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KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL CEBMX20601 – PDF DOWNLOAD
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KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL
MACHINE MODEL SERIAL NUMBERS
PC200-6 A80001 and up
PC2OOLC-6 A80001 and up
PC21 OLC-6 A80001 and up
PC22OLC-6 A80001 and up
PC25OLC-6 A80001 and up
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Description
KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL
FILE DETAILS:
KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6
Serial Number: A80001 and up
Book Code: CEBMX20601
Language: English
Pages: 721
File Format: Portable Document Format (PDF)
KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL CEBMX20601 – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU EXCAVATOR PC200-6 PC200LC-6 PC210-6 PC220LC-6 PC250LC-6 SHOP SERVICE MANUAL
MAIN MENU...................................................................................................................................... 0 COVER.......................................................................................................................................... 1 CONTENTS....................................................................................................................................... 10 01 GENERAL..................................................................................................................................... 25 GENERAL ASSEMBLY DRAWING................................................................................................................... 26 PC200-6, PC200LC-6, PC210LC-6.......................................................................................................... 26 PC220LC-6, PC250LC-6................................................................................................................... 28 SPECIFICATIONS............................................................................................................................. 31 PC200-6, PC200LC-6..................................................................................................................... 31 PC210LC-6.............................................................................................................................. 33 PC220LC-6.............................................................................................................................. 35 PC250LC-6.............................................................................................................................. 37 WEIGHT TABLE............................................................................................................................... 39 PC200-6, PC200LC-6..................................................................................................................... 39 PC200-6, PC200LC-6..................................................................................................................... 31 PC210LC-6.............................................................................................................................. 41 PC220LC-6, PC250LC-6................................................................................................................... 43 LIST OF LUBRICANT AND WATER................................................................................................................ 45 10 STRUCTURE AND FUNCTION...................................................................................................................... 47 ENGINE RELATED PARTS....................................................................................................................... 48 RADIATOR, OIL COOLER, AFTERCOOLER.......................................................................................................... 49 POWERTRAIN................................................................................................................................. 51 FINAL DRIVE................................................................................................................................ 52 FINAL DRIVE................................................................................................................................ 53 SWING CIRCLE............................................................................................................................... 54 SWING MACHINERY............................................................................................................................ 55 TRACK FRAME, RECOIL SPRING................................................................................................................. 56 TRACK SHOE................................................................................................................................. 57 HYDRAULIC PIPING DRAWING................................................................................................................... 59 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 60 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 61 HYDRAULIC TANK............................................................................................................................. 63 HYDRAULIC PUMP............................................................................................................................. 64 LINE OIL FILTER............................................................................................................................ 85 CONTROL VALVE.............................................................................................................................. 86 CLSS....................................................................................................................................... 95 SWING MOTOR................................................................................................................................136 CENTER SWIVEL JOINT........................................................................................................................139 TRAVEL MOTOR...............................................................................................................................140 TRAVEL MOTOR...............................................................................................................................142 VALVE CONTROL..............................................................................................................................151 WORK EQUIPMENT, SWING PPC VALVE............................................................................................................152 TRAVEL PPC VALVE...........................................................................................................................156 SERVICE PPC VALVE..........................................................................................................................160 SAFETY LOCK VALVE..........................................................................................................................163 PPC ACCUMULATOR............................................................................................................................163 PPC SHUTTLE, TRAVEL JUNCTION VALVE.........................................................................................................164 EPC, SOLENOID VALVE........................................................................................................................171 BOOM HOLDING VALVE.........................................................................................................................176 HYDRAULIC CYLINDER.........................................................................................................................179 ADDITIONAL FILTER FOR BREAKER..............................................................................................................180 WORK EQUIPMENT.............................................................................................................................181 ELECTRICAL WIRING DIAGRAM..................................................................................................................182 ELECTRICAL CIRCUIT DIAGRAM (1/2)...........................................................................................................184 ENGINE CONTROL SYSTEM......................................................................................................................186 ELECTRONIC CONTROL SYSTEM..................................................................................................................191 MACHINE MONITOR SYSTEM.....................................................................................................................216 20 TESTING AND ADJUSTMENT......................................................................................................................223 TABLE OF JUDGEMENT STANDARD VALUE..........................................................................................................224 STANDARD VALUE FOR ELECTRICAL PARTS........................................................................................................236 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...........................................................................................245 MEASURING ENGINE SPEED.....................................................................................................................246 MEASURING EXHAUST GAS COLOR................................................................................................................247 ADJUSTING VALVE CLEARANCE..................................................................................................................248 MEASURING COMPRESSION