
H-29 Attachment Circuit Is Not Changed…1236
H-30 Oil Flow In Attachment Circuit Cannot Be Controlled…1236
50 DISASSEMBLY AND ASSEMBLY…1237
HOW TO READ THIS SECTION…1241
Removal And Installation Of Assemblies…1241
Special Tools…1241
Removal…1241
Installation…1241
Disassembly And Assembly Of Assemblies…1242
Special Tools…1242
Disassembly…1242
Assembly…1243
SPECIAL TOOLS LIST…1244
SKETCHES OF SPECIAL TOOLS…1249
CONNECTOR REPAIR PROCEDURES…1254
Stripping Insulation…1254
Wire Inspection…1254
Contact Terminal Removal (HD30 Type)…1255
Crimping Contact Terminal (HD30 Type)…1256
Insertion Of Contact Terminal (HD30 Type)…1257
Contact Terminal Removal (DT Type)…1258
Crimping Contact Terminal (DT Type)…1259
Insertion Of Contact Terminal (DT Type)…1260
ENGINE AND COOLING SYSTEM…1261
Fuel Supply Pump Assembly…1261
Special Tools…1261
Removal…1261
Installation…1265
Fuel Injector Assembly…1267
Special Tools…1267
Removal…1267
Installation…1272
Engine Front Seal…1277
Special Tools…1277
Removal…1277
Installation…1279
Engine Rear Seal…1281
Special Tools…1281
Removal…1281
Installation…1282
Cylinder Head…1285
Special Tools…1285
Removal…1285
Installation…1293
Radiator…1303
Removal…1303
Installation…1305
Hydraulic Oil Cooler…1307
Removal…1307
Installation…1309
Aftercooler Assembly…1310
Removal…1310
Installation…1312
Fuel Cooler…1313
Removal…1313
Installation…1313
Engine And Hydraulic Pump…1314
Special Tools…1314
Removal…1314
Installation…1323
POWER TRAIN…1326
Final Drive…1326
Removal…1326
PC200LC-8 Final Drive…1328
Special Tools…1328
Disassembly…1328
Assembly…1331
Swing Motor and Swing Machinery…1338
Removal…1338
Installation…1340
Swing Motor and Swing Machinery…1341
Special Tools…1341
Disassembly…1341
Assembly…1346
Swing Circle Assembly…1352
Removal…1352
Installation…1352
UNDERCARRIAGE AND FRAME…1353
Carrier Roller…1353
Special Tools…1353
Disassembly…1353
Assembly…1354
Track Roller…1357
Special Tools…1357
Disassembly…1357
Assembly…1357
Idler, Recoil Spring…1359
Removal…1359
Installation…1359
Idler…1360
Special Tools…1360
Disassembly…1360
Assembly…1361
Recoil Spring…1364
Special Tools…1364
Disassembly…1364
Assembly…1365
Sprocket…1367
Removal…1367
Installation…1367
Track Shoe…1368
Special Tools…1368
Expanding Track Shoe…1368
Installation of Track Shoe…1370
Revolving Frame…1371
Removal…1371
Installation…1373
Counterweight…1374
Special Tools…1374
Removal…1374
Installation…1376
HYDRAULIC SYSTEM…1377
Center Swivel Joint…1377
Removal…1377
Installation…1378
Special Tools…1379
Disassembly…1379
Assembly…1380
Hydraulic Tank…1381
Removal…1381
Installation…1384
Control Valve…1385
Removal…1385
Installation…1390
Special Tools…1391
Precautions for Replacing Pressure Compensation Valve Seal…1392
Precautions for Assembling Control Valve…1394
Hydraulic Pump…1397
Special Tools…1397
Removal…1397
Installation…1401
Oil Seal In Hydraulic Pump Input Shaft…1402
Special Tools…1402
Removal…1402
Installation…1402
Work Equipment PPC Valve…1403
Disassembly…1403
Assembly…1403
Travel PPC Valve…1405
Special Tools…1405
Disassembly…1405
Assembly…1406
Hydraulic Cylinder…1408
Special Tools…1408
Disassembly…1409
Assembly…1411
WORK EQUIPMENT…1415
Work Equipment Assembly…1415
Special Tools…1415
Removal…1415
Installation…1417
CAB AND ITS ATTACHMENTS…1418
Operator's Cab…1418
Removal…1418
Installation…1421
Operator Cab Glass (Fixed Glass)…1422
Special Tools…1423
Removal…1423
Installation…1424
Front Window…1433
Removal…1433
Installation…1436
Floor Frame Assembly…1441
Special Tools…1441
Removal…1441
Installation…1445
ELECTRICAL SYSTEM…1446
Air Conditioner Unit Assembly…1446
Special Tools…1446
Removal…1446
Installation…1450
KOMTRAX Communication Modem…1451
Removal…1451
Installation…1451
Monitor…1452
Removal…1452
Installation…1453
Pump Controller…1454
Removal…1454
Installation…1455
Engine Controller…1457
Removal…1457
Installation…1458
90 DIAGRAMS AND SCHEMATICS…1459
HYDRAULIC SYSTEM…1461
Hydraulic Circuit Diagram…1461
ELECTRICAL SYSTEM…1462
Electrical Circuit Diagram…1462
Connector Arrangement Diagram…1463
Electrical Circuit Diagram for Air Conditioner…1464
SEAM016301 – Hydraulic Excavator PC200-6 Operation & Maintenance Manual…1465
1. FOREWORD…1466
2. SAFETY INFORMATION…1467
3. INTRODUCTION…1468
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1469
5. CONTENTS…1470
SAFETY …1474
6. GENERAL PRECAUTIONS …1475
7. PRECAUTIONS DURING OPERATION …1482
7.1 BEFORE STARTING ENGINE …1482
7.2 AFTER STARTING ENGINE …1484
7.3 TRANSPORTATION …1491
7.4 BATTERY…1492
7.5 TOWING …1494
7.6 LIFTING OPERATIONS …1494
8. PRECAUTIONS FOR MAINTENANCE …1495
8.1 BEFORE CARRYING OUT MAINTENANCE …1495
8.2 DURING MAINTENANCE…1499
9. POSITION FOR ATTACHING SAFETY LABELS …1504
OPERATION …1508
10. GENERAL VIEW …1509
10.1 GENERAL VIEW OF MACHINE …1509
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1510
11. EXPLANATION OF COMPONENTS …1511
11.1 MACHINE MONITOR …1511
11.2 SWITCHES …1516
11.3 CONTROL LEVERS AND PEDALS …1520
11.4 CEILING WINDOW …1525
11.5 FRONT WINDOW…1526
11.6 DOOR LOCK …1528
11.7 ASHTRAY …1528
11.8 CAP, COVER WITH LOCK …1529
11.9 COOLER …1530
11.10 CASSETTE/RADIO …1532
11.11 FUSE…1538
11.12 FUSIBLE LINK …1539
11.13 TOOL BOX …1539
11.14 GREASE PUMP HOLDER …1539
11.15 HANDLING ACCUMULATOR…1540
12. OPERATION …1541
12.1 CHECK BEFORE STARTING ENGINE …1541
12.2 STARTING ENGINE…1550
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …1552
12.4 MOVING MACHINE OFF…1554
12.5 STEERING MACHINE …1557
12.6 STOPPING MACHINE…1559
12.7 SWINGING…1560
12.8 OPERATION OF WORK EQUIPMENT …1561
12.9 PROHIBITIONS FOR OPERATION …1562
12.10 PRECAUTIONS FOR OPERATION…1564
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1565
12.12 HOW TO ESCAPE FROM MUD …1567
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1568
12.14 REPLACEMENT AND INVERSION OF BUCKET …1569
12.15 PARKING MACHINE …1571
12.16 CHECK AFTER FINISHING WORK …1572
12.17 STOPPING ENGINE …1573
12.18 CHECK AFTER STOPPING ENGINE …1574
12.19 LOCKING …1574
13. TRANSPORTATION …1575
13.1 LOADING, UNLOADING WORK…1575
13.2 PRECAUTIONS FOR LOADING …1577
13.3 PRECAUTIONS FOR TRANSPORTATION …1578
14. COLD WEATHER OPERATION …1579
14.1 PRECAUTIONS FOR LOW TEMPERATURE …1579
