Komatsu HYDRAULIC EXCAVATOR PC200-6 Shop Manual SEBM010201K PDF

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Komatsu HYDRAULIC EXCAVATOR PC200-6 Shop Manual SEBM010201K – PDF  DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC200-6 Shop Manual SEBM010201K – PDF  DOWNLOAD

Language : English
Pages :531
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC200-6 Shop Manual SEBM010201K – PDF  DOWNLOAD

SERIAL NUMBERS PC200-6 – C10001 andup

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 HYDRAULIC EXCAVATOR PC200-6 Shop Manual SEBM010201K – PDF  DOWNLOAD

SERIAL NUMBERS PC200-6 – C10001 andup

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 3
SAFETY NOTICE 3
FOREWORD 5
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
HOISTING INSTRUCTIONS 7
COATING MATERIALS 8
STANDARD TIGHTENING TORQUE 10
ELECTRIC WIRE CODE 13
CONVERSION TABLE 14
01 GENERAL 20
SPECIFICATION DIMENSION DRAWINGS 21
SPECIFICATIONS 22
WEIGHT TABLE 24
FUEL, COOLANT AND LUBRICANTS 26
10 STRUCTURE AND FUNCTION 28
ENGINE RELATED PARTS 29
RADIATOR, OIL COOLER, AFTERCOOLER 30
ENGINE CONTROL 31
POWER TRAIN 32
FINAL DRIVE 33
SWING CIRCLE 34
SWING MACHINERY 35
TRACK FRAME, RECOIL SPRING 36
TRACK SHOE 37
HYDRAULIC PIPING DRAWING 38
HYDRAULIC CIRCUIT DIAGRAM 39
HYDRAULIC TANK 40
HYDRAULIC PUMP 41
CONTROL VALVE 60
SELF-REDUCING PRESSURE VALVE 68
CLSS 73
SWING MOTOR107
CENTER SWIVEL JOINT111
TRAVEL MOTOR113
VALVE CONTROL121
WORK EQUIPMENT, SWING PPC VALVE122
TRAVEL PPC VALVE126
SERVICE PPC VALVE130
ACCUMULATOR133
STRAIGHT-TRAVEL SYSTEM134
EPC SOLENOID VALVE135
BOOM HOLDING VALVE137
ADDITIONAL FILTER FOR BREAKER140
WORK EQUIPMENT141
ACTUAL ELECTRICAL WIRING DIAGRAM142
ELECTRICAL CIRCUIT DIAGRAM144
ELECTRIC CONTROL SYSTEM146
MACHINE MONITOR SYSTEM153
SENSORS156
20 TESTING AND ADJUSTING158
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 159
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 160
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 168
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 171
MEASURING ENGINE SPEED172
MEASURING EXHAUST GAS COLOR 173
ADJUSTING VALVE CLEARANCE 174
MEASURING COMPRESSION PRESSURE 175
MEASURING BLOW-BY PRESSURE 175
TESTING AND ADJUSTING FUEL INJECTION TIMING 176
MEASURING ENGINE OIL PRESSURE 177
TESTING AND ADJUSTING FAN BELT TENSION 178
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 178
MEASURING SPEED SENSOR 179
ADJUSTING FUEL CONTROL LEVER 180
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 182
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 185
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 187
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE 190
TESTING SOLENOID VALVE OUTPUT PRESSURE 191
MEASURING PPC VALVE OUTPUT PRESSURE 192
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 194
TESTING TRAVEL DEVIATION 195
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 196
MEASURING OIL LEAKAGE 198
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 200
TESTING CLEARANCE OF SWING CIRCLE BEARING201
TESTING AND ADJUSTING TRACK SHOE TENSION202
BLEEDING AIR203
TROUBLESHOOTING205
POINTS TO REMEMBER WHEN TROUBLESHOOTING206
SEQUENCE OF EVENTS IN TROUBLESHOOTING207
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE208
CHECKS BEFORE TROUBLESHOOTING216
CONNECTOR TYPES AND MOUNTING LOCATIONS217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS222
METHOD OF USING TROUBLESHOOTING CHARTS232
