Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual – PDF DOWNLOAD
Original price was: $56.95