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1581
14.3 AFTER COLD WEATHER …1581
15. LONG-TERM STORAGE …1582
15.1 BEFORE STORAGE …1582
15.2 DURING STORAGE …1583
15.3 AFTER STORAGE …1583
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE …1583
16. TROUBLESHOOTING …1584
16.1 PHENOMENA THAT ARE NOT FAILURES …1584
16.2 METHOD OF TOWING MACHINE …1584
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE …1584
16.4 PRECAUTIONS ON PARTICULAR JOBSITES …1585
16.5 IF BATTERY IS DISCHARGED …1585
16.6 OTHER TROUBLE…1589
MAINTENANCE …1593
17. GUIDES TO MAINTENANCE …1594
18. OUTLINES OF SERVICE …1597
18.1 OUTLINE OF OIL, FUEL, COOLANT …1597
18.2 OUTLINE OF ELECTRIC SYSTEM …1600
18.3 OUTLINE OF HYDRAULIC SYSTEM …1601
19. WEAR PARTS LIST …1602
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …1604
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1608
21.1 INTRODUCTION OF NECESSARY TOOLS …1608
21.2 TORQUE LIST …1609
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1610
23. MAINTENANCE SCHEDULE CHART …1614
23.1 MAINTENANCE SCHEDULE CHART …1614
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER …1616
24. SERVICE PROCEDURE …1617
24.1 INITIAL 250 HOURS SERVICE …1617
24.2 WHEN REQUIRED …1618
24.3 CHECK BEFORE STARTING …1636
24.4 EVERY 100 HOURS SERVICE …1641
24.5 EVERY 250 HOURS SERVICE …1644
24.6 EVERY 500 HOURS SERVICE …1650
24.7 EVERY 1000 HOURS SERVICE …1655
24.8 EVERY 2000 HOURS SERVICE …1658
24.9 EVERY 4000 HOURS SERVICE …1661
24.10 EVERY 5000 HOURS SERVICE …1662
SPECIFICATIONS …1667
25. SPECIFICATIONS …1668
OPTIONS, ATTACHMENTS …1671
26. GENERAL PRECAUTIONS …1672
26.1 PRECAUTIONS RELATED TO SAFETY …1672
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS …1673
27. HANDLING BUCKET WITH HOOK …1674
27.1 CHECKING FOR DAMAGE TO BUCKET WITH …1674
27.2 PROHIBITED OPERATIONS …1674
27.3 PRECAUTIONS DURING OPERATIONS …1674
28. USING SEAT BELT …1675
28.1 SEAT BELT …1675
29. MACHINES READY FOR ATTACHMENTS …1677
29.1 EXPLANATION OF COMPONENTS…1677
29.2 HYDRAULIC CIRCUIT …1679
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE …1681
29.4 OPERATION …1683
29.5 LONG-TERM STORAGE …1684
29.6 SPECIFICATIONS …1684
30. INTRODUCTION OF ATTACHMENTS …1685
30.1 SPECIFICATION, USE …1685
30.2 ATTACHMENT INSTALLATION COMBINATION TABLE …1686
30.3 SELECTION OF TRACK SHOES …1687
30.4 SELECTION OF BUCKET TEETH …1688
30.5 HANDLING RUBBER PAD SHOE …1689
30.6 HANDLING TRAPEZOIDAL BUCKET …1691
30.7 HANDLING EXTENSION ARM…1692
30.8 HANDLING CLAMSHELL BUCKET …1693
31. EXTENDING MACHINE SERVICE LIFE …1694
31.1 HYDRAULIC BREAKER …1694
31.2 POWER RIPPER …1697
31.3 FORK GRAB …1698
31.4 GRAPPLE BUCKET …1699
31.5 SCRAP GRAPPLE …1700
31.6 CRUSHER & CUTTER …1701
31.7 HYDRAULIC PILE DRIVER …1702
31.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE …1703
SEAM021701 – Hydraulic Excavator PC200-6 avance Series Operation & Maintenance Manual…1705
COVER…1705
1. FOREWORD…1708
2. SAFETY INFORMATION…1709
3. INTRODUCTION…1710
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. DISTRIBUTOR…1711
5. CONTENTS…1712
SAFETY…1716
6. GENERAL PRECAUTIONS…1717
7. PRECAUTIONS DURING OPERATION…1725
7.1 BEFORE STARTING ENGINE…1725
7.2 AFTER STARTING ENGINE…1727
7.3 SHIPPING…1734
7.4 BATTERY…1735
7.5 TOWING…1737
7.6 LIFTING OPERATIONS…1737
7.7 BUCKET WITH HOOK…1738
8. PRECAUTIONS FOR MAINTENANCE…1740
8.1 BEFORE CARRYING OUT MAINTENANCE…1740
8.2 DURING MAINTENANCE…1744
9. POSITION FOR ATTACHING SAFETY LABELS…1750
OPERATION…1754
10. GENERAL VIEW…1755
10.1 GENERAL VIEW OF MACHINE…1755
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1756
11. EXPLANATION OF COMPONENTS…1757
11.1 MACHINE MONITOR…1757
11.2 SWITCHES…1762
11.3 CONTROL LEVERS AND PEDALS…1766
11.4 CEILING WINDOW…1771
11.5 FRONT WINDOW…1772
11.6 DOOR LOCK…1774
11.7 ASHTRAY…1774
11.8 CAP, COVER WITH LOCK…1775
11.9 HANDLING CAR HEATER…1776
11.10 FUSE…1777
11.11 FUSIBLE LINK…1778
11.12 TOOL BOX…1778
11.13 GREASE PUMP HOLDER…1778
11.14 HANDLING ACCUMULATOR…1779
12. OPERATION…1780
12.1 CHECK BEFORE STARTING ENGINE…1780
12.2 STARTING ENGINE…1790
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1792
12.4 MOVING MACHNE OFF…1794
12.5 STEERING MACHINE …1797
12.6 STOPPING MACHINE…1799
12.7 SWINGING…1800
12.8 OPERATION OF WORK EQUIPMENT…1801
12.9 PROHIBITIONS FOR OPERATION…1802
12.10 PRECAUTIONS FOR OPERATION…1804
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1805
12.12 HOW TO ESCAPE FROM MUD…1807
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1808
12.14 REPLACEMENT AND INVERSION OF BUCKET…1809
12.15 PARKING MACHINE…1811
12.16 CHECK AFTER FINISHING WORK…1812
12.17 STOPPING ENGINE…1813
12.18 CHECK AFTER STOPPING ENGINE…1814
12.19 LOCKING…1814
13. TRANSPORTATION…1815
13.1 LOADING, UNLOADING WORK…1815
13.2 PRECAUTIONS…1817
13.3 PRECAUTIONS FOR TRANSPORATION…1818
14. COLD WEATHER OPERATION…1819
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1819
14.2 PRECAUTIONS FOR LOADING…1821
14.3 AFTER COLD WEATHER…1821
15. LONG-TERM STORAGE…1822
15.1 BEFORE STORAGE…1822
15.2 DURING STORAGE…1823
15.3 AFTER STORAGE…1823
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…1823
16. TROUBLESHOOTING…1824
16.1 PHENOMENA THAT ARE NOT FAILURES…1824
16.2 METHOD OF TOWING MACHINE…1824
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING MACHINE…1824
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…1825
16.5 IF BATTERY IS DISCHARGED…1825
16.6 OTHER TROUBLE…1829
MAINTENANCE…1834
17. GUIDES TO MAINTENANCE…1835
18. OUTLINES OF SERVICE…1838
18.1 OUTLINE OF OIL, FUEL, COOLANT…1838
18.2 OUTLINE OF ELECTRIC SYSTEM…1841
18.3 OUTLINE OF HYDRAULIC SYSTEM…1713
19. WEAR PARTS LIST…1843
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1844
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1849
21.1 INTRODUCTION OF NECESSARY TOOLS…1849
21.2 TORQUE LIST…1850
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1851
23. MAINTENANCE SCHEDULE CHART…1855
23.1 MAINTENANCE SCHEDULE CHART…1855
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…1857
24. SERVICE PROCEDURE…1858
24.1 INITIAL 250 HOURS SERVICE…1858
24.2 WHEN EQUIRED…1859
24.3 CHECK BEFORE STARTING…1878
24.4 EVERY 100 HOURS SERVICE…1883