PRESSURE.............................................................................................................249 MEASURING BLOWBY PRESSURE..................................................................................................................249 TESTING AND ADJUSTING FUEL INJECTION TIMING................................................................................................250 MEASURING ENGINE OIL PRESSURE..............................................................................................................251 TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION..........................................................................................252 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR..........................................................................252 ADJUSTING ENGINE SPEED SENSOR..............................................................................................................253 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE..........................................................................................254 TESTING CLEARANCE OF SWING CIRCLE BEARING..................................................................................................255 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................................256 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT......................................................257 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)..............................................................260 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE..................................262 TESTING AND ADJUSTING CONTROL PUMP CONTROL CIRCUIT OIL PRESSURE............................................................................265 TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE..........................................................................................267 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE..........................................................................269 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE..................................................................................................271 ADJUSTING TRAVEL LEVER.....................................................................................................................272 TESTING TRAVEL DEVIATION...................................................................................................................273 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................................274 MEASURING OIL LEAKAGE......................................................................................................................276 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................................277 BLEEDING AIR...............................................................................................................................278 TROUBLESHOOTING............................................................................................................................280 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................281 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................282 PRECAUTION WHEN CARRYING OUT MAINTENANCE...............................................................................................283 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................290 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................291 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................295 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.................................................................................308 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL..................................................................................309 METHOD OF USING JUDGEMENT TABLE........................................................................................................318 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................320 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTlNG PROCEDURE...............................................................................322 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)..........................................................................327 TROUBLESHOOTING....................................................................................................................280 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM..........................................328 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................329 JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS............................................................331 ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM..................................................................................332 E-1 Abnormality in engine throttle controller power system (engine speed stays at low idling) .....................................333 E-2 [E3:08] Abnormality in fuel control dial input value is displayed..............................................................334 E-3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayed................................................335 E-4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed................................................336 E-5 [E3:01] Abnormality in network reception system is displayed...................................................................337 E-6 [E3:05] Abnormality in model code is displayed.................................................................................339 E-7 [E3:06] Abnormality in governor potentiometer system is displayed..............................................................340 E-8 [E3:07] Abnormality in pump controller throttle system is displayed............................................................341 E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed..........................................................342 E-11 Engine does not start.........................................................................................................343 E-12 Engine speed is irregular.....................................................................................................345 E-13 Lack of output (engine high idling speed is too low)..........................................................................349 E-14 Engine does not stop..........................................................................................................351 E-15 Defective operation of battery relay system (engine does not stop)............................................................353 TROUBLESHOOTING OF ENGINE (S MODE).....................................................................................................354 METHOD OF USING TROUBLESHOOTING CHART..............................................................................................355 S-1 Starting performance is poor (Starting always takes time)..................................................................359 S-2 Engine does not start......................................................................................................360 Engine does not turn.......................................................................................................360 Engine turns but no exhaust gas comes out (Fuel is not being injected).....................................................361 Exhaust gas comes out but engine does not start (Fuel is being injected)...................................................362 S-3 Engine does not pick up smoothly (Follow-up is poor).......................................................................363 S-4 Engine stops during operations.............................................................................................364 S-5 Engine does not rotate smoothly............................................................................................365 S-6 Engine lacks output (no power).............................................................................................366 S-7 Exhaust gas is black (incomplete combustion)...............................................................................367 S-8 Oil consumption is excessive (or exhaust gas is blue)......................................................................368 S-9 Oil becomes contaminated quickly...........................................................................................369 S-10 Fuel consumption is excessive.............................................................................................370 S-11 Oil is in cooling water, or water spurts back, or water level goes down...................................................371 S-12 Oil pressure lamp lights up (drop in oil pressure)........................................................................372 S-13 Oil level rises...........................................................................................................373 S-14 Water temperature becomes too high (overheating)..........................................................................374 S-15 Abnormal noise is made....................................................................................................375 S-16 Vibration is excessive....................................................................................................376 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).....................................................................................377 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM.....................................................................378 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................379 