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)234
METHOD OF USING TROUBLESHOOTING CHARTS235
S-1 Starting performance is poor (starting always takes time)239
S-2 Engine does not start240
(1) Engine does not turn240
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)241
(3) Exhaust smoke comes out but engine does not start (fuel is being injected)242
S-3 Engine does not pick up smoothly (follow-up is poor)243
S-4 Engine stops during operations244
S-5 Engine does not rotate smoothly (hunting)245
S-6 Engine lacks output (no power)246
S-7 Exhaust smoke is black (incomplete combustion)247
S-8 Oil consumption is excessive (or exhaust smoke is blue)248
S-9 Oil becomes contaminated quickly249
S-10 Fuel consumption is excessive250
S-11 Oil is in cooling water, or water spurts back, or water level goes down251
S-12 Oil pressure caution lamp lights up (drop in oil pressure)252
S-13 Oil level rises (water, fuel in oil)253
S-14 Water temperature becomes too high (overheating)254
S-15 Abnormal noise is made255
S-16 Vibration is excessive256
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)257
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS258
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM260
FAILURE CODES261
E-1 Abnormality in PC-EPC control system261
a) Engine stops even when throttle lever is not returned to STOP position When sudden load is applied, engine stalls261
b) Lacks power when throttle lever is at FULL, work equipment speed is slow262
E-2 Abnormality in travel speed selector system (travel speed does not switch)264
E-3 Abnormality in swing holding brake solenoid system265
a) Swing holding brake solenoid is not actuated (cannot swing)265
b) Remains actuated (swing cannot be locked)266
E-4 Abnormality in PPC oil pressure lock solenoid system267
a) Solenoid is not actuated (safety lock is not canceled)267
b) Remains actuated (safety lock is not actuated)268
E-5 Abnormality in engine starting system (engine does not start)269
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)272
TABLE OF FAILURE MODES AND CAUSES (1/2)273
TABLE OF FAILURE MODES AND CAUSES (2/2)275
H-1 Speeds of all work equipments, travel, swing are slow or lacks power277
H-2 There is excessive drop in engine speed, or engine stalls279
H-3 No work equipment, travel, swing move280
H-4 Abnormal noise generated (around pump)280
H-5 Fine control ability is poor or response is poor281
H-6 Boom is slow or lacks power282
H-7 Arm is slow or lacks power284
H-8 Bucket is slow or lacks power286
H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)286
H-10 Excessive hydraulic drift (boom, arm, bucket)287
H-11 Excessive time lag (engine at low idling)288
H-12 Other equipment moves when single circuit is relieved288
H-13 In compound operations, work equipment with larger load is slow288
H-14 In swing + boom RAISE, boom RAISE is slow289
H-15 In swing + travel, travel speed drops excessively289
H-16 Travel deviation (deviation is excessive in normal travel and when starting)290
a) Deviation is excessive in normal travel290
b) Deviation is excessive when starting290
H-17 Travel speed is slow291
H-18 Steering does not turn easily or lacks power292
H-19 Travel does not move (one side only)293
H-20 Travel speed does not switch293
H-21 Does not swing294
a) Does not swing to either left or right294
b) Does not swing in one direction294
H-22 Swing acceleration is poor or swing speed is slow295