24.5 EVERY 250 HOURS SERVICE…1886
24.6 EVERY 500 HOURS SERVICE…1892
24.7 EVERY 1000 HOURS SERVICE…1897
24.8 EVERY 2000 HOURS SERVICE…1900
24.9 EVERY 4000 HOURS SERVICE…1903
24.10 EVERY 5000 HOURS SERVICE…1904
SPECIFICATIONS…1910
25. SPECIFICATIONS…1911
OPTIONS AND ATTACHMENTS…1916
26. GENERAL PRECAUTIONS…1917
26.1 PRECAUTIONS RELATED TO SAFETY…1917
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1918
27. HANDLING BUCKET WITH HOOK…1919
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1919
27.2 PROHIBITED OPERATIONS…1919
27.3 PRECAUTIONS DURING OPERATIONS…1919
28. AIR CONDITIONER (MACHINES EQUIPPED WITH AIR CONDITIONER)…1920
28.1 AIR CONDITIONER…1920
29. MACHINES READY FOR ATTACHMENTS…1923
29.1 EXPLANATION OF COMPONENTS…1923
29.2 HYDRAULIC CIRCUIT…1925
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…1927
29.4 OPERATION…1929
29.5 LONG-TERM STORAGE…1930
29.6 SPECIFICATIONS…1930
30. INTRODUCTION OF ATTACHMENTS…1931
30.1 BUCKET SELECTION…1931
30.2 BUCKET INSTALLATION COMINATIONS…1931
30.3 BACKHOE CONTROL PATTERN CONVERSION…1933
30.4 SELECTION OF TRACK SHOES…1934
30.5 HANDLING RUBBER PAD SHOE…1935
30.6 HANDLING TRAPEZODIAL BUCKET…1937
30.7 HANDLING EXTENSION ARM…1938
30.8 HANDLING CLAMSHELL BUCKET…1939
31. EXTENDING MACHINE SERVICE LIFE…1940
31.1 HYDRAULIC BREAKER…1940
31.2 POWER RIPPER…1943
31.3 FORK GRAB…1944
31.4 GRAPPLE BUCKET…1945
31.5 SCRAP GRAPPLE…1946
31.6 CRUSHER & CUTTER…1947
31.7 HYDRAULIC PILE DRIVER…1948
31.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…1949
SEAM023800PT – Hydraulic Excavator PC200-6, PC200LC-6 Operation & Maintenance Manual…1953
COVER…1954
CONTENTS…1961
1. FOREWORD…1957
2. SAFETY INFORMATION…1958
3. INTRODUCTION…1959
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1960
SAFETY…1965
6. GENERAL PRECAUTIONS…1966
7. PRECAUTIONS DURING OPERATION…1973
7.1 BEFORE STARTING ENGINE…1973
7.2 AFTER STARTING ENGINE…1975
7-3 TRANSPORTATION…1982
7-4 BATTERY…1983
7.5 TOWING…1985
7.6 LIFTING OPERATIONS…1985
8. PRECAUTIONS FOR MAINTENANCE…1986
8.1 BEFORE CARRYING OUT MAINTENANCE…1986
8.2 DURING MAINTENANCE…1990
9. POSITION FOR ATTACHING SAFETY LABELS…1996
OPERATION…2003
10. GENERAL VIEW…2004
10.1 GENERAL VIEW OF MACHINE…2004
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…2005
11. EXPLANATION OF COMPONENTS …2006
11.1 MACHINE MONITOR…2006
11.2 SWITCHES…2017
11.3 CONTROL LEVERS, PEDALS…2021
11.4 CEILING WINDOW…2026
11.5 FRONT WINDOW…2027
11.6 DOOR LOCK…2029
11.7 CAP, COVER WITH LOCK…2030
11.8 HOT/COOL BOX…2031
11.9 LUGGAGE BOX…2031
11.10 ASHTRAY…2031
11.11 AIR CONDITIONER…2032
11.12 CAR RADIO…2035
11.13 FUSE…2040
11.14 FUSIBLE LINK…2041
11.15 CONTROLLERS…2041
11.16 TOOL BOX…2041
11.17 GREASE PUMP HOLDER…2041
11.18 HANDLING ACCUMULATOR…2042
12. OPERATION…2044
12.1 CHECK BEFORE STARTING ENGINE…2044
12.2 STARTING ENGINE…2054
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…2057
12.4 MOVING MACHINE OFF…2063
12.5 STEERING MACHINE…2066
12.6 STOPPING MACHINE…2068
12.7 SWINGING…2069
12.8 OPERATION OF WORK EQUIPMENT…2070
12.9 HANDLING ACTIVE MODE…2071
12.10 WORKING MODE SELECTION…2073
12.11PROHIBITIONS FOR OPERATION…2075
12.12 PRECAUTIONS FOR OPERATION…2077
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILL…2078
12.14 HOW TO EXCAOR FRON…2080
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…2081
12.16 REPLACEMENT AND INVERSION OF BUCKET…2082
12.17 PARKING MACHINE…2084
12.18 CHECK AFTER FINISHING WORK…2085
12.19 STOPPING ENGINE…2086
12.20 CHECK AFTER STOPPING ENGINE…2087
12.21 LOCKING…2087
13. TRANSPORTATION…2088
13.1 LOADING, UNLOADING WORK…2088
13.2 PRECAUTION…2090
13.3 PRECAUTIONS FOR TRANSPORTATION…2091
14. COLD WEATHER…2092
14.1 PRECAUTIONS FOR LOADING…2092
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…2094
14.3 AFTER COLD WEATHER…2094
15. LONG-TERM STORAGE…2095
15.1 BEFORE STORAGE…2095
15.2 DURING STORAGE…2096
15.3 AFTER STORAGE…2096
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…2096
16. TROUBLESHOOTING…2097
16.1 PHENOMENA THAT ARE NOT FAILURES…2097
16.2 METHOD OF TOWING MACHINE…2097
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…2097
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…2098
16.5 IF BATTERY IS DISCHARGED…2098
16.6 OTHER TROUBLE…2102
MAINTENANCE…2107
17. GUIDES TO MAINTENANCE…2108
18. OUTLINES OF SERVICE…2111
18.1 OUTLINE OF OIL, FUEL, COOLANT…2111
18.2 OUTLINE OF ELECTRIC SYSTEM…2114
18.3 OUTLINE OF HYDRAULIC SYSTEM…2115
19. WEAR PARTS LIST…2116
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2118
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2122
21.1 INTRODUCTION OF NECESSARY TOOLS…2122
21.2 TORQUE LIST…2123
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2124
23. MAINTENANCE SCHEDULE CHART…2128
23.1 MAINTENANCE SCHEDULE CHART…2128
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…2130
24. SERVICE PROCEDURE…2131
24.1 INITIAL 250 HOURS SERVICE…2131
REPLACE FUEL CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION)…2131
CHECK ENGINE VALVE CLEARANCE, ADJUST…2131
24.2 WHEN REQUIRED …2132
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2132
CLEAN INSIDE OF COOLING SYSTEM…2134
CHECK AND TIGHTEN TRACK SHOE BOLTS…2138
CHECK AND TIGHTEN TRACK TENSION…2139
CHECK ELECTRICAL INTAKE AIR HEATER…2141
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…2142
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…2145
ADJUST BUCKET CLEARANCE…2146
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2147
CHECK AND ADJUST AIR CONDITIONER…2148
REPLACE ADDITIONAL BREAKET FILTER ELEMENT…2149
24.3 CHECK BEFORE STARTING…2150
CHECK COOLANT LEVEL, ADD WATER…2150
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…2150
CHECK FUEL LEVEL IN HYDRAULIC TANK, ADD OIL…2151
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…2152
CHECK AIR CLEANER FOR CLOGGING…2153
CHECK ELECTRIC WIRINGS…2153
LUBRICATE CLAMSHELL BUCKET (12 POINTS)…2154
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER (OPTION)…2154
24.4 EVERY 100 HOURS SERVICE…2155
BOOM CYLINDER FOOT PIN (2 POINTS)…2155
BOOM FOOT PIN (2 POINTS)…2155
BOOM CYLINDER ROD END (2 POINTS)…2155
ARM CYLINDER FOOT PIN (1 POINT)…2155
BOOM-ARM COUPLING PIN (1 POINT)…2156