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS....................................................................383 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM.............................................................................................384 C-1 Abnormality in pump controller power source system (swing brake is not canceled, etc.).........................................385 C-2 [E2:32][E2:36] Sort circuit in front/rear pump TVC solenoid system is displayed................................................386 C-3 [E2:33][E2:37] Disconnection in front/rear pump TVC solenoid system is displayed...............................................388 C-4 [E2:03] Short circuit in swing brake solenoid system is displayed..............................................................390 C-5 [E2:13] Disconnection in swing brake solenoid system is displayed..............................................................392 C-6................................................................................................................................394 [E2:02] Short circuit in LS select solenoid system is displayed................................................................394 [E2:04] Short circuit in pump merge-divider solenoid system is displayed.......................................................394 [E2:05] Short circuit in 2-stage relief solenoid system is displayed...........................................................394 [E2:06] Short circuit in travel speed solenoid system is displayed.........................................................394 C-7................................................................................................................................396 [E2:12] Disconnection in LS select solenoid system is displayed................................................................396 [E2:14] Disconnection in pump merge-divider solenoid system is displayed.......................................................396 [E2:15] Disconnection in 2-stage relief solenoid system is displayed...........................................................396 [E2:16] Disconnection in travel speed solenoid system is displayed.............................................................396 C-8 [E2:17] Model selection input error is displayed...............................................................................398 C-9 [E2:18] Network response overtime is displayed.................................................................................399 C-10 [E2:22] Short circuit in LS control EPC solenoid system is displayed..........................................................401 C-11 [E2:23] Disconnection in LS control EPC solenoid system is displayed..........................................................402 C-12...............................................................................................................................403 [E2:24] Abnormality in front pump pressure sensor system is displayed..........................................................403 [E2:25] Abnormality in rear pump pressure sensor system is displayed...........................................................403 C-13 [E2:26] Abnormality in pump pressure sensor power source system is displayed..................................................405 C-14 [E2:27] Abnormality in engine speed sensor system is displayed................................................................406 C-15 [E2:28] Abnormality in auto-deceleration output system is displayed...........................................................407 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)........................................................................408 F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up.................................................................409 F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up................................................................410 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up............................................................411 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up............................................................412 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up................................................................413 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up...............................................................414 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up...........................................................415 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up...........................................................416 F-9 Bit pattern 21-(3) Swing lock switch does not light up.........................................................................417 F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system)...............................418 F-11 Bit pattern 22-(5) Kerosene mode connection does not light up.................................................................419 F-12 Bit pattern 22-(6) L.H. knob switch does not light up.........................................................................420 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................................421 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM..............................................................422 PUMP MERGE-DIVIDER LOGIC...........................................................................................................424 ALL WORK EQUIPMENT, TRAVEL, SWING..................................................................................................426 H-1 Speeds of all work equipment, swing, travel and slow or lack power.........................................................426 H-2 There is excessive drop in engine speed, or engine stall...................................................................428 H-3 No work equipment, travel, swing move......................................................................................429 H-4 Abnormal noise generated (around pump).....................................................................................429 H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)..........................................................430 H-6 Fine control ability is poor or response is poor...........................................................................430 WORK EQUIPMENT.....................................................................................................................421 H-7 Boom is slow or lacks power................................................................................................431 H-8 Arm is slow or lacks power.................................................................................................433 H-9 Bucket is slow or lacks power..............................................................................................435 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)........................................436 H-11 Excessive hydraulic drift (boom, arm, bucket).............................................................................436 H-12 Excessive time lag (engine at low idling).................................................................................437 H-13 Lack of power when pressure rises.........................................................................................437 H-14 Other equipment moves when single circuit is relieved.....................................................................437 H-15 In L/O, F/O modes, work equipment speed is faster than specified speed....................................................438 COMPOUND OPERATIONS................................................................................................................421 H-16 In Compound operations, work equipment with larger load is slow...........................................................438 H-17 In swing + boom RAISE, boom RAISE is slow.................................................................................439 H-18 In swing + arm OUT, arm OUT is slow.......................................................................................439 H-19 In swing + travel, travel speed drops excessively.........................................................................439 TRAVEL SYSTEMS.....................................................................................................................421 H-20 Travel deviation..........................................................................................................440 H-21 Travel speed is slow......................................................................................................441 H-22 Steering does not turn easily or lacks power..............................................................................443 H-23 Travel speed doeas not switch or is faster than specified speed...........................................................445 H-24 Travel does not move (one side only)......................................................................................445 SWING SYSTEM.......................................................................................................................421 H-25 Does not swing............................................................................................................446 H-26 Swing acceleration is poor or swing speed is slow (both left and right, one direction only)...............................447 H-27 Excessive overrun when stopping swing.....................................................................................449 H-28 Excessive shock when stopping swing (one direction only)..................................................................450 H-29 Excessive abnormal noise when stopping swing..............................................................................450 