Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual PDF
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Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
Description
Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
Language : English
Pages : 744
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
SERIAL NUMBERS
PC200LL-7L A86001 and UP
PC220LL-7L A86001 and UP
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu Galeo PC200LL-7L PC220LL-7L Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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
S.V 11/12/24