ARM CYLINDER ROD END (1 POINT)…2156
BUCKET CYLINDER FOOT PIN (1 POINT)…2156
ARM-LINK COUPLING PIN (1 POINT)…2156
ARM-BUCKET COUPLING PIN (1 POINT)…2156
LINK COUPLING PIN (2 POINT)…2156
BUCKET CYLINDER ROD END (1 POINT)…2156
BUCKET-LINK COUPLING PIN (1 POINT)…2156
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…2156
DRAIN WATER AND SEDIMENT FROM FUEL TANK…2157
24.5 EVERY 250 HOURS SERVICE…2158
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2158
CHECK LEVEL OF BATTERY ELECTROLYTE…2159
CHANGE OIL ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2160
LUBRICATE SWING CIRCLE (2 POINTS)…2161
CHECK FAN TENSION, ADJUST…2162
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…2163
24.6 EVERY 500 HOURS SERVICE…2164
REPLACE FUEL FILTER CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION)…2164
CHECK SWING PINION GREASE LEVEL, ADD GREASE…2165
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…2166
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…2167
REPLACE HYDRAULIC TANK BREAHER ELEMENT…2167
REPLACE HYDRAULIC FILTER ELEMENT…2168
24.7 EVERY 1000 HOURS SERVICE…2169
CHANGE OIL IN SWING MACHINERY CASE…2169
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…2170
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…2170
CHECK PLAY OF TURBOCHARGER ROTOR…2170
CHECK ALTERNATOR BELT TENSION AND REPLACE ALTERNATOR BELT…2171
REPLACE CORROSION RESISTOR CARTRIDGE…2171
24.8 EVERY 2000 HOURS SERVICE…2172
CHANGE OIL IN FINAL DRIVE CASE…2172
CLEAN HYDRAULIC TANK STRAINER…2173
CLEAN, CHECK TURBOCHARGER…2173
CHECK ALTERNATOR, STARTING MOTOR…2173
CHECK ENGINE VALVE CLEARANCE, ADJUST…2173
CHECK VIBRATION DAMPER…2174
24.9 EVERY 4000 HOURS SERVICE…2175
CHECK WATER PUMP…2175
24.10 EVERY 5000 HOURS SERVICE…2176
CHANGE OIL IN HYDRAULIC TANK…2176
SPECIFICATIONS…2181
25. SPECIFICATIONS…2182
OPTIONS, ATTACHMENTS…2186
26. GENERAL PRECAUTIONS…2187
26.1 PRECAUTIONS RELATED TO SAFETY…2187
26.2 PRECAUTIONS RELATED TO SAFETY…2188
27. HANDLING BUCKET WITH HOOK…2189
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…2189
27.2 PROHIBITED OPERATIONS…2189
27.3 PRECAUTIONS DURING OPERATIONS…2189
28. USING SEAT BELT…2190
28.1 SEAT BELT…2190
29. HANDLING CAR HEATER…2192
29.1 EXPLANATION OF COMPONENTS…2192
29.2 PREPARING CAR HEATER…2193
30. MACHINE READY FOR ATTACHMENTS…2194
30.1 EXPLANATION OF COMPONENTS…2194
30.2 HYDRAULIC CIRCUIT…2196
30.3 ATTACHMENT MOUNTING/D IMOUNTING…2198
30.4 OPERATION…2200
30.5 LONG-TERM STORAGE…2201
30.6 SPECIFICATIONS…2201
31. INTRODUCTION OF ATTACHMENTS…2202
31.1 SPECIFICATION, USE…2202
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…2203
31.3 SELECTION OF TRACK SHOES…2204
31.4 SELECTION OF BUCKET TEETH…2205
31.5 HANDLING RUBBER PAD SHOE…2206
31.6 HANDLING TAPEZOID …2208
31.7 HANDING EXTENSION ARM…2209
31.8 HANDLING CLAMSHELL BUCKET…2210
31.9 HANDLING VARIABLE 2-PIECE BOOM, ROTATING ARM…2211
32. EXTENDING MACHINE SERVICE LIFE…2220
32.1 HYDRAULIC BREAKER…2220
32.2 POWER RIPPER…2224
32.3 FORK GRAB…2225
32.4 GRAPPLE BUCKET…2226
32.5 SCRAP BUCKET…2227
32.6 CRUSHER & CUTTER…2228
32.7 HYDRAULIC PILE DRIVER…2229
32.8 HYDRAULIC EXCAVTOR WITH MULTI-PURPOSE CRANE …2230
SEAM045200ATH – Hydraulic Excavator GALEO PC200-7, PC200LC-7 Operation & Maintenance Manual…2232
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SEBM010201 – Hydraulic Excavator PC200-6 Shop Manual…2606
COVER…2606
CONTENTS…2607
SAFETY …2608
SAFETY NOTICE …2608
FOREWORD …2610
GENERAL…2610
HOW TO READ THE SHOP MANUAL…2611
HOISTING INSTRUCTIONS…2612
COATING MATERIALS…2613
STANDARD TIGHTENING TORQUE…2615
ELECTRIC WIRE CODE…2618
CONVERSION TABLE…2619
01 GENERAL…2625
SPECIFICATION DIMENSION DRAWINGS…2626
SPECIFICATIONS …2627
WEIGHT TABLE …2629
FUEL, COOLANT AND LUBRICANTS…2631
10 STRUCTURE AND FUNCTION…2633
ENGINE RELATED PARTS …2634
RADIATOR, OIL COOLER, AFTERCOOLER …2635
ENGINE CONTROL …2636
POWER TRAIN …2637
FINAL DRIVE …2638
SWING CIRCLE …2639
SWING MACHINERY …2640
TRACK FRAME, RECOIL SPRING …2641
TRACK SHOE …2642
HYDRAULIC PIPING DRAWING…2643
HYDRAULIC CIRCUIT DIAGRAM …2644
HYDRAULIC TANK …2645
HYDRAULIC PUMP …2646
CONTROL VALVE …2665
SELF-REDUCING PRESSURE VALVE …2673
CLSS …2678
SWING MOTOR…2712
CENTER SWIVEL JOINT…2716
TRAVEL MOTOR…2718
VALVE CONTROL…2726
WORK EQUIPMENT, SWING PPC VALVE…2727
TRAVEL PPC VALVE…2731
SERVICE PPC VALVE…2735
ACCUMULATOR…2738
STRAIGHT-TRAVEL SYSTEM…2739
EPC SOLENOID VALVE…2740
BOOM HOLDING VALVE…2742
ADDITIONAL FILTER FOR BREAKER…2745
WORK EQUIPMENT…2746
ACTUAL ELECTRICAL WIRING DIAGRAM…2747
ELECTRICAL CIRCUIT DIAGRAM…2749
ELECTRIC CONTROL SYSTEM…2751
MACHINE MONITOR SYSTEM…2758
SENSORS…2761
20 TESTING AND ADJUSTING…2763
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS …2764
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS …2765
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM …2773
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING …2776
MEASURING ENGINE SPEED…2777
MEASURING EXHAUST GAS COLOR …2778
ADJUSTING VALVE CLEARANCE …2779
MEASURING COMPRESSION PRESSURE …2780
MEASURING BLOW-BY PRESSURE …2780
TESTING AND ADJUSTING FUEL INJECTION TIMING …2781
MEASURING ENGINE OIL PRESSURE …2782
TESTING AND ADJUSTING FAN BELT TENSION …2783
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR …2783
MEASURING SPEED SENSOR …2784
ADJUSTING FUEL CONTROL LEVER …2785
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT …2787
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) …2790
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE …2792
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE …2795
TESTING SOLENOID VALVE OUTPUT PRESSURE …2796
MEASURING PPC VALVE OUTPUT PRESSURE …2797
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE …2799
TESTING TRAVEL DEVIATION …2800
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT …2801
MEASURING OIL LEAKAGE …2803
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT …2805
TESTING CLEARANCE OF SWING CIRCLE BEARING…2806
TESTING AND ADJUSTING TRACK SHOE TENSION…2807
BLEEDING AIR…2808
TROUBLESHOOTING…2810
POINTS TO REMEMBER WHEN TROUBLESHOOTING…2811
SEQUENCE OF EVENTS IN TROUBLESHOOTING…2812
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…2813