H-30 Excessive hydraulic drift of swing........................................................................................451 H-31 Swing speed is faster than specified swing speed..........................................................................452 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................453 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCRS AND PROBLEMS ON MACHINE.......................................................454 MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM.............................................................................................455 M-1 [E1:01] Abnormality in error data is displayed.................................................................................456 M-2 [E1:02] Error in clock data is displayed.......................................................................................456 M-3 [E1:03] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed.................456 M-4 When starting switch is turned on, none of lamps on monitor panel light up for 3 seconds.......................................457 M-5 When starting switch is turned ON, monitor panel-lamps all stay lighted up and do not go out...................................458 M-6 When starting switch is turned ON, items lighted up on monitor panel are different from machine model..........................458 M-7 When starting switch is turned ON (engine stopped), CHECK items flash (fluids level for CHECK items are at specified level)....459 M-8 Preheating is not being used but preheating display lights up..................................................................461 M-9 When starting switch is turned ON and engine is started, CHECK items flash.....................................................462 M-10 When starting switch is turned ON (engine stopped), CAUTION items flash.......................................................464 M-11 When starting switch is turned ON and engine is started, CAUTION items flash..................................................466 M-12 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second........................................469 M-13 Liquid crystal night lighting on monitor panel does not light up (liquid crystal display is normal)...........................470 M-14 Coolant temperature gauge does not rise.......................................................................................471 M-15 Collant temperature gauge does not give any display (none of gauge lamps light up during operation)...........................472 M-16 Fuel level gauge always displays FULL.........................................................................................473 M-17 Fuel level gauge does not give display........................................................................................473 M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking display does not light up.....................................474 M-19 Swing lock prolix switch is ON (prolix), but monitor panel parking display does not flash.....................................474 M-20 Defective fuel level sensor system............................................................................................475 M-21 Defective coolant temperature sensor system...................................................................................476 M-22 Defective engine oil level sensor system......................................................................................477 M-23 Defective coolant level sensor system.........................................................................................478 M-24 Defective hydraulic oil level sensor system...................................................................................479 M-25 Working light, panel lighting do not light up, or switch is not being used but lights light up................................480 M-26 Wiper does not work or switch is not being used but wiper is actuated.........................................................482 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................486 METHOD OF USING MANUAL.....................................................................................................................490 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................491 SPECIAL TOOL LIST..........................................................................................................................493 STARTING MOTOR.............................................................................................................................498 REMOVAL................................................................................................................................498 INSTALLATION...........................................................................................................................498 ALTERNATOR.................................................................................................................................498 REMOVAL................................................................................................................................498 INSTALLATION...........................................................................................................................498 AIR CONDITIONER COMPRESSOR.................................................................................................................499 REMOVAL................................................................................................................................499 INSTALLATION...........................................................................................................................499 AIR CONDITIONER CONDENSER..................................................................................................................500 REMOVAL................................................................................................................................500 INSTALLATION...........................................................................................................................500 ENGINE OIL COOLER CORE.....................................................................................................................501 REMOVAL................................................................................................................................501 INSTALLATION...........................................................................................................................501 FUEL INJECTION PUMP........................................................................................................................502 REMOVAL................................................................................................................................502 INSTALLATION...........................................................................................................................504 WATER PUMP.................................................................................................................................505 REMOVAL................................................................................................................................505 INSTALLATION...........................................................................................................................505 NOZZLE HOLDER..............................................................................................................................506 REMOVAL................................................................................................................................506 INSTALLATION...........................................................................................................................506 TURBOCHARGER...............................................................................................................................507 REMOVAL................................................................................................................................507 INSTALLATION...........................................................................................................................507 THERMOSTAT.................................................................................................................................508 REMOVAL................................................................................................................................508 INSTALLATION...........................................................................................................................508 ENGINE FRONT OIL SEAL......................................................................................................................509 REMOVAL................................................................................................................................509 INSTALLATION...........................................................................................................................509 ENGINE REAR OIL SEAL.......................................................................................................................510 REMOVAL................................................................................................................................510 INSTALLATION...........................................................................................................................510 GOVERNOR MOTOR.............................................................................................................................511 REMOVAL................................................................................................................................511 INSTALLATION...........................................................................................................................511 