Komatsu Galeo PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Shop Manual PDF

PC200-7                       DBB0001 and up
PC200LC-7                  DBE0001 and up

PC210-7                       DBF0001 and up
PC210LC-7                  DBG0001 and up

PC220-7                       DBH0001 and up
PC220LC-7                  DBJ0001 and up

COVER 1
SUB-COVER 2
CONTENTS 3
SAFETY 4
FOREWORD 6
GENERAL 6
HOW TO READ THE SHOP MANUAL 7
HOISTING INSTRUCTIONS 8
METHOD OF DISASSEMBLING， CONNECTING PUSH-PULL TYPE COUPLER 9
COATING MATERIALS 11
STANDARD TIGHTENING TORQUE 13
ELECTRIC WIRE CODE 16
UNITS 17
01 GENERAL 18
SPECIFICATION DIMENSION DRAWINGS 19
PC200-7, PC200LC-7 19
DIMENSIONS 19
WORKING RANGES 19
DIMENSIONS 20
WORKING RANGES 20
PC210-7,PC210LC-7 21
DIMENSIONS 21
WORKING RANGES 21
DIMENSIONS 22
WORKING RANGES 22
PC220-7,PC220LC-7 23
DIMENSIONS 23
WORKING RANGES 23
DIMENSIONS 24
WORKING RANGES 24
SPECIFICATIONS 25
PC200-7,PC200LC-7 25
PC210-7,PC210LC-7 27
PC220-7,PC220LC-7 29
WEIGHT TABLE 31
PC200-7,PC200LC-7 31
PC210-7,PC210LC-7 33
PC220-7,PC220LC-7 35
FUEL, COOLANT, AND LUBRICANTS 37
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 38
ENGINE RELATED PARTS 39
RADIATOR·OIL COOLER·AFTERCOOLER 40
POWER TRAIN 41
FINAL DRIVE 42
SWING MACHINERY 44
PC200/210(LC)-7 44
PC220(LC)-7 46
SWING CIRCLE 48
PC200/210(LC)-7 48
PC220(LC)-7 49
TRACK FRAME·RECOIL SPRING 50
IDLER 52
CARRIER ROLLER 54
TRACK ROLLER 55
TRACK SHOE 56
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE 56
TRIPLE GROUSER SHOE 59
SWAMP SHOE 59
HYDRAULIC EQUIPMENT LAYOUT DRAWING 60
HYDRAULIC TANK 62
HYDRAULIC PUMP 63
HPV95+95 63
LS VALVE 68
PC VALVE 68
FUNCTION 69
OPERATION 70
LS(PC)-EPC VALVE 81
FUNCTION 82
OPERATION 82
CONTROL VALVE 84
CONTROL VALVE 84
PC200/210(LC)-7 84
OUTLINE 84
ARM CONTROL VALVE 90
R H TRAVEL CONTROL VALVE 90
BUCKET CONTROL VALVE 92
SERVICE VALVE 92
SWING CONTROL VALVE 93
BOOM CONTROL VALVE 93
L H TRAVEL CONTROL VALVE 93
PC220(LC)-7 97
OUTLINE 97
ARM CONTROL VALVE 103
R H TRAVEL CONTROL VALVE 103
BUCKET CONTROL VALVE 105
SERVICE VALVE 105
SWING CONTROL VALVE 106
L H TRAVEL CONTROL VALVE 106
MAIN RELIEF VALVE 110
FUNCTION 110
OPERATION 110
VARIABLE PRESSURE COMPENSATION VALVE 111
CLSS 112
OUTLINE OF CLSS 112
FEATURES 112
STRUCTURE 112
SELF PRESSURE REDUCING VALVE 115
FUNCTION 115
OPERATION 115
SWING MOTOR 118
SPECIFICATIONS 118
RELIEF VALVE PORTION 122
REVERSE PREVENTION VALVE 123
CENTER SWIVEL JOINT 125
TRAVEL MOTOR 126
OPERATION OF MOTOR 129
OPERATION OF PARKING BRAKE 131
OPERATION OF BRAKE VALVE 132
TRAVEL JUNCTION VALVE 135
FUNCTION 135
OPERATION 135
TRAVEL PPC SHUTTLE VALVE 137
FUNCTION 137
OPERATION 137
OPERTION SYSTEM 139
WORK EQUIPMENT·SWING PPC VALVE 140
OPERATION 142
TRAVEL PPC VALVE 144
OPERATION 147
SERVICE PPC VALVE 153
OPERATION 154
WHEN OPERATED 154
SOLENOID VALVE 156
OPERATION 157
WHEN SOLENOID IS TURNED OFF 157
WHEN SOLENOID IS TURNED ON 157
PPC ACCUMULATOR 158
SPECIFICATIONS 158
RETURN OIL FILTER 159
FOR BREAKER 159
SPECIFICATIONS 159
BOOM HYDRAULIC DRIFT PREVENTION VALVE 160
FUNCTION 161
LIFT CHECK VALVE 163
FUNCTION 163
OPERATION 163
ATTACHMENT CIRCUIT SELECTOR VALVE 164
FUNCTION 164
OPERATION 165
HYDRAULIC CYLINDER 166
PC200/210(LC)-7 166
BOOM CYLINDER 166
ARM CYLINDER 166
BUCKET CYLINDER 166
100 HOURS GREASING 167
500 HOURS GREASING 167
PC220(LC)-7 168
BOOM CYLINDER 168
ARM CYLINDER 168
BUCKET CYLINDER 168
100 HOURS GREASING 169
500 HOURS GREASING 169
WORK EQUIPMENT 170
PC200/210(LC)-7 171
100 HOURS GREASING 171
500 HOURS GREASING 171
PC220(LC)-7 172
100 HOURS GREASING 172
500 HOURS GREASING 172
1 DIMENSION OF ARM 173
2 DIMENSION OF BUCKET 175
AIR CONDITIONER 177
AIR CONDITIONER PIPING 177
ENGINE CONTROL 178
1 OPERATION OF SYSTEM 179
1 COMPONENT 180
GOVERNOR MOTOR 181
GOVERNOR AND PUMP CONTROLLER 182
ELECTRONIC CONTROL SYSTEM 184
MACHINE CONTROL SYSTEM DIAGRAM 185
1 ENGINE AND PUMP CONTROL FUNCTION 187