CHECKS BEFORE TROUBLESHOOTING…2821
CONNECTOR TYPES AND MOUNTING LOCATIONS…2822
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2827
METHOD OF USING TROUBLESHOOTING CHARTS…2837
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…2839
METHOD OF USING TROUBLESHOOTING CHARTS…2840
S-1 Starting performance is poor (starting always takes time)…2844
S-2 Engine does not start…2845
(1) Engine does not turn…2845
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)…2846
(3) Exhaust smoke comes out but engine does not start (fuel is being injected)…2847
S-3 Engine does not pick up smoothly (follow-up is poor)…2848
S-4 Engine stops during operations…2849
S-5 Engine does not rotate smoothly (hunting)…2850
S-6 Engine lacks output (no power)…2851
S-7 Exhaust smoke is black (incomplete combustion)…2852
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2853
S-9 Oil becomes contaminated quickly…2854
S-10 Fuel consumption is excessive…2855
S-11 Oil is in cooling water, or water spurts back, or water level goes down…2856
S-12 Oil pressure caution lamp lights up (drop in oil pressure)…2857
S-13 Oil level rises (water, fuel in oil)…2858
S-14 Water temperature becomes too high (overheating)…2859
S-15 Abnormal noise is made…2860
S-16 Vibration is excessive…2861
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…2862
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS…2863
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM…2865
FAILURE CODES…2866
E-1 Abnormality in PC-EPC control system…2866
a) Engine stops even when throttle lever is not returned to STOP position. When sudden load is applied, engine stalls…2866
b) Lacks power when throttle lever is at FULL, work equipment speed is slow…2867
E-2 Abnormality in travel speed selector system (travel speed does not switch)…2869
E-3 Abnormality in swing holding brake solenoid system…2870
a) Swing holding brake solenoid is not actuated (cannot swing)…2870
b) Remains actuated (swing cannot be locked)…2871
E-4 Abnormality in PPC oil pressure lock solenoid system…2872
a) Solenoid is not actuated (safety lock is not canceled)…2872
b) Remains actuated (safety lock is not actuated)…2873
E-5 Abnormality in engine starting system (engine does not start)…2874
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…2877
TABLE OF FAILURE MODES AND CAUSES (1/2)…2878
TABLE OF FAILURE MODES AND CAUSES (2/2)…2880
H-1 Speeds of all work equipments, travel, swing are slow or lacks power…2882
H-2 There is excessive drop in engine speed, or engine stalls…2884
H-3 No work equipment, travel, swing move…2885
H-4 Abnormal noise generated (around pump)…2885
H-5 Fine control ability is poor or response is poor…2886
H-6 Boom is slow or lacks power…2887
H-7 Arm is slow or lacks power…2889
H-8 Bucket is slow or lacks power…2891
H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)…2891
H-10 Excessive hydraulic drift (boom, arm, bucket)…2892
H-11 Excessive time lag (engine at low idling)…2893
H-12 Other equipment moves when single circuit is relieved…2893
H-13 In compound operations, work equipment with larger load is slow…2893
H-14 In swing + boom RAISE, boom RAISE is slow…2894
H-15 In swing + travel, travel speed drops excessively…2894
H-16 Travel deviation (deviation is excessive in normal travel and when starting)…2895
a) Deviation is excessive in normal travel…2895
b) Deviation is excessive when starting…2895
H-17 Travel speed is slow…2896
H-18 Steering does not turn easily or lacks power…2897
H-19 Travel does not move (one side only)…2898
H-20 Travel speed does not switch…2898
H-21 Does not swing…2899
a) Does not swing to either left or right…2899
b) Does not swing in one direction…2899
H-22 Swing acceleration is poor or swing speed is slow…2900
H-23 Excessive overrun when stopping swing…2902
a) One direction only…2902
b) Both directions…2902
H-24 Excessive shock when stopping swing (one direction only)…2903
H-25 Excessive abnormal noise when stopping swing…2903
H-26 Excessive hydraulic drift of swing…2904
a) When swing lock is ON…2904
b) When swing lock is OFF…2904
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…2905
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM…2906
M-1 When the starting switch is turned ON, no display is given (lamps does not light up for 3 seconds)…2907
M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out…2907
M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds…2908
a) No gauge lamps light up (caution lamps light up)…2908
b) Swing lock, preheating lamps do not light up…2908
c) Charge caution lamp does not light up…2908
d) Engine oil pressure caution lamp does not light up…2908
M-4 When power is turned on (before engine is started), charge caution lamp does not light up…2909
M-5 When Dower is turned on (before engine is started), engine oil pressure caution lamp does not light up…2909
M-6 During preheating, preheating pilot lamp does not light up…2910
M-7 When switch is operated, swing lock lamp does not light up…2910
M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil pressure is normal)…2911
M-9 Charge caution lamp lights up when engine is running…2911
M-10 Abnormality in coolant temperature gauge…2912
a) After engine is started, level stays at bottom (white range) and does not move…2912
b) After engine is started, level immediately rises. Engine is not overheating but indicator enters red range…2912
c) Coolant temperature gauge goes out…2912
M-11 Abnormality in fuel gauge…2913
a) All fuel gauge segments go out…2913
b) Even when fuel level goes down, fuel gauge continues to show FULL…2913
c) Even when tank is filled, fuel gauge does not show FULL…2913
M-12 Defective operation of alarm buzzer…2915
a) Buzzer does not sound…2915
b) Buzzer continues to sound and does not stop…2915
M-13 Engine is running, but service meter does not move…2916
a) Charge caution lamp lights up…2916
b) Charge caution lamp does not light up…2916
M-14 Night lighting does not light up…2917
a) Gauge lighting does not light up…2917
b) Service meter lighting does not light up (service meter is working normally)…2917
M-15 Wiper does not move, or does not stop moving…2918