CYLINDER HEAD..............................................................................................................................512 REMOVAL................................................................................................................................512 INSTALLATION...........................................................................................................................514 AFTERCOOLER................................................................................................................................516 REMOVAL................................................................................................................................516 INSTALLATION...........................................................................................................................516 HYDRAULIC OIL COOLER - PC200-6, PC210-6....................................................................................................517 REMOVAL................................................................................................................................517 INSTALLATION...........................................................................................................................517 HYDRAULIC OIL COOLER - PC220-6, PC250-6....................................................................................................518 REMOVAL................................................................................................................................518 INSTALLATION...........................................................................................................................518 RADIATOR HYDRAULIC OIL COOLER - PC200-6, PC210-6...........................................................................................519 REMOVAL................................................................................................................................519 INSTALLATION...........................................................................................................................520 RADIATOR HYDRAULIC OIL COOLER - PC220-6, PC250-6...........................................................................................521 REMOVAL................................................................................................................................521 INSTALLATION...........................................................................................................................522 ENGINE HYDRAULIC PUMP......................................................................................................................523 REMOVAL................................................................................................................................523 INSTALLATION...........................................................................................................................526 DAMPER.....................................................................................................................................527 REMOVAL................................................................................................................................527 INSTALLATION...........................................................................................................................527 FUEL TANK..................................................................................................................................528 REMOVAL................................................................................................................................528 INSTALLATION...........................................................................................................................528 CENTER SWIVEL JOINT........................................................................................................................529 REMOVAL................................................................................................................................529 INSTALLATION...........................................................................................................................529 DISASSEMBLY............................................................................................................................530 ASSEMBLY...............................................................................................................................530 FINAL DRIVE................................................................................................................................531 REMOVAL................................................................................................................................531 INSTALLATION...........................................................................................................................531 FINAL DRIVE PC200-6 6, PC200LC-6, PC210LC-6, PC220LC-6.....................................................................................532 DISASSEMBLY............................................................................................................................532 ASSEMBLY...............................................................................................................................535 FINAL DRIVE PC250LC........................................................................................................................539 DISASSEMBLY............................................................................................................................539 ASSEMBLY...............................................................................................................................542 SPROCKET...................................................................................................................................547 REMOVAL................................................................................................................................547 INSTALLATION...........................................................................................................................547 TRAVEL MOTOR...............................................................................................................................548 DISASSEMBLY............................................................................................................................548 ASSEMBLY...............................................................................................................................553 SWING MOTOR................................................................................................................................561 REMOVAL................................................................................................................................561 INSTALLATION...........................................................................................................................561 SWING MACHINERY............................................................................................................................562 REMOVAL................................................................................................................................562 INSTALLATION...........................................................................................................................562 DISASSEMBLY............................................................................................................................563 ASSEMBLY...............................................................................................................................566 REVOLVING FRAMES...........................................................................................................................570 REMOVAL................................................................................................................................570 INSTALLATION...........................................................................................................................571 SWING CIRCLE...............................................................................................................................572 REMOVAL................................................................................................................................572 INSTALLATION...........................................................................................................................573 IDLER, RECOIL SPRING.......................................................................................................................574 REMOVAL................................................................................................................................574 INSTALLATION...........................................................................................................................574 RECOIL SPRING..............................................................................................................................575 DISASSEMBLY............................................................................................................................575 ASSEMBLY...............................................................................................................................576 IDLER......................................................................................................................................577 DISASSEMBLY............................................................................................................................577 ASSEMBLY...............................................................................................................................578 TRACK