H-23 Excessive overrun when stopping swing297
a) One direction only297
b) Both directions297
H-24 Excessive shock when stopping swing (one direction only)298
H-25 Excessive abnormal noise when stopping swing298
H-26 Excessive hydraulic drift of swing299
a) When swing lock is ON299
b) When swing lock is OFF299
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)300
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM301
M-1 When the starting switch is turned ON, no display is given (lamps does not light up for 3 seconds)302
M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out302
M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds303
a) No gauge lamps light up (caution lamps light up)303
b) Swing lock, preheating lamps do not light up303
c) Charge caution lamp does not light up303
d) Engine oil pressure caution lamp does not light up303
M-4 When power is turned on (before engine is started), charge caution lamp does not light up304
M-5 When Dower is turned on (before engine is started), engine oil pressure caution lamp does not light up304
M-6 During preheating, preheating pilot lamp does not light up305
M-7 When switch is operated, swing lock lamp does not light up305
M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil pressure is normal)306
M-9 Charge caution lamp lights up when engine is running306
M-10 Abnormality in coolant temperature gauge307
a) After engine is started, level stays at bottom (white range) and does not move307
b) After engine is started, level immediately rises Engine is not overheating but indicator enters red range307
c) Coolant temperature gauge goes out307
M-11 Abnormality in fuel gauge308
a) All fuel gauge segments go out308
b) Even when fuel level goes down, fuel gauge continues to show FULL308
c) Even when tank is filled, fuel gauge does not show FULL308
M-12 Defective operation of alarm buzzer310
a) Buzzer does not sound310
b) Buzzer continues to sound and does not stop310
M-13 Engine is running, but service meter does not move311
a) Charge caution lamp lights up311
b) Charge caution lamp does not light up311
M-14 Night lighting does not light up312
a) Gauge lighting does not light up312
b) Service meter lighting does not light up (service meter is working normally)312
M-15 Wiper does not move, or does not stop moving313
a) Wiper does not move when wiper switch is turned to ON313
b) Wiper moves even when wiper switch is not turned to ON313
M-16 Heater does not work315
a) Does not work at either Hi or Lo315
b) Does not work at Lo only315
c) Does not work at Hi only315
30 DISASSEMBLY AND ASSEMBLY316
METHOD OF USING MANUAL318
PRECAUTIONS WHEN CARRYING OUT OPERATION319
SPECIAL TOOL LIST321
SKETCHES OF SPECIAL TOOLS325
STARTING MOTOR ASSEMBLY326
REMOVAL AND INSTALLATION326
ALTERNATOR ASSEMBLY327
REMOVAL AND INSTALLATION327
AIR CONDITIONER COMPRESSOR ASSEMBLY328
REMOVAL AND INSTALLATION328
CONDENSER ASSEMBLY329
REMOVAL AND INSTALLATION329
ENGINE OIL COOLER CORE ASSEMBLY330
REMOVAL AND INSTALLATION330
FUEL INJECTION PUMP ASSEMBLY331
REMOVAL331
INSTALLATION334
WATER PUMP ASSEMBLY336
REMOVAL336
INSTALLATION337
NOZZLE HOLDER ASSEMBLY338
REMOVAL AND INSTALLATION338
TURBOCHARGER ASSEMBLY339
REMOVAL AND INSTALLATION339
THERMOSTAT ASSEMBLY340
REMOVAL340
INSTALLATION341
CYLINDER HEAD ASSEMBLY342
REMOVAL342
INSTALLATION346
RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY349
REMOVAL349
INSTALLATION351