a) Wiper does not move when wiper switch is turned to ON…2918
b) Wiper moves even when wiper switch is not turned to ON…2918
M-16 Heater does not work…2920
a) Does not work at either Hi or Lo…2920
b) Does not work at Lo only…2920
c) Does not work at Hi only…2920
30 DISASSEMBLY AND ASSEMBLY…2921
METHOD OF USING MANUAL…2923
PRECAUTIONS WHEN CARRYING OUT OPERATION…2924
SPECIAL TOOL LIST…2926
SKETCHES OF SPECIAL TOOLS…2930
STARTING MOTOR ASSEMBLY…2931
REMOVAL AND INSTALLATION…2931
ALTERNATOR ASSEMBLY…2932
REMOVAL AND INSTALLATION…2932
AIR CONDITIONER COMPRESSOR ASSEMBLY…2933
REMOVAL AND INSTALLATION…2933
CONDENSER ASSEMBLY…2934
REMOVAL AND INSTALLATION…2934
ENGINE OIL COOLER CORE ASSEMBLY…2935
REMOVAL AND INSTALLATION…2935
FUEL INJECTION PUMP ASSEMBLY…2936
REMOVAL…2936
INSTALLATION…2939
WATER PUMP ASSEMBLY…2941
REMOVAL…2941
INSTALLATION…2942
NOZZLE HOLDER ASSEMBLY…2943
REMOVAL AND INSTALLATION…2943
TURBOCHARGER ASSEMBLY…2944
REMOVAL AND INSTALLATION…2944
THERMOSTAT ASSEMBLY…2945
REMOVAL…2945
INSTALLATION…2946
CYLINDER HEAD ASSEMBLY…2947
REMOVAL…2947
INSTALLATION…2951
RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY…2954
REMOVAL…2954
INSTALLATION…2956
ENGINE, MAIN PUMP ASSEMBLY…2957
REMOVAL…2957
INSTALLATION…2961
DAMPER ASSEMBLY…2962
REMOVAL AND INSTALLATION…2962
FUEL TANK ASSEMBLY…2963
REMOVAL AND INSTALLATION…2963
CENTER SWIVEL JOINT ASSEMBLY…2964
REMOVAL…2964
INSTALLATION…2965
DISASSEMBLY AND ASSEMBLY…2966
FINAL DRIVE ASSEMBLY…2967
REMOVAL AND INSTALLATION…2967
DISASSEMBLY…2968
ASSEMBLY…2971
SPROCKET…2976
REMOVAL AND INSTALLATION…2976
SWING MOTOR, SWING MACHINERY ASSEMBLY…2977
REMOVAL…2977
INSTALLATION…2978
DISASSEMBLY…2979
ASSEMBLY…2983
REVOLVING FRAME ASSEMBLY…2988
REMOVAL…2988
INSTALLATION…2989
SWING CIRCLE ASSEMBLY…2990
REMOVAL…2990
INSTALLATION…2991
IDLER, RECOIL SPRING ASSEMBLY…2992
REMOVAL AND INSTALLATION…2992
RECOIL SPRING ASSEMBLY…2993
DISASSEMBLY…2993
ASSEMBLY…2994
IDLER ASSEMBLY…2995
DISASSEMBLY…2995
ASSEMBLY…2996
TRACK ROLLER ASSEMBLY…2998
REMOVAL AND INSTALLATION…2998
DISASSEMBLY…2999
ASSEMBLY…3001
CARRIER ROLLER ASSEMBLY…3003
REMOVAL AND INSTALLATION…3003
DISASSEMBLY…3004
ASSEMBLY…3006
TRACK SHOE ASSEMBLY…3008
REMOVAL AND INSTALLATION…3008
HYDRAULIC TANK ASSEMBLY…3009
REMOVAL…3009
INSTALLATION…3010
MAIN PUMP ASSEMBLY…3011
REMOVAL…3011
INSTALLATION…3013
MAIN PUMP INPUT SHAFT OIL SEAL…3014
REMOVAL AND INSTALLATION…3014
CONTROL VALVE ASSEMBLY…3015
REMOVAL…3015
INSTALLATION…3017
DISASSEMBLY…3018
ASSEMBLY…3023
MAIN RELIEF VALVE ASSEMBLY…3029
DISASSEMBLY AND ASSEMBLY…3029
PC VALVE ASSEMBLY…3030
REMOVAL…3030
INSTALLATION…3031
LS VALVE ASSEMBLY…3032
REMOVAL AND INSTALLATION…3032
PC-EPC VALVE ASSEMBLY…3033
REMOVAL AND INSTALLATION…3033
SOLENOID VALVE ASSEMBLY…3034
REMOVAL AND INSTALLATION…3034
WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY…3035
REMOVAL AND INSTALLATION…3035
DISASSEMBLY…3036
ASSEMBLY…3037
TRAVEL PPC VALVE ASSEMBLY…3038
REMOVAL AND INSTALLATION…3038
DISASSEMBLY…3039
ASSEMBLY…3040
BOOM LOCK VALVE ASSEMBLY…3041
REMOVAL AND INSTALLATION…3041
BOOM CYLINDER ASSEMBLY…3042
REMOVAL…3042
INSTALLATION…3043
ARM CYLINDER ASSEMBLY…3044
REMOVAL…3044
INSTALLATION…3045
BUCKET CYLINDER ASSEMBLY…3046
REMOVAL…3046
INSTALLATION…3047
HYDRAULIC CYLINDER ASSEMBLY…3048
DISASSEMBLY…3048
ASSEMBLY…3051
WORK EQUIPMENT ASSEMBLY…3055
REMOVAL…3055
INSTALLATION…3056
BUCKET ASSEMBLY…3057
REMOVAL…3057
INSTALLATION…3058
ARM ASSEMBLY…3059
REMOVAL…3059
INSTALLATION…3060
BUCKET, ARM ASSEMBLY…3061
REMOVAL…3061
INSTALLATION…3062
BOOM ASSEMBLY…3063
REMOVAL…3063
INSTALLATION…3064
OPERATOR’S CAB ASSEMBLY…3065
REMOVAL AND INSTALLATION…3065
COUNTERWEIGHT ASSEMBLY…3066
REMOVAL AND INSTALLATION…3066
MONITOR ASSEMBLY…3067
REMOVAL AND INSTALLATION…3067
40 MAINTENANCE STANDARD…3068
SWING MACHINERY …3069
SWING CIRCLE …3071
FINAL DRIVE …3072
TRACK FRAME, RECOIL SPRING …3074
IDLER …3075
CARRIER ROLLER…3077
TRACK ROLLER …3078
TRACK SHOE …3079
HYDRAULIC PUMP …3084
CONTROL VALVE …3085
SELF-REDUCING PRESSURE VALVE …3092
SWING MOTOR…3093
TRAVEL MOTOR …3094
WORK EQUIPMENT, SWING PPC VALVE …3095
TRAVEL PPC VALVE …3096
SERVICE PPC VALVE …3097
CENTER SWIVEL JOINT …3098
BOOM HOLDING VALVE …3100
HYDRAULIC CYLINDER …3101
WORK EQUIPMENT …3103
DIMENSION OF WORK EQUIPMENT …3105
90 OTHERS…3109
HYDRAULIC PIPING DRAWING…3110
HYDRAULIC CIRCUIT DIAGRAM…3111
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)…3116
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)…3117
ELECTRICAL CIRCUIT DIAGRAM (1/2)…3118
ELECTRICAL CIRCUIT DIAGRAM (2/2)…3123
OPERATION OF CLSS SYSTEM AS A WHOLE…3128
1. When all work equipment is at neutral…3128
2. One side actuated, other side neutral…3129
3. Arm OUT, standard mode relief (cut-off control)…3130
4. Bucket DUMP, power max. relief…3131
5. Boom RAISE…3132
6. Swing operated independently…3133
7. Travel operated independently…3134
8. Compound operation…3135
SEBM010202 – Hydraulic Excavator PC200LC-6 Shop Manual…3137
COVER…3137
CONTENTS…3138
01 GENERAL…3139
SPECIFICATION DIMENSION DRAWINGS…3140
SPECIFICATIONS…3141
WEIGHT TABLE…3143
FUEL, COOLANT AND LUBRICANTS…3145
10 STRUCTURE AND FUNCTION…3146
ENGINE RELATED PARTS…3147
RADIATOR OIL COOLER AFTERCOOLER…3148
ENGINE CONTROL…3149
POWER TRAIN…3150
FINAL DRIVE…3151
SWING CIRCLE…3152
SWING MACHINERY…3153
TRACK FRAME RECOIL SPRING…3154
TRACK SHOE…3155
HYDRAULIC PIPING DRAWING…3156
HYDRAULIC CIRCUIT DIAGRAM…3157
HYDRAULIC TANK…3158
HYDRAULIC PUMP…3159
IN-LINE FILTER…3178
CONTROL VALVE…3179
SELF-REDUCING PRESSURE VALVE…3187
CLSS…3192
SWING MOTOR…3226
CENTER SWIVEL JOINT…3230
TRAVEL MOTOR…3232
VALVE CONTROL…3240
WORK EQUIPMENT SWING PPC VALVE…3241
TRAVEL PPC VALVE…3245
SERVICE PPC VALVE…3249
ACCUMULATOR…3252
STRAIGHT-TRAVEL SYSTEM…3253
EPC SOLENOID VALVE…3254
BOOM HOLDING VALVE…3256
ADDITIONAL FILTER FOR BREAKER…3259
WORK EQUIPMENT…3260
ACTUAL ELECTRICAL WIRING DIAGRAM…3261
ELECTRIC CIRCUIT SYSTEM…3263
ELECTRIC CONTROL SYSTEM…3265
MACHINE MONITOR SYSTEM…3271
SENSORS…3274
20 TESTING AND ADJUSTING…3276
STANDARD VALVE TABLE FOR ENGINE RELATED PARTS…3277
STANDARD VALVE TABLE FOR ENGINE CHASSIS RELATED PARTS…3278
STANDARD VALVE TABLE FOR ENGINE ELECTRICAL SYSTEM…3286