ROLLER...............................................................................................................................580 REMOVAL................................................................................................................................580 INSTALLATION...........................................................................................................................580 DISASSEMBLY............................................................................................................................582 ASSEMBLY...............................................................................................................................583 CARRIER ROLLER.............................................................................................................................585 REMOVAL................................................................................................................................585 INSTALLATION...........................................................................................................................585 DISASSEMBLY............................................................................................................................586 ASSEMBLY...............................................................................................................................587 TRACK SHOE.................................................................................................................................589 REMOVAL................................................................................................................................589 INSTALLATION...........................................................................................................................589 HYDRAULIC TANK.............................................................................................................................590 REMOVAL................................................................................................................................590 INSTALLATION...........................................................................................................................591 CONTROL PUMP...............................................................................................................................592 REMOVAL................................................................................................................................592 INSTALLATION...........................................................................................................................592 MAIN PUMP..................................................................................................................................593 REMOVAL................................................................................................................................593 INSTALLATION...........................................................................................................................594 DISASSEMBLY............................................................................................................................595 ASSEMBLY...............................................................................................................................601 MAIN PUMP INPUT SHAFT OIL SEAL.............................................................................................................617 REMOVAL................................................................................................................................617 INSTALLATION...........................................................................................................................617 CONTROL VALVE..............................................................................................................................618 REMOVAL................................................................................................................................618 INSTALLATION...........................................................................................................................619 REMOVAL 7 - SPOOL......................................................................................................................620 INSTALLATION 7 - SPOOL.................................................................................................................621 DISASSEMBLY............................................................................................................................622 ASSEMBLY...............................................................................................................................624 PUMP MERGE-DIVIDER VALVE...................................................................................................................626 DISASSEMBLY............................................................................................................................626 ASSEMBLY...............................................................................................................................626 PRESSURE COMPENSATION VALVE................................................................................................................627 DISASSEMBLY............................................................................................................................627 ASSEMBLY...............................................................................................................................627 MAIN RELIEF VALVE..........................................................................................................................628 DISASSEMBLY............................................................................................................................628 ASSEMBLY...............................................................................................................................629 TVC - LS VALVE.............................................................................................................................630 FRONT PUMP.............................................................................................................................630 REMOVAL............................................................................................................................630 INSTALLATION.......................................................................................................................630 REAR PUMP..............................................................................................................................631 REMOVAL............................................................................................................................631 INSTALLATION.......................................................................................................................631 LS CONTROL EPC VALVE.......................................................................................................................632 REMOVAL................................................................................................................................632 INSTALLATION...........................................................................................................................632 SOLENOID VALVE.............................................................................................................................633 REMOVAL................................................................................................................................633 INSTALLATION...........................................................................................................................633 WORK EQUIPMENT/SWING PPC VALVE.............................................................................................................634 REMOVAL................................................................................................................................634 INSTALLATION...........................................................................................................................634 DISASSEMBLY............................................................................................................................635 ASSEMBLY...............................................................................................................................636 TRAVEL PPC VALVE...........................................................................................................................637 REMOVAL................................................................................................................................637 INSTALLATION...........................................................................................................................637 DISASSEMBLY............................................................................................................................638 ASSEMBLY...............................................................................................................................638 BOOM LOCK VALVE............................................................................................................................640 REMOVAL................................................................................................................................640 INSTALLATION...........................................................................................................................640 BOOM CYLINDER..............................................................................................................................641 REMOVAL................................................................................................................................641 INSTALLATION...........................................................................................................................642 ARM CYLINDER...............................................................................................................................643 REMOVAL................................................................................................................................643 INSTALLATION...........................................................................................................................644 BUCKET CYLINDER............................................................................................................................645 REMOVAL................................................................................................................................645 INSTALLATION...........................................................................................................................646 HYDRAULIC CYLINDER.........................................................................................................................647 DISASSEMBLY............................................................................................................................647 ASSEMBLY...............................................................................................................................649 WORK EQUIPMENT.............................................................................................................................652 REMOVAL................................................................................................................................652 INSTALLATION...........................................................................................................................653 BUCKET.....................................................................................................................................654 REMOVAL................................................................................................................................654 INSTALLATION...........................................................................................................................655 ARM........................................................................................................................................656 REMOVAL................................................................................................................................656 INSTALLATION...........................................................................................................................657 BUCKET ARM.................................................................................................................................658 REMOVAL................................................................................................................................658 INSTALLATION...........................................................................................................................659 BOOM.......................................................................................................................................660 REMOVAL................................................................................................................................660 INSTALLATION...........................................................................................................................661 OPERATOR'S CAB.............................................................................................................................662 REMOVAL................................................................................................................................662 INSTALLATION...........................................................................................................................664 COUNTERWEIGHT..............................................................................................................................665 REMOVAL................................................................................................................................665 INSTALLATION...........................................................................................................................665 ENGINE THROTTLE CONTROLLER.................................................................................................................666 REMOVAL................................................................................................................................666 INSTALLATION...........................................................................................................................666 PUMP CONTROLLER............................................................................................................................667 REMOVAL................................................................................................................................667 INSTALLATION...........................................................................................................................667 MONITOR....................................................................................................................................668 REMOVAL................................................................................................................................668 INSTALLATION...........................................................................................................................668 40 MAINTENANCE STANDARD........................................................................................................................669 FINAL DRIVE................................................................................................................................670 FINAL DRIVE................................................................................................................................672 SWING MACHINERY............................................................................................................................674 SWING CIRCLE...............................................................................................................................676 TRACK FRAME, RECOIL SPRING.................................................................................................................677 TRACK FRAME, RECOIL SPRING.................................................................................................................678 IDLER......................................................................................................................................679 IDLER......................................................................................................................................681 CARRIER ROLLER.............................................................................................................................683 CARRIER ROLLER.............................................................................................................................684 TRACK ROLLER...............................................................................................................................685 TRACK ROLLER...............................................................................................................................686 TRACK SHOE.................................................................................................................................687 TRACK SHOE.................................................................................................................................689 HYDRAULIC PUMP.............................................................................................................................691 CONTROL PUMP, RELIEF VALVE.................................................................................................................692 SWING MOTOR................................................................................................................................700 TRAVEL MOTOR...............................................................................................................................701 TRAVEL MOTOR...............................................................................................................................702 WORK EQUIPMENT, SWING PPC VALVE............................................................................................................703 TRAVEL PPC VALVE...........................................................................................................................704 SERVICE PPC VALVE..........................................................................................................................705 PPC SHUTTLE, TRAVEL JUNCTION VALVE.........................................................................................................706 EPC, SOLENOID VALVE........................................................................................................................708 CENTER SWIVEL JOINT........................................................................................................................709 BOOM HOLDING VALVE.........................................................................................................................710 HYDRAULIC CYLINDER.........................................................................................................................711 HYDRAULIC CYLINDER.........................................................................................................................713 WORK EQUIPMENT.............................................................................................................................715
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