ENGINE, MAIN PUMP ASSEMBLY352
REMOVAL352
INSTALLATION356
DAMPER ASSEMBLY357
REMOVAL AND INSTALLATION357
FUEL TANK ASSEMBLY358
REMOVAL AND INSTALLATION358
CENTER SWIVEL JOINT ASSEMBLY359
REMOVAL359
INSTALLATION360
DISASSEMBLY AND ASSEMBLY361
FINAL DRIVE ASSEMBLY362
REMOVAL AND INSTALLATION362
DISASSEMBLY363
ASSEMBLY366
SPROCKET371
REMOVAL AND INSTALLATION371
SWING MOTOR, SWING MACHINERY ASSEMBLY372
REMOVAL372
INSTALLATION373
DISASSEMBLY374
ASSEMBLY378
REVOLVING FRAME ASSEMBLY383
REMOVAL383
INSTALLATION384
SWING CIRCLE ASSEMBLY385
REMOVAL385
INSTALLATION386
IDLER, RECOIL SPRING ASSEMBLY387
REMOVAL AND INSTALLATION387
RECOIL SPRING ASSEMBLY388
DISASSEMBLY388
ASSEMBLY389
IDLER ASSEMBLY390
DISASSEMBLY390
ASSEMBLY391
TRACK ROLLER ASSEMBLY393
REMOVAL AND INSTALLATION393
DISASSEMBLY394
ASSEMBLY396
CARRIER ROLLER ASSEMBLY398
REMOVAL AND INSTALLATION398
DISASSEMBLY399
ASSEMBLY401
TRACK SHOE ASSEMBLY403
REMOVAL AND INSTALLATION403
HYDRAULIC TANK ASSEMBLY404
REMOVAL404
INSTALLATION405
MAIN PUMP ASSEMBLY406
REMOVAL406
INSTALLATION408
MAIN PUMP INPUT SHAFT OIL SEAL409
REMOVAL AND INSTALLATION409
CONTROL VALVE ASSEMBLY410
REMOVAL410
INSTALLATION412
DISASSEMBLY413
ASSEMBLY418
MAIN RELIEF VALVE ASSEMBLY424
DISASSEMBLY AND ASSEMBLY424
PC VALVE ASSEMBLY425
REMOVAL425
INSTALLATION426
LS VALVE ASSEMBLY427
REMOVAL AND INSTALLATION427
PC-EPC VALVE ASSEMBLY428
REMOVAL AND INSTALLATION428
SOLENOID VALVE ASSEMBLY429
REMOVAL AND INSTALLATION429
WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY430
REMOVAL AND INSTALLATION430
DISASSEMBLY431
ASSEMBLY432
TRAVEL PPC VALVE ASSEMBLY433
REMOVAL AND INSTALLATION433
DISASSEMBLY434
ASSEMBLY435
BOOM LOCK VALVE ASSEMBLY436
REMOVAL AND INSTALLATION436
BOOM CYLINDER ASSEMBLY437
REMOVAL437
INSTALLATION438
ARM CYLINDER ASSEMBLY439
REMOVAL439
INSTALLATION440
BUCKET CYLINDER ASSEMBLY441
REMOVAL441
INSTALLATION442
HYDRAULIC CYLINDER ASSEMBLY443
DISASSEMBLY443
ASSEMBLY446
WORK EQUIPMENT ASSEMBLY450
REMOVAL450
INSTALLATION451
BUCKET ASSEMBLY452
REMOVAL452
INSTALLATION453
ARM ASSEMBLY454
REMOVAL454
INSTALLATION455
BUCKET, ARM ASSEMBLY456
REMOVAL456
INSTALLATION457
BOOM ASSEMBLY458
REMOVAL458
INSTALLATION459
OPERATOR’S CAB ASSEMBLY460
REMOVAL AND INSTALLATION460
COUNTERWEIGHT ASSEMBLY461
REMOVAL AND INSTALLATION461
MONITOR ASSEMBLY462
REMOVAL AND INSTALLATION462
40 MAINTENANCE STANDARD463
SWING MACHINERY 464
SWING CIRCLE 466
FINAL DRIVE 467
TRACK FRAME, RECOIL SPRING 469
IDLER 470
CARRIER ROLLER472
TRACK ROLLER 473
TRACK SHOE 474
HYDRAULIC PUMP 479
CONTROL VALVE 480
SELF-REDUCING PRESSURE VALVE 487
SWING MOTOR488
TRAVEL MOTOR 489
WORK EQUIPMENT, SWING PPC VALVE 490
TRAVEL PPC VALVE 491
SERVICE PPC VALVE 492
CENTER SWIVEL JOINT 493
BOOM HOLDING VALVE 495
HYDRAULIC CYLINDER 496
WORK EQUIPMENT 498
DIMENSION OF WORK EQUIPMENT 500
90 OTHERS504
HYDRAULIC PIPING DRAWING505
HYDRAULIC CIRCUIT DIAGRAM506
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)511
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)512
ELECTRICAL CIRCUIT DIAGRAM (1/2)513
ELECTRICAL CIRCUIT DIAGRAM (2/2)518
OPERATION OF CLSS SYSTEM AS A WHOLE523
1 When all work equipment is at neutral523
2 One side actuated, other side neutral524
3 Arm OUT, standard mode relief (cut-off control)525
4 Bucket DUMP, power max relief526
5 Boom RAISE527
6 Swing operated independently528
7 Travel operated independently529
8 Compound operation530

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24