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…3289
MEASURING ENGINE SPEED…3290
MEASURING EXHAUST COLOR…3291
ADJUSTING VALVE CLEARANCE…3292
MEASURING COMPRESSION PRESSURE…3293
MEASURING BLOW BY PRESSURE…3293
TESTING AND ADJUSTING FUEL INJECTION TIMING…3294
MEASURING ENGINE OIL PRESSURE…3295
TESTING AND ADJUSTING FAN BELT TENSION…3296
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…3296
ADJUSTING ENGINE SPEED SENSOR…3297
ADJUSTING FUEL CONTROL LEVER…3298
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…3300
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…3303
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE …3304
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE…3307
TESTING SOLENOID VALVE OUTPUT PRESSURE…3308
MEASURING PPC VALVE PUTPUT PRESSURE…3309
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…3311
TESTING TRAVEL DEVIATION…3312
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…3313
MEASURING OIL LEAKAGE…3315
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…3317
TESTING CLEARANCE OF SWING CIRCLE BEARING…3318
TESTING AND ADJUSTING TRACK SHOE TENSION…3319
BLEEDING AIR…3320
TROUBLESHOOTING…3322
POINTS TO REMEMBER WHEN TROUBLESHOOTING…3323
SEQUENCE OF EVENTS IN TROUBLESHOOTING…3324
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…3325
CHECKS BEFORE TROUBLESHOOTING…3333
CONNECTOR TYPES AND MOUNTING LOCATIONS…3334
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…3339
METHOD OF USING TROUBLESHOOTING CHARTS…3349
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…3351
METHOD OF USING TROUBLESHOOTING CHARTS…3352
S-1 STARTING PERFORMANCE IS POOR (ALWAYS TAKES TIME)…3356
S-2 ENGINE DOES NOT START…3357
(1) ENGINE DOES NOT RUN…3357
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…3358
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES START (FUEL IS BEING INJECTED)…3359
S-3 ENGINE DOES NOT PICK SMOOTHY (FOLLOW-UP IS POOR)…3360
S-4 ENGINE STOPS DURING OPERATIONS…3361
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…3362
S-6 ENGINE LACKS OUTPUT (NO POWER)…3363
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION…3364
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)…3365
S-9 OIL BECOMES CONTAMINATED QUICKLY…3366
S-10 FUEL CONSUMPTION IS EXCESSIVE…3367
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…3368
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…3369
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…3370
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…3371
S-15 ABNORMAL NOISE IS MADE…3372
S-16 VIBRATION IS EXCESSIVE…3373
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…3374
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS…3375
ELECTRICAL CIRCUIT DIAGRAM FOR SYSTEM…3377
FAILURE CODES…3378
E-1 ABNORMALITY IN PC-EPC CONTROL SYSTEM…3378
A) ENGINE STOPS EVEN WHEN THROTTLE LEVER IS NOT RETURNED TO STOP POSITION. WHEN SUDDEN LOAD IS APPLIED, ENGINE STALLS…3378
B) LACKS POWER WHEN THROTTLT LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW …3379
E-2 ABNORMALITY IN TRAVEL SPEED SELECTOR SYSTEM (TRAVEL SPEED DOES NOT SWITCH)…3381
E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM…3382
A) SWING HOLDING BRAKE SOLENOID IS NOT ACTUATED (CANNOT SWING)…3382
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)…3383
E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM…3384
A) SOLENOID IS NOT ACTUATED (SAFETY LOCK IS NOT CANCELED)…3384
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)…3385
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)…3386
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…3389
TABLE OF FAILURE MODES AND CAUSES…3390
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACKS POWER…3394
H-2 THERE IS NOT EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…3396
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…3397
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…3397
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…3398
H-6 BOOM IS SLOW OR LACKS POWER…3399
H-7 ARM IS SLOW OR LACKS POWER…3401
H-8 BUCKET IS SLOW OR LACKS POWER…3403
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL…3403
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…3404
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…3405
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…3405
H-13 IN COMPUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS LOW…3405
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…3406
H-15 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…3406
H-16 TRAVEL DEVIATION…3407
A) DEVIATION IS EXCESSIVE IN NORMAL TRAVEL…3407
B) DEVIATION IS EXCESSIVE WHEN STARTING…3407
H-17 TRAVEL SPEED IS SLOW…3408
H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER…3409
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…3410
H-20 TRAVEL SPEED DOES NOT SWITCH…3410
H-21 DOES NOT SWING…3411
A) DOES NOT SWING TO EITHER LEFT OR RIGHT…3411
B) DOES NOT SWING IN ONE DIRECTION…3411
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS LOW…3412
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…3414
A) ONE DIRECTION ONLY…3414
B) BOTH DIRECTIONS…3414
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…3415
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…3415
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…3416
A) WHEN SWING LOCK IS ON…3416
B) WHEN SWING LOCK IS OFF…3416
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…3417
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM…3418
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)…3419
M-2 WHEN THE STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT…3419
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS…3420
A) NO GAUGE LAMP LIGHTS UP (CAUTION LAMPS LIGHT UP…3420
B) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP)…3420
C) CHARGE CAUTION LAMP DOES NOT LIGHT UP …3420
D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…3420
M-4 WHEN POWER IS ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP …3421
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…3421
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP…3422
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP…3422
