Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 & UP) – PDF DOWNLOAD
Original price was: $71.95.$27.95Current price is: $27.95.
- KOMATSU GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:A86001 & UP
- PUBLICATION NUMBER:CEBM014300
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 & UP)
KOMATSU GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 & UP) – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 & UP)
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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, ADJUSTING AND TROUBLESHOOTING
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 GALEO PC200LL-7L PC220LL-7L HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 & UP)
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 CONTENTS.................................................................................. 2 FOREWORD.................................................................................. 5 SAFETY................................................................................ 5 SAFETY NOTICE..................................................................... 5 IMPORTANT SAFETY NOTICE....................................................... 5 GENERAL PRECAUTIONS........................................................... 5 PREPARATIONS FOR WORK......................................................... 5 PRECAUTIONS DURING WORK....................................................... 5 GENERAL............................................................................... 7 HOW TO READ THE SHOP MANUAL........................................................... 8 VOLUMES........................................................................... 8 DISTRIBUTION AND UPDATING......................................................... 8 FILING METHOD..................................................................... 8 REVISED EDITION MARK.............................................................. 8 REVISIONS......................................................................... 8 SYMBOLS........................................................................... 8 HOISTING INSTRUCTIONS................................................................. 9 HOISTING.......................................................................... 9 WIRE ROPES........................................................................ 9 COATING MATERIALS..................................................................... 10 STANDARD TIGHTENING TORQUE............................................................ 12 BOLTS AND NUTS STANDARD TIGHTENING TORQUE......................................... 12 HOSE NUTS TIGHTENING TORQUE....................................................... 13 SPLIT FLANGE BOLTS TIGHTENING TORQUE.............................................. 13 FLARED NUTS TIGHTENING TORQUE..................................................... 13 O-RING BOSS PIPING JOINTS TIGHTENING TORQUE....................................... 14 O-RING BOSS PLUGS TIGHTENING TORQUE............................................... 14 ENGINE SERIES TIGHTENING TORQUE................................................... 15 HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE...................... 16 ELECTRIC WIRE CODE.................................................................... 17 CLASSIFICATION BY THICKNESS....................................................... 17 CLASSIFICATION BY COLOR AND CODE.................................................. 17 CONVERSION TABLES..................................................................... 18 METHOD OF USING THE CONVERSION TABLE.............................................. 18 UNITS............................................................................. 24 01 GENERAL................................................................................ 25 SPECIFICATION DIMENSION DRAWINGS...................................................... 26 PC200/220LL-7L.................................................................... 26 DIMENSIONS.................................................................... 26 WORKING RANGE - ROAD BUILDER.................................................. 28 SPECIFICATIONS........................................................................ 30 WEIGHT TABLE.......................................................................... 32 FUEL, COOLANT AND LUBRICANTS.......................................................... 34 PC200LL-7L........................................................................ 34 PC220LL-7L........................................................................ 35 10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS............................................ 37 ENGINE RELATED PARTS.................................................................. 41 RADIATOR, OIL COOLER AND AFTERCOOLER.................................................. 42 POWER TRAIN........................................................................... 43 FINAL DRIVE........................................................................... 44 PC200LL-7L........................................................................ 44 PC220LL-7L........................................................................ 46 SWING MACHINERY....................................................................... 48 PC200LC-7......................................................................... 48 PC220LC-7......................................................................... 50 SWING CIRCLE.......................................................................... 52 PC200LC-7......................................................................... 52 PC220LL-7L........................................................................ 53 UNDERCARRIAGE......................................................................... 54 IDLER................................................................................. 56 TRACK AND CARRIER ROLLER.............................................................. 58 TRACK CHAIN AND SHOES................................................................. 61 TRIPLE GROUSER SHOE - PC200LL-7L.................................................. 66 TRIPLE GROUSER SHOE - PC220LL-7L.................................................. 67 HYDRAULIC EQUIPMENT................................................................... 