FUNCTION 188
MODE E / MODE B/(MODE L) 190
2 PUMP/VALVE CONTROL FUNCTION 192
FUNCTION 192
3 ONE-TOUCH POWER MAXIMIZING FUNCTION 194
FUNCTION 194
4 AUTO-DECELERATION FUNCTION 196
FUNCTION 196
OPERATION 197
WHEN CONTROL LEVERS ARE SET IN NEUTRAL 197
WHEN ANY CONTROL LEVER IS OPERATED 197
5 AUTO-WARM-UP/OVERHEAT PREVENTION 198
FUNCTION 198
6 SWING CONTROL FUNCTION 200
FUNCTION 200
7 TRAVEL CONTROL FUNCTION 202
FUNCTION 202
8 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION(OPTION) 204
FUNCTION 204
9 SYSTEM COMPONENT PARTS 205
FUNCTION 205
7-SEGMENT MONITOR SYSTEM 209
SENSOR 216
20 TESTING AND ADJUSTING 219
TESTING AND ADJUSTING 237
INSPECTION AND ADJUSTMENT OF ENGINE RPM 238
MEASUREMENT OF EXHAUST GAS COLOR 240
ADJUSTMENT OF VALVE CLEARANCE 241
MEASUREMENT OF COMPRESSION PRESSURE 243
MEASUREMENT OF BLOW-BY PRESSURE 244
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 245
MEASUREMENT OF ENGINE OIL PRESSURE 247
ADJUSTMENT OF ENGINE SPEED SENSOR 248
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION 248
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM 249
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 250
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION 251
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL 252
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE 256
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE 257
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE 260
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE 264
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE 267
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE 268
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT 269
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 270
MEASUREMENT OF OIL LEAKAGE AMOUNT 271
AIR BLEEDING OF VARIOUS PARTS 273
INSPECTION PROCEDURES FOR DIODE 275
DISPLAY METHOD AND SPECIAL FUNCTIONS OF 7-SEGMENT MONITOR PANEL 276
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM 289
PM-TUNE UP SERVICE (PC200,200LC-7) 290
PM-TUNE UP SERVICE (PC220,220LC-7) 294
TROUBLESHOOTING 298
POINTS TO REMEMBER WHEN TROUBLESHOOTING 299
SEQUENCE OF EVENTS IN TROUBLESHOOTING 300
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 301
CHECKS BEFORE TROUBLESHOOTING 309
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 310
CONNECTOR LOCATION CHART AND ELECTRICAL CIR-CUIT DIAGRAM BY SYSTEM 314
CONNECTOR LOCATION STEREOGRAM 320
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) 325
GOVERNOR CONTROL SYSTEM CIRCUIT DIAGRAM (G GIRCUIT) OF GOVERNOR-PUMP CONTROLLER 327
PUMP CONTROL SYSTEM CIRCUIT DIAGRAM(P CIRCUIT) OF GOVERNOR-PUMP CONTROLLER 329
CONNECTON TABLE FOR CONNECTOR PIN NUMBERS 331
X TYPE CONNECTOR 331
SWP TYPE CONNECTOR 332
M TYPE CONNECTOR 334
S TYPE CONNECTOR 335
MIC TYPE CONNECTOR 337
AMP040 TYPE CONNECTOR 339
L TYPE CONNECTOR 341
BENDIX MS CONNECTOR 341
KES 1 (AUTOMOBILE) CONNECTOR 342
CONNECTOR FOR RELAY (SOCKET TYPE) 343
F TYPE CONNECTOR 344
HD30 SERIES CONNECTOR 345
DT SERIES CONNECTOR 350
DTM SERIES CONNECTOR 352
DTHD SERIES CONNECTOR 352
TROUBLESHOOTING WHEN SERVICE CODE 353
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 355
SERVICE CODE IN ELECTRICAL SYSTEM E101(ABNORMAL DATA IN ERROR HISTORY) 357
SERVICE CODE IN ELECTRICAL SYSTEM E112(SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 359
SERVICE CODE IN ELECTRICAL SYSTEM E113(SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 361
SERVICE CODE IN ELECTRICAL SYSTEM E114(SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM) 363
SERVICE CODE IN ELECTRICAL SYSTEM E115(ABNORMAL WINDSHIELD WIPER MOTION) 365
SERVICE CODE IN ELECTRICAL SYSTEM E116(ABNORMALITY IN RETRACTING WINDSHIELD WIPER) 367
SERVICE CODE IN ELECTRICAL SYSTEM E201 (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID) 369
SERVICE CODE IN ELECTRICAL SYSTEM E203 (SHORT-CIRCUITING IN SWING AND PARKING BRAKE SOLENOID-IN GOVERNOR·PUMP CONTROLLER SYS 371
SERVICE CODE IN ELECTRICAL SYSTEM E204 (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID) 373
SERVICE CODE IN ELECTRICAL SYSTEM E205 (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID) 375
SERVICE CODE IN ELECTRICAL SYSTEM E206 (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID) 377
SERVICE CODE IN ELECTRICAL SYSTEM E211(DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID) 379
SERVICE CODE IN ELECTRICAL SYSTEM E213(DISCONNECTION IN SWING PARKING BRAKE SOLENOID) 381
SERVICE CODE IN ELECTRICAL SYSTEM E214 (DISCONNECTION OF MERGE/DIVIDE SOLENOID) 383
SERVICE CODE IN ELECTRICAL SYSTEM E215(DISCONNECTION IN 2-STAGE RELIEF SOLENOID) 385
SERVICE CODE IN ELECTRICAL SYSTEM E216(DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID) 387
SERVICE CODE IN ELECTRICAL SYSTEM E217 (ABNORMALITY IN INPUTTING MODEL CODE) 389
PC200/210(LC)-7 389
PC220(LC)-7 391
SERVICE CODE IN ELECTRICAL SYSTEM E218 (DISCONNECTION OF S-NET SIGNAL) 393
SERVICE CODE IN ELECTRICAL SYSTEM E222(SHORT-CIRCUITING IN LS-EPC SOLENOID) 395
SERVICE CODE IN ELECTRICAL SYSTEM E223(DISCONNECTION IN LS-EPC SOLENOID SYSTEM) 396
SERVICE CODE IN ELECTRICAL SYSTEM E224(ABNORMALITY IN F PUMP PRESSURE SENSOR) 397
SERVICE CODE IN ELECTRICAL SYSTEM E225(ABNORMALITY IN R PUMP PRESSURE SENSOR) 399
SERVICE CODE IN ELECTRICAL SYSTEM E226(ABNORMALITY IN PRESSURE SENSOR POWER SOURCE) 401
SERVICE CODE IN ELECTRICAL SYSTEM E227 (ABNORMALITY IN ENGINE ROTATION SENSOR IN GOVERNOR·PUMP CONTROLLER SYSTEM) 403
SERVICE CODE IN ELECTRICAL SYSTEM E228 (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY) 404
SERVICE CODE IN ELECTRICAL SYSTEM E232(SHORT-CIRCUITING IN PC-EPC SOLENOID) 405
SERVICE CODE IN ELECTRICAL SYSTEM E233(DISCONNECTION IN PC-EPC SOLENOID SYSTEM) 407
SERVICE CODE IN ELECTRICAL SYSTEM E238(DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY) 409
SERVICE CODE IN ELECTRICAL SYSTEM E256 (INCORRECT NONVOLATILE MEMORY DATA) 411
SERVICE CODE IN ELECTRICAL SYSTEM E306 (ABNORMALITY IN GOVERNOR POTENTIOMETER) 412
SERVICE CODE IN ELECTRICAL SYSTEM E308(ABNORMALITY IN FUEL DIAL) 414
SERVICE CODE IN ELECTRICAL SYSTEM E315 (SHORT-CIRCUITING IN BATTERY RELAY) 416
SERVICE CODE IN ELECTRICAL SYSTEM E316(STEP-OUT IN GOVERNOR MOTOR) 418
SERVICE CODE IN ELECTRICAL SYSTEM E317(DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B) 419
SERVICE CODE IN ELECTRICAL SYSTEM E318(SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PHASE B) 421
SERVICE CODE IN ELECTRICAL SYSTEM E501(“MODEL SELECTION” FUNCTION NOT PROVIDED YET) 423
SERVICE CODE IN ELECTRICAL SYSTEM E502(MODEL SELECTING SIGNAL FAULT) 424
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (OUT -0F-RATE ENGINE ROTATION AT HIGH IDLING) 425
FAILURE CODE IN MECHANICAL SYSTEM A000N2 (OUT-OF-RATE ENGINE ROTATION AT LOW IDLING) 425
FAILURE CODE IN MECHANICAL SYSTEM AA10NX(AIR CLEANER CLOGGING) 426
FAILURE CODE IN MECHANICAL SYSTEM AB00KE(ABNORMALLY LOWERED CHARGING VOLTAGE) 427
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ABNORMALLY LOWERED ENGINE OIL PRESSURE) 429
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK(ABNORMALLY LOWERED ENGINE OIL LEVEL) 430
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS(ENGINE COOLING WATER OVERHEATING) 431
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK(ABNORMALLY LOWERED RADIATOR WATER LEVEL) 432
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDRAULIC OIL OVERHEATING) 433
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 434
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 435
E-1 ENGINE DOES NOT START 436
E-2 ENGINE STOPS WHILE IN OPERATION 439
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING 440
E-4 ENGINE DOES NOT STOP 442
E-5 AUTO-DECELERATOR DOES NOT WORK 444
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK 445
E-7 PREHEATER DOES NOT WORK 446
E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE 448
E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK 450
E-10 NO DISPLAY IN MONITOR PANEL AT ALL 451
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING 452
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 452
E-13 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING 453
E-14 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 454
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 455
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY 456
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 457
E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 459
E-19 WINDSHIELD WIPER DOES NOT WORK 460
E-20 ALARMING BUZZER CANNOT BE CANCELLED 462
E-21 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 463
E-22 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 464
E-23 “ARM DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 465
E-24 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 466
E-25 “BUCKET DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 467
E-26 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 468
E-27 “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 469
E-28 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 471
E-29 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 473
E-30 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 475
E-31 AIR CONDITIONER DOES NOT WORK 477
E-32 TRAVEL ALARM DOES NOT SOUND 478
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 480
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 220
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 222
FLOW CONTROL CHARACTERISTIC OF PC VALVE(STD) 236
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 481
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 483
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 484
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS 485
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE 486
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 486
H-5 AUTO-DECELERATOR DOES NOT WORK 487
H-6 FINE CONTROL MODE DOES NOT FUNCTION 487
H-7 BOOM MOVES SLOWLY OR LACKS LACKS POWER 488
H-8 ARM MOVES SLOWLY OR LACKS POWER 489
H-9 BUCKET MOVES SLOWLY OR LACKS POWER 490
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 490
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT 491
H-12 WORK EQUIPMENT HAS BIG TIME LAG 492
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT 492
H-14 ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE 492
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY 493
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY 493
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 493
H-18 MACHINE SWERVES IN TRAVEL 494
H-19 MACHINE TRAVELS SLOWLY 495
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER 496
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST 497
H-22 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY) 498
H-23 MACHINE DOES NOT SWING 499
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 500
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING 501
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING 502
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING 502
H-28 SWING NATURAL DRIFT IS TOO BIG 503
30 DISASSEMBLY AND ASSEMBLY 504
HOW TO READ THIS MANUAL 506
REMOVAL AND INSTALLATION OF ASSEMBLIES 506
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES 507
PRECAUTIONS WHEN PERFORMING OPERATION 508
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY 510
REMOVAL 510
INSTALLATION 510
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 511
REMOVAL 511
INSTALLATION 513
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 515
REMOVAL 515
INSTALLATION 515
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 517
REMOVAL 517
INSTALLATION 518
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 519
SPECIAL TOOLS 519
REMOVAL 519
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 525
REMOVAL 525
INSTALLATION 526
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 527
REMOVAL 527
INSTALLATION 528
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES 529
SPECIAL TOOLS 529
REMOVAL 529
INSTALLATION 533
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 535
REMOVAL 535
INSTALLATION 535
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY 536
SPECIAL TOOLS 536
DISASSEMBLY 536
Untitled 538
SKETCHES OF SPECIAL TOOLS 543
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 544
REMOVAL 544
INSTALLATION 544
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 545
SPECIAL TOOLS 545
DISASSEMBLY 545
ASSEMBLY 547
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 552
SPECIAL TOOLS 552
ASSEMBLY 552
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 553
SPECIAL TOOLS 553
ASSEMBLY 553
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 554
SPECIAL TOOLS 554
DISASSEMBLY 554
ASSEMBLY 555
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 557
SPECIAL TOOLS 557
DISASSEMBLY 557
ASSEMBLY 558
REMOVAL AND INSTALLATION OF SPROCKET 559
REMOVAL 559
INSTALLTION 559
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 560
SPECIAL TOOLS 560
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY(IRON) 560
INSTALLATION 561
REMOVAL AND EXPANSION OF ROAD LINERS 562
INSTALLATION OF ROAD LINERS 563
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY 564
REMOVAL 564
INSTALLATION 564
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY 565
REMOVAL 565
INSTALLATION 566
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 567
REMOVAL 567
INSTALLATION 568
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 569
SPECIAL TOOLS 569
DISASSEMBLY 569
ASSEMBLY 569
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 570
REMOVAL 570
INSTALLATION 571
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSMEBLY 572
REMOVAL 572
INSTALLATION 574
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 575
SPECIAL TOOLS 575
ASSEMBLY 576
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 578
SPECIAL TOOLS 578
REMOVAL 578
INSTALLATION 580
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT 581
SPECIAL TOOLS 581
REMOVAL 581
INSTALLATION 581
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 582
ASSEMBLY 582
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 583
ASSEMBLY 583
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 584
SPECIAL TOOLS 584
DISASSEMBLY 584
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 590
SPECIAL TOOLS 590
REMOVAL 590
INSTALLATION 591
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 593
SPECIAL TOOLS 593
REMOVAL 593
INSTALLATION 595
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY 596
REMOVAL 596
INSTALLATION 596
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 597
REMOVAL 597
INSTALLATION 598
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY 599
REMOVAL 599
INSTALLATION 599
REMOVAL AND INSTALLATION OF GOVERNOR PUMP CONTROLLER ASSEMBLY 600
REMOVAL 600
INSTALLATION 600
90 OTHERS 601
HYDRAULIC CIRCUIT DIAGRAM (PC200,210(LC)-7) 602
HYDRAULIC CIRCUIT DIAGRAM (PC220,220LC-7) 603
ELECTRICAL CIRCUIT DIAGRAM(1/4) 604
ELECTRICAL CIRCUIT DIAGRAM(2/4) 605
ELECTRICAL CIRCUIT DIAGRAM(3/4) 606
ELECTRICAL CIRCUIT DIAGRAM(4/4) 607
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER(PC200,210,220(LC)-7) 608
UNDER COVER 609

PC200-7                       DBB0001 and up
PC200LC-7                  DBE0001 and up

PC210-7                       DBF0001 and up
PC210LC-7                  DBG0001 and up

PC220-7                       DBH0001 and up
PC220LC-7                  DBJ0001 and up

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

● Always wear safety glasses when hitting parts with a hammer.

● Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.

5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.