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)…3423
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING…3423
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE…3424
A) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE…3424
B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE…3424
C) COOLANT TEMPERATURE GAUGE GOES OUT…3424
M-11 ABNORMALITY IN FUEL GAUGE…3425
A) ALL FUEL GAUGE SEGMENTS GO OUT…3425
B) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL…3425
C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL…3425
M-12 DEFECTIVE OPERATION OF ALARM BUZZER…3427
A) BUZZER DOES NOT SOUND…3427
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…3427
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE…3428
A) CHARGE CAUTION LAMP LIGHTS UP…3428
B) CHARGE CAUTION LAMP DOES NOT LIGHT UP…3428
M-14 NIGHT LIGHTING DOES NOT LIGHT UP…3429
A) GAUGE LIGHTING DOES NOT LIGHT UP…3429
B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)…3429
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING…3430
A) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED ON…3430
B) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED ON…3430
M-16 HEATER DOES NOT WORK AT EITHER HI OR LO…3432
A) DOES NOT WORK AT EITHER HI OR LO…3432
B) DOES NOT WORK AT LO ONLY …3432
C) DOES NOT WORK AT HI ONLY …3432
30 DISASSEMBLY AND ASSEMBLY…3433
METHOD OF USING MANUAL…3435
PRECAUTIONS WHEN CARRYING OUT OPERATION…3436
SPECIAL TOOL LIST…3438
SKETCHES OF SPECIAL TOOLS…3442
STARTING MOTOR ASSEMBLY…3443
REMOVAL AND INSTALLATION…3443
ALTERNATIVE ASSEMBLY…3444
REMOVAL AND INSTALLATION…3444
AIR CONDITIONER COMPRESSOR ASSEMBLY…3445
REMOVAL AND INSTALLATION…3445
CONDENSER ASSEMBLY…3446
REMOVAL AND INSTALLATION…3446
ENGINE OIL COOLER CORE ASSEMBLY…3447
REMOVAL AND INSTALLATION…3447
FUEL INJECTION PUMP ASSEMBLY…3448
REMOVAL…3448
INSTALLATION…3451
WATER PUMP ASSEMBLY…3453
REMOVAL AND INSTALLATION…3454
NOZZLE HOLDER ASSEMBLY…3455
REMOVAL AND INSTALLATION…3455
TURBOCHARGER ASSEMBLY…3456
REMOVAL AND INSTALLATION…3456
THERMOSTAT ASSEMBLY…3457
REMOVAL AND INSTALLATION…3458
CYLINDER HEAD ASSEMBLY…3459
REMOVAL…3459
INSTALLATION…3463
RADIATOR – HYDRAULIC COOLER ASSEMBLY…3466
REMOVAL…3466
INSTALLATION…3468
ENGINE – MAIN PUMP ASSEMBLY…3469
REMOVAL…3469
INSTALLATION…3473
DAMPER ASSEMBLY…3474
REMOVAL AND INSTALLATION…3474
FUEL TANK ASSEMBLY…3475
REMOVAL AND INSTALLATION…3475
CENTER SWIVEL JOINT ASSEMBLY…3476
REMOVAL AND INSTALLATION…3477
DISASSEMBLY AND ASSEMBLY…3478
FINAL DRIVE ASSEMBLY…3479
REMOVAL AND INSTALLATION…3479
DISASSEMBLY…3480
ASSEMBLY…3483
SPROCKET …3488
REMOVAL AND INSTALLATION…3488
SWIMG MOTOR, SWING MACHINERY…3489
REMOVAL AND INSTALLATION…3490
DISASSEMBLY…3491
ASSEMBLY…3495
REVOLVING FRAME ASSEMBLY …3500
REMOVAL…3500
INSTALLATION…3501
SWING CIRCLE ASSEMBLY…3502
REMOVAL…3502
INSTALLATION…3503
IDLER – RECOIL SPRING ASSEMBLY…3504
REMOVAL AND INSTALLATION…3504
RECOIL SPRING ASSEMBLY…3505
DISASSEMBLY…3505
ASSEMBLY…3506
IDLER ASSEMBLY…3507
DISASSEMBLY…3507
ASSEMBLY…3508
TRACK ROLLER ASSEMBLY…3510
REMOVAL AND INSTALLATION…3510
DISASSEMBLY…3511
ASSEMBLY…3513
CARRIER ROLLER ASSEMBLY…3515
REMOVAL AND INSTALLATION…3515
DISASSEMBLY…3516
ASSEMBLY…3518
TRACK SHOE ASSEMBLY…3520
REMOVAL AND INSTALLATION…3520
HYDRAULAIC TANK ASSEMBLY…3521
REMOVAL…3521
INSTALLATION…3522
MAIN PUMP ASSEMBLY…3523
REMOVAL…3523
INSTALLATION…3525
MAIN PUMP INPUT SHAFT OIL SEAL…3526
REMOVAL AND INSTALLATION…3526
CONTROL VALVE ASSEMBLY…3527
REMOVAL…3527
INSTALLATION…3529
DISASSEMBLY…3530
ASSEMBLY…3535
MAIN RELIEF VALVE ASSEMBLY…3541
DISASSEMBLY AND ASSEMBLY…3541
PC VALVE ASSEMBLY…3542
REMOVAL AND INSTALLATION…3543
LS VALVE ASSEMBLY…3544
REMOVAL AND INSTALLATION…3544
PC-EPC VALVE ASSEMBLY…3545
REMOVAL AND INSTALLATION…3545
SOLENOID VALVE ASSEMBLY…3546
REMOVAL AND INSTALLATION…3546
WORK EQUIPMENT – SWING PPC VALVE ASSEMBLY…3547
REMOVAL AND INSTALLATION…3547
DISASSEMBLY…3548
ASSEMBLY…3549
TRAVEL PPC VALVE ASSEMBLY…3550
REMOVAL AND INSTALLATION…3550
DISASSEMBLY AND ASSEMBLY…3551
ASSEMBLY…3552
BOOM LOCK VALVE ASSEMBLY…3553
REMOVAL AND INSTALLATION…3553
BOOM CYLINDER ASSEMBLY…3554
REMOVAL…3554
INSTALLATION…3555
ARM CYLINDER ASSEMBLY …3556
REMOVAL…3556
INSTALLATION…3557
BUCKET CYLINDER ASSEMBLY…3558
REMOVAL…3558
INSTALLATION…3559
HYDRAULIC CYLINDER ASSEMBLY…3560
DISASSEMBLY…3560
ASSEMBLY…3563
WORK EQUIPMENT ASSEMBLY…3567
REMOVAL…3567
INSTALLATION…3568
BUCKET ASSEMBLY…3569
REMOVAL…3569
INSTALLATION…3570
ARM ASSEMBLY…3571
REMOVAL…3571
INSTALLATION…3572
BUCKET – ARM ASSEMBLY…3573
REMOVAL…3573
INSTALLATION…3574
BOOM ASSEMBLY…3434
REMOVAL…3434
INSTALLATION…3434
OPERATOR'S CAB ASSEMBLY…3575
REMOVAL AND INSTALLATION…3575
COUNTERWEIGHT ASSEMBLY…3576
REMOVAL AND INSTALLATION…3576
MONITOR ASSEMBLY…3577
REMOVAL AND INSTALLATION…3577
40 MAINTENANCE STANDARD…3578
SWING MACHINERY…3579
SWING CIRCLE…3581
FINAL DRIVE…3582
TRACK FRAME – RECOIL SPRING…3584
IDLER…3585
CARRIER ROLLER…3587
TRACK ROLLER…3588
TRACK SHOE…3589
HYDRAULIC PUMP…3594
CONTROL VALVE…3595
SELF-REDUCING PRESSURE VALVE…3602
SWING MOTOR…3603
TRAVEL MOTOR…3604
WORK EQUIPMENT – SWING PPC VALVE…3605
TRAVEL PPC VALVE…3606
SERVICE PPC VALVE…3607
CENTER SWIVEL JOINT…3608
BOOM HOLDING VALVE…3610
HYDRAULIC CYLINDER…3611
WORK EQUIPMENT…3613
DIMENSION OF WORK EQUIPMENT…3615
90 OTHERS…3619
HYDRAULIC PIPING DRAWING…3620
HYDRAULIC CIRCUIT DIAGRAM…3626
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)…3628
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)…3632
ELECTRICAL CIRCUIT DIAGRAM (1/2)…3636
ELECTRICAL CIRCUIT DIAGRAM (2/2)…3640
OPERATION OF CLSS SYSTEM AS A WHOLE…3644
1. WHEN ALL WORK EQUIPMENT IS NEUTRAL…3644
2. ONE SIDE ACTUATED, OTHER SIDE NEUTRAL…3648
3. ARM OUT, STANDARD MODE RELIEF (CUT-OFF CONTROL)…3652
4. BUCKET DUMP, POWER MAX RELIEF…3656
5. BOOM RAISE…3660
6. SWING OPERATED INDEPENDENTLY…3664
7. TRAVEL OPERATED INDEPENDENTLY…3668
8. COMPOUND OPERATION…3672
SEBM0205B04 – Hydraulic Excavator PC200-2, PC200LC-2, PC220-2, PC220LC-2 Shop Manual…3677
TEN00205-00 – Hydraulic Excavator PC200-8, PC200LC-8 Operation & Maintenance Manual…4229
TEN00205-00…4231
Komatsu Hydraulic Excavator PC200, PC200LC, PC220, PC220LC Repair Service Manuals