68 HYDRAULIC TANK........................................................................ 70 HYDRAULIC PUMP........................................................................ 71 HPV95+95.......................................................................... 71 LS VALVE...................................................................... 75 PC VALVE...................................................................... 76 LS-EPC VALVE...................................................................... 88 MAIN CONTROL VALVE.................................................................... 92 MAIN RELIEF VALVE.....................................................................108 VARIABLE PRESSURE COMPENSATION VALVE..................................................109 CLSS..................................................................................110 OUTLINE OF CLSS...................................................................110 SELF PRESSURE REDUCING VALVE..........................................................113 SWING MOTOR...........................................................................116 PC200LL-7L........................................................................116 KMF125ABE-5...................................................................116 PC220LL-7L........................................................................119 KMF230ABE-5...................................................................119 OPERATION OF SWING LOCK...........................................................122 RELIEF VALVE PORTION..............................................................123 REVERSE PREVENTION VALVE..............................................................124 CENTER SWIVEL JOINT...................................................................126 TRAVEL MOTOR..........................................................................127 PC200LL-7L........................................................................127 HMV110-2......................................................................127 PC220LL-7L........................................................................130 HMV160ADT-2...................................................................130 MOTOR.........................................................................133 PARKING BRAKE.................................................................135 BRAKE VALVE...................................................................135 SAFETY VALVE..................................................................136 TRAVEL JUNCTION VALVE.................................................................138 TRAVEL PPC SHUTTLE VALVE..............................................................140 VALVE CONTROL.........................................................................142 CONNECTIONS.......................................................................142 LEVER POSITIONS...................................................................143 EQUIPMENT PPC VALVE...................................................................144 TRAVEL PPC VALVE......................................................................148 TRAVEL SIGNAL/STEERING FUNCTION...................................................151 SERVICE PPC VALVE.....................................................................155 SOLENOID VALVE........................................................................158 ATTACHMENT SOLENOID VALVE.............................................................159 PPC ACCUMULATOR.......................................................................161 BOOM DRIFT PREVENTION VALVE...........................................................162 LIFT CHECK VALVE......................................................................166 EQUIPMENT CYLINDERS...................................................................168 PC200LL-7.........................................................................168 BOOM CYLINDER.................................................................168 ARM CYLINDER..................................................................168 BUCKET CYLINDER...............................................................168 PC220LL-7.........................................................................170 BOOM CYLINDER.................................................................170 ARM CYLINDER..................................................................170 BUCKET CYLINDER...............................................................170 WORK EQUIPMENT........................................................................172 PC200LL-7.........................................................................173 100 HOURS.....................................................................173 500 HOURS.....................................................................173 PC220LL-7.........................................................................174 100 HOURS.....................................................................174 500 HOURS.....................................................................174 ARM DIMENSION.....................................................................176 BUCKET DIMENSIONS.................................................................178 AIR CONDITIONER.......................................................................180 ENGINE CONTROLS.......................................................................181 OPERATION OF SYSTEM...............................................................182 STARTING ENGINE...............................................................182 ENGINE SPEED CONTROL..........................................................182 STOPPING ENGINE...............................................................182 COMPONENT.........................................................................183 FUEL CONTROL DIAL.............................................................183 GOVERNOR MOTOR....................................................................184 ENGINE THROTTLE AND PUMP CONTROLLER...............................................185 INPUT AND OUTPUT SIGNALS......................................................186 ELECTRONIC CONTROL SYSTEM.............................................................187 MACHINE CONTROL SYSTEM DIAGRAM....................................................188 ENGINE AND PUMP CONTROL FUNCTION..............................................190 PUMP VALVE CONTROL............................................................194 ONE TOUCH POWER MAXIMIZING....................................................196 AUTO DECELERATION FUNCTION....................................................197 AUTO WARM UP OVERHEAT PREVENTION..............................................199 SWING CONTROL FUNCTION........................................................201 SWING CONTROL FUNCTION WITH SOFT SWING........................................203 TRAVEL CONTROL FUNCTION.......................................................205 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION...................................207 SYSTEM COMPONENT PARTS............................................................208 ENGINE REVOLUTION SENSOR......................................................208 PPC OIL PRESSURE SWITCH.......................................................209 PUMP PRESSURE SENSOR..........................................................210 MULTI MONITOR SYSTEM..................................................................211 MONITOR PANEL.....................................................................212 INPUT AND OUTPUT SIGNALS......................................................213 MONITOR CONTROL, DISPLAY PORTION..................................................214 MONITOR PORTION...............................................................214 MONITOR ITEMS AND DISPLAY.....................................................215 SWITCHES..........................................................................219 SELECT MODE FUNCTION..........................................................221 METHOD OF USE.................................................................221 MAINTENANCE FUNCTION..........................................................224 METHOD OF CHECKING STATUS MAINTENANCE ITEMS...................................225 MAINTENANCE OPERATION.........................................................225 BRIGHTNESS CONTRAST ADJUSTMENT FUNCTION.......................................226 SERVICE METER CHECK FUNCTION..................................................227 DISPLAY LCD CHECK FUNCTION....................................................227 USER CODE DISPLAY FUNCTION....................................................227 SENSORS...............................................................................229 ENGINE OIL LEVEL SENSOR...........................................................229 COOLANT TEMPERATURE SENSOR........................................................229 HYDRAULIC OIL TEMPERATURE SENSOR..................................................229 ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE).....................................230 FUEL LEVEL SENSOR.................................................................230 AIR CLEANER CLOGGING SENSOR.......................................................231 CAB RISER AND RELATED PARTS...........................................................232 POWER CONTROL.....................................................................233 CAB RISER HYDRAULIC SYSTEM............................................................234 20 TESTING, ADJUSTING AND TROULBESHOOTING.................................................235 STANDARD VALUE TABLES.................................................................236 ENGINE PARTS......................................................................236 CHASSIS PARTS.....................................................................237 FLOW CONTROL CHARACTERISTIC OF PC VALVE...........................................246 TESTING AND ADJUSTING.................................................................247 TOOLS FOR TESTING.................................................................250 ENGINE............................................................................251 AIR BOOST PRESSURE............................................................251 AIR COMPRESSOR BELT TENSION...................................................251 BLOW-BY PRESSURE..............................................................251 COMPRESSION PRESSURE..........................................................251 ENGINE OIL PRESSURE...........................................................251 ENGINE RPM....................................................................251 ENGINE SPEED SENSOR...........................................................251 EXHAUST GAS COLOR.............................................................251 FUEL INJECTION TIMING.........................................................251 VALVE CLEARANCE...............................................................251 AIR CONDITIONER BELT..............................................................252 ENGINE CONTROL FAILURE............................................................253 SWING CIRCLE BEARINGS.............................................................254 TRACK SHOE TENSION................................................................255 EQUIPMENT, SWING AND TRAVEL PRESSURES.............................................256 MEASUREMENT...................................................................256 PRE MEASUREMENT WORK......................................................256 COMBINATION OF PUMP, ACTUATOR AND VALVE...................................256 UNLOAD PRESSURE...........................................................257 WORK EQUIPMENT RELIEF PRESSURE............................................257 SWING RELIEF PRESSURE.....................................................257 TRAVEL CIRCUIT RELIEF PRESSURE............................................257 ADJUSTMENT....................................................................258 MAIN RELIEF PRESSURE......................................................258 SWING RELIEF PRESSURE.....................................................259 CONTROL CIRCUIT OIL PRESSURE......................................................260 PUMP PC CONTROL CIRCUIT PRESSURE..................................................261 TESTING.......................................................................261 PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)....................261 PC-EPC OUTPUT PRESSURE....................................................262 ADJUSTMENT....................................................................263 PUMP LS CONTROL CIRCUIT PRESSURE..................................................264 MEASUREMENT...................................................................264 LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)....................264 LS DIFFERENTIAL PRESSURE..................................................265 LS-EPC VALVE OUTPUT PRESSURE..............................................267 ADJUSTMENT....................................................................268 SOLENOID VALVE OUTPUT PRESSURE....................................................269 TESTING.......................................................................269 ATTACHMENT SOLENOID VALVE OUTPUT..............................................270 TABLE FOR FUNCTIONING CONDITIONS..............................................271 PPC LOCK SOLENOID VALVE...................................................271 SWING AND PARKING BRAKE SOLENOID..........................................271 TRAVEL INTERCONNECTION SOLENOID VALVE.....................................271 TRAVEL SPEED SHIFTING SOLENOID VALVE......................................272 2 STAGE RELIEF SOLENOID VALVE.............................................272 MERGE DIVIDE SOLENOID VALVE...............................................272 PPC VALVE OUTPUT PRESSURE.........................................................273 ATTACHMENT PPC VALVE OUTPUT...................................................274 EQUIPMENT AND SWING PPC VALVE.....................................................275 WORK EQUIPMENT DRIFT..............................................................276 BOOM AND BUCKET CYLINDERS.....................................................276 ARM CYLINDER..................................................................276 BOOM LOCK VALVE...............................................................277 PPC VALVE.....................................................................277 RELEASE REMAINING OIL PRESSURE....................................................278 OIL LEAKAGE AMOUNT................................................................279 BOOM CYLINDER.................................................................279 ARM CYLINDER..................................................................279 BUCKET CYLINDER...............................................................280 SWING MOTOR...................................................................280 TRAVEL MOTOR..................................................................281 SOFT SWING ADJUSTMENTS............................................................282 BLEEDING AIR......................................................................283 HYDRAULIC PUMP................................................................283 HYDRAULIC CYLINDERS...........................................................284 SWING MOTOR...................................................................284 TRAVEL MOTOR..................................................................284 DIODE INSPECTION PROCEDURES.......................................................285 USING DIGITAL TYPE CIRCUIT TESTER.............................................285 USING ANALOG TYPE CIRCUIT TESTER..............................................285 CAB DOOR STOP ADJUSTMENT..........................................................286 MULTI MONITOR PANEL...............................................................287 MONITOR PANEL FUNCTIONS - CONVENTIONAL AND SPECIAL............................288 CONVENTIONAL FUNCTION: OPERATOR'S MENU....................................288 SPECIAL FUNCTION: SERVICE MENU............................................288 OPERATOR'S MENU AND DISPLAY (OUTLINE).........................................289 2. SHOWING KOMATSU LOGO...................................................289 3. MACHINE INSPECTION BEFORE STARTING WORK................................289 4. MACHINE MAINTENANCE....................................................289 5. SHOWING PRECAUTION ITEMS...............................................289 6. CONFIRMING WORKING MODE AND TRAVEL SPEED...............................290 7. DISPLAY OF ORDINARY ITEMS..............................................290 8. ADJUSTING DISPLAY LUMINANCE AND CONTRAST...............................290 9. ADJUSTING BREAKER AND ATTACHMENT FLOW RATE.............................290 10. CONFIRMING MAINTENANCE INFORMATION....................................291 11. SHOWING SERVICE METER READING.........................................291 12. CHECKING DISPLAY LCD..................................................291 13. SHOWING OCCURRENCE OF CAUTION ITEM....................................291 14. SHOWING USERS CODE NO.................................................292 15. SHOWING SERVICE CODE AND FAILURE CODE NO..............................292 TABLE FOR SERVICE AND FAILURE CODE NOS........................................295 OPERATION AND DISPLAY OF SERVICE MENU.........................................297 WAY OF SWITCHING TO SERVICE MENU..........................................297 16. FUNCTION OF MONITORING [01]...........................................298 TABLE FOR MONITORING ITEMS....................................................300 17. FUNCTION FOR ABNORMALITY RECORD [02]..................................302 18. FUNCTION FOR MAINTENANCE RECORD [03]..................................304 19. FUNCTION FOR MAINTENANCE MODE CHANGE [04].............................305 20. FUNCTION FOR PHONE NUMBER ENTRY [05]..................................306 21. FUNCTION FOR /DEFAULT [06]............................................307 22. FUNCTION FOR ADJUSTMENT [07]..........................................308 ELECTRICAL SYSTEM PREPARATIONS....................................................311 MONITOR PANEL.................................................................311 GOVERNOR PUMP CONTROLLER......................................................311 PC200LL-7L AND PC220LL-7L -- PM - TUNE UP SERVICE.............................313 ENGINE TUNE UP............................................................314 HYDRAULIC SYSTEM..........................................................315 TROUBLESHOOTING GENERAL...............................................................319 TROUBLESHOOTING POINTS TO REMEMBER................................................320 SEQUENCE OF EVENTS................................................................322 MAINTENANCE POINTS TO REMEMBER....................................................323 WHEN HANDLING ELECTRIC EQUIPMENT..............................................323 WHEN TROUBLESHOOTING ELECTRIC CIRCUITS........................................327 WHEN HANDLING HYDRAULIC EQUIPMENT.............................................328 CHECKS BEFORE TROUBLESHOOTING.....................................................330 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING......................................331 CLASSIFICATION OF TROUBLESHOOTING.............................................331 STEPS FOR TROUBLESHOOTING.....................................................331 FAILURE LOOKING PHENOMENON AND TROUBLESHOOTING NO.............................332 ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM..............................................335 CONNECTOR TABLE...............................................................335 CONNECTOR LOCATION............................................................340 MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)..............................346 GOVERNOR CONTROL SYSTEM CIRCUIT DIAGRAM (G CIRCUIT)...........................348 PUMP CONTROL SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)...............................350 TABLE FOR CONNECTOR PIN NUMBERS...................................................352 CONNECTOR REPAIR PROCEDURES.......................................................372 CONTACT TERMINAL REMOVAL (HD30 TYPE)..........................................372 STRIPPING INSULATION..........................................................373 CRIMPING CONTACT TERMINAL (HD30 TYPE).........................................374 INSERTION OF CONTACT TERMINAL (HD30 TYPE).....................................375 CONTACT TERMINAL REMOVAL (DT TYPE)............................................376 STRIPPING INSULATION..........................................................377 CRIMPING CONTACT TERMINAL (DT TYPE)...........................................378 INSERTION OF CONTACT TERMINAL (DT TYPE).......................................379 TROUBLESHOOTING ELECTRICAL SERVICE CODES AND MECHANICAL FAILURE CODES.................381 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....................................383 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.................383 USER CODE MEMORY RETENTION FUNCTION...........................................383 INFORMATION CONTAINED IN TESTING PROCEDURES.......................................384 E101 - ERROR IN DATA HISTORY......................................................386 E112 - SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION.....................388 E112 - SHORT IN GUARD WIPER MOTOR DRIVE FORWARD ROTATION..........................389 E113 - SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION.....................391 E113 - SHORT IN GUARD WIPER MOTOR DRIVE REVERSE ROTATION..........................392 E114 - SHORT OR OPEN IN WINDOW WASHER SYSTEM......................................394 E114 - SHORT OR OPEN IN GUARD WASHER SYSTEM.......................................395 E115 - ABNORMAL WINDSHIELD WIPER MOTION...........................................397 E115 - ABNORMAL GUARD WIPER MOTION................................................398 E116 - ABNORMALITY IN PARKING WIPER ARM...........................................400 E116 - ABNORMALITY IN PARKING WIPER ARM (GUARD)...................................401 E201- SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID...............................404 E203 - SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM......................406 E203 - SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM (WITH SOFT SWING)....408 E204 - SHORT IN MERGE/DIVIDE SOLENOID.............................................410 E205 - SHORT IN 2 STAGE RELIEF SOLENOID...........................................412 E206 - SHORT IN TRAVEL SPEED SHIFT SOLENOID.......................................414 E211 - OPEN IN TRAVEL INTERLOCKING SOLENOID.......................................416 E213 - OPEN IN SWING PARKING BRAKE SOLENOID.......................................418 E213 - OPEN IN SWING PARKING BRAKE SOLENOID (WITH SOFT SWING).....................420 NO CODE - SHORT OR OPEN IN SOFT SWING SOLENOID SYSTEM.............................422 E214 - OPEN IN MERGE/DIVIDE SOLENOID..............................................426 E215 - OPEN IN 2 STAGE RELIEF SOLENOID............................................428 E216 - OPEN IN TRAVEL SPEED SOLENOID..............................................430 E217 - ABNORMAL INPUT FOR MODEL CODE - PC200LC-7L (PC200LL-7L)....................432 E217 - ABNORMAL INPUT FOR MODEL CODE - PC220LC-7L (PC220LL-7L)....................434 E218 - OPEN IN S-NET SIGNAL.......................................................436 E222 - SHORT IN LS-EPC SOLENOID...................................................438 E223 - OPEN IN LS-EPC SOLENOID SYSTEM.............................................440 E224 - ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL.....................................442 E225 - ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL.....................................444 E226 - ABNORMAL PRESSURE SENSOR POWER SUPPLY......................................446 E227 - ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER.....................448 E228 - SHORT IN ATTACHMENT RETURN SWITCHING RELAY.................................450 NO CODE - SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM.............................452 NO CODE - OPEN IN CAB TILT SYSTEM.................................................456 E232 - SHORT IN PC-EPC SOLENOID...................................................458 E233 - OPEN IN PC-EPC SOLENOID SYSTEM.............................................460 E238 - OPEN IN ATTACHMENT RETURN SWITCH RELAY.....................................462 E245 - SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM...............................464 E246 - OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM................................466 E256 - INCORRECT NONVOLATILE MEMORY DATA..........................................468 E306 - ABNORMAL GOVERNOR POTENTIOMETER SIGNALS....................................470 E308 - ABNORMAL FUEL DIAL SIGNALS.................................................472 E315 - SHORT IN BATTERY RELAY SYSTEM..............................................474 E316 - STEP OUT IN GOVERNOR MOTOR.................................................476 E317 - OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”...................................478 E318 - SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”..................................480 E501 - MODEL SELECTION FUNCTION NOT PROVIDED......................................482 E502 - MODEL SELECTING SIGNAL FAULT...............................................483 A000N1 - ENGINE SPEED OUT OF RANGE AT HIGH IDLE...................................484 A000N2 - ENGINE SPEED OUT OF RANGE AT LOW IDLE....................................485 AA10NX - AIR CLEANER CLOG INDICATOR FAILURE.......................................486 AB00KE - LOW CHARGING VOLTAGE INDICATED...........................................488 B@BAZG - ABNORMAL ENGINE OIL PRESSURE.............................................490 B@BAZK - ABNORMAL ENGINE OIL LEVEL................................................492 B@BCNS - ENGINE COOLANT INDICATING OVERHEAT CONDITION.............................494 B@BCZK - ABNORMAL COOLANT LEVEL INDICATION........................................496 B@HANS - HYDRAULIC OIL OVERHEAT INDICATION........................................498 TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)............................................501 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....................................503 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.................503 USER CODE MEMORY RETENTION FUNCTION...........................................503 INFORMATION CONTAINED IN TESTING PROCEDURES.......................................504 E-1 - ENGINE WILL NOT CRANK.......................................................506 E-2 - ENGINE STOPS WHILE IN OPERATION.............................................508 E-3 - ENGINE SPEED IRREGULAR, OR HUNTING..........................................510 E-4 - ENGINE DOES NOT STOP........................................................512 E-5 - AUTO DECELERATOR DOES NOT WORK..............................................514 E-6 - AUTO ENGINE WARM UP DEVICE DOES NOT WORK....................................515 E-7 - COLD START PREHEATER DOES NOT WORK..........................................516 E-8 - ALL WORK EQUIPMENT, SWING AND TRAVEL DOES NOT OPERATE.......................518 E-9 - ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE.................................520 E-10 - NO DISPLAY ON MONITOR PANEL................................................522 E-11 - PART OF DISPLAY ON MONITOR PANEL IS MISSING................................524 E-12 - MONITOR PANEL DISPLAY CONTENTS IRRELEVANT TO THE MODEL.....................525 E-13 - FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL.................526 E-14 - ENGINE COOLANT TEMPERATURE GAUGE NOT INDICATING CORRECTLY..................528 E-15 - HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.................530 E-16 - FUEL GAUGE DOES NOT DISPLAY CORRECTLY......................................532 E-17 - SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY..............................534 E-18 - WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS....................536 E-19 - WINDSHIELD WIPER DOES NOT WORK.............................................538 E-19 - GUARD WIPER DOES NOT WORK..................................................539 E-20 - ALARM BUZZER CANNOT BE CANCELLED...........................................542 E-21 - BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR..............................544 E-22 - BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR..............................546 E-23 - ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR..............................548 E-24 - ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR.............................550 E-25 - BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR.............................552 E-26 - BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR.............................554 E-27 - SWING NOT CORRECTLY DISPLAYED ON MONITOR...................................556 E-28 - TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR..................................558 E-29 - TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR............560 E-30 - SERVICE NOT CORRECTLY DISPLAYED ON MONITOR.................................562 E-31 - AIR CONDITIONER SYSTEM DOES NOT WORK.......................................564 E-32 - TRAVEL ALARM DOES NOT SOUND................................................568 TROUBLESHOOTING MECHANICAL SYSTEM (H MODE)............................................571 SYSTEM CHART......................................................................572 HYDRAULIC AND MECHANICAL SYSTEMS..............................................572 INFORMATION CONTAINED IN TESTING TABLES...........................................574 H-1 - WORK EQUIPMENT LACKS POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW.............575 H-2 - ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS.................................576 H-3 - NO WORK EQUIPMENT, TRAVEL OR SWING OPERATION................................577 H-4 - ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP.................................578 H-5 - AUTO DECELERATOR DOES NOT WORK..............................................579 H-6 - FINE CONTROL MODE DOES NOT FUNCTION.........................................580 H-7 - BOOM MOVES SLOWLY OR LACKS POWER............................................581 H-8 - ARM MOVES SLOWLY OR LACKS POWER.............................................582 H-9 - BUCKET MOVES SLOWLY OR LACKS POWER..........................................583 H-10 - WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION.........................584 H-11 - WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT...............................585 H-12 - WORK EQUIPMENT EXCESSIVE LAG TIME..........................................586 H-13 - OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT.................587 H-14 - ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE................................588 H-15 - WORK EQUIPMENT WITH HEAVIER LOADS MOVES SLOWLY.............................589 H-16 - SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY..........................590 H-17 - SWING AND TRAVEL, TRAVEL SPEED DROPS SHARPLY...............................591 H-18 - MACHINE TRAVEL DIRECTION VARIES............................................592 H-19 - MACHINE TRAVEL IS SLOW.....................................................593 H-20 - MACHINE CANNOT BE STEERED OR LACKS POWER...................................594 H-21 - TRAVEL SPEED IS TOO SLOW OR TOO FAST.......................................595 H-22 - TRACKS DO NOT TURN (ON ONE SIDE ONLY)......................................596 H-23 - MACHINE DOES NOT SWING.....................................................597 H-24 - SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW.........................598 H-25 - EXCESSIVE OVERRUN WHEN STOPPING SWING......................................599 H-26 - SUDDEN SHOCK WHEN STOPPING SWING...........................................600 H-27 - ABNORMAL NOISE WHEN STOPPING SWING.........................................601 H-28 - SWING HAS EXCESSIVE DRIFT..................................................602 30 DISASSEMBLY AND ASSEMBLY...............................................................603 METHOD OF USING MANUAL................................................................607 PRECAUTIONS DURING OPERATION..........................................................608 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK........................................608 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...................................609 PRECAUTIONS WHEN COMPLETING THE OPERATIONS........................................610 OTHER PRECAUTIONS.................................................................610 SPECIAL TOOL LIST.....................................................................611 SKETCHES OF SPECIAL TOOLS.............................................................615 ENGINE................................................................................616 AFTERCOOLER CORE..................................................................616 ALTERNATOR........................................................................616 CYLINDER HEAD.....................................................................616 ENGINE FRONT SEAL.................................................................616 ENGINE OIL COOLER.................................................................616 ENGINE REAR SEAL..................................................................616 FUEL INJECTION PUMP...............................................................616 NOZZLE HOLDER.....................................................................616 STARTING MOTOR....................................................................616 THERMOSTAT........................................................................616 TURBOCHARGER......................................................................616 WATER PUMP........................................................................616 RADIATOR..............................................................................617 REMOVAL...........................................................................617 INSTALLATION......................................................................618 HYDRAULIC OIL COOLER..................................................................619 REMOVAL...........................................................................619 INSTALLATION......................................................................620 ENGINE AND HYDRAULIC PUMPS............................................................621 REMOVAL...........................................................................621 INSTALLATION......................................................................625 FINAL DRIVE...........................................................................627 REMOVAL...........................................................................627 INSTALLATION......................................................................628 DISASSEMBLY - 200LL...............................................................629 ASSEMBLY - 200LL..................................................................632 DISASSEMBLY - 220LL...............................................................637 ASSEMBLY - 220LL..................................................................641 SWING MOTOR AND SWING MACHINERY.......................................................648 REMOVAL - 200LL...................................................................648 REMOVAL - 220LL...................................................................649 INSTALLATION 200LL AND 220LL......................................................650 DISASSEMBLY - 200LL AND 220LL.....................................................651 ASSEMBLY - 200LL AND 220LL........................................................654 TRACK/CARRIER ROLLER..................................................................660 PC200LL-7L........................................................................660 ASSEMBLY......................................................................660 PC220LL-7L........................................................................661 ASSEMBLY......................................................................661 IDLER.................................................................................662 DISASSEMBLY.......................................................................662 ASSEMBLY..........................................................................663 RECOIL SPRING.........................................................................665 DISASSEMBLY.......................................................................665 ASSEMBLY..........................................................................666 SPROCKET..............................................................................667 REMOVAL...........................................................................667 INSTALLATION......................................................................667 TRACK SHOE............................................................................668 REMOVAL AND EXPANSION TRACK SHOE..................................................668 INSTALLATION TRACK SHOE...........................................................669 SWING CIRCLE..........................................................................670 REMOVAL...........................................................................670 INSTALLATION......................................................................671 REVOLVING FRAME.......................................................................672 REMOVAL...........................................................................672 INSTALLATION......................................................................674 CENTER SWIVEL JOINT...................................................................675 REMOVAL...........................................................................675 INSTALLATION......................................................................676 DISASSEMBLY.......................................................................677 ASSEMBLY..........................................................................677 HYDRAULIC TANK........................................................................678 REMOVAL...........................................................................678 INSTALLATION......................................................................680 CONTROL VALVE.........................................................................681 REMOVAL...........................................................................681 INSTALLATION......................................................................684 PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL.........................685 ASSEMBLY..........................................................................686 HYDRAULIC PUMP........................................................................687 REMOVAL...........................................................................687 INSTALLATION......................................................................689 INPUT SHAFT - OIL SEAL............................................................690 REMOVAL.......................................................................690 INSTALLATION..................................................................690 WORK EQUIPMENT PPC VALVE..............................................................691 ASSEMBLY..........................................................................691 TRAVEL PPC VALVE......................................................................692 ASSEMBLY..........................................................................692 HYDRAULIC CYLINDER....................................................................693 DISASSEMBLY.......................................................................693 ASSEMBLY..........................................................................696 WORK EQUIPMENT........................................................................700 REMOVAL...........................................................................700 INSTALLATION......................................................................702 AIR CONDITIONER UNIT..................................................................703 REMOVAL...........................................................................703 INSTALLATION......................................................................706 COUNTERWEIGHT.........................................................................707 REMOVAL...........................................................................707 INSTALLATION......................................................................707 OPERATOR’S CAB........................................................................708 REMOVAL...........................................................................708 INSTALLATION......................................................................710 MONITOR...............................................................................711 REMOVAL...........................................................................711 INSTALLATION......................................................................711 GOVERNOR PUMP CONTROLLER..............................................................712 REMOVAL...........................................................................712 INSTALLATION......................................................................712 90 OTHERS.................................................................................713 ELECTRICAL............................................................................715 CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3) - FOLDOUT 1.................................715 CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3) - FOLDOUT 2.................................717 CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3) - FOLDOUT 3.................................719 CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1) - FOLDOUT 4.................................721 CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2) - FOLDOUT 5.................................723 CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2) - FOLDOUT 6.................................725 CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2) - FOLDOUT 7.................................727 CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2) - FOLDOUT 8.................................729 CIRCUIT DIAGRAM SHEET 5 - FOLDOUT 9...............................................731 CIRCUIT DIAGRAM SOFT SWING (OPTION) - FOLDOUT 10..................................733 HYDRAULIC.............................................................................735 HYDRAULIC DIAGRAM (SHEET 1 OF 4) - FOLDOUT 11.....................................735 HYDRAULIC DIAGRAM (SHEET 2 OF 4) - FOLDOUT 12.....................................737 HYDRAULIC DIAGRAM (SHEET 3 OF 4) - FOLDOUT 13.....................................739 HYDRAULIC DIAGRAM (SHEET 4 OF 4) - FOLDOUT 14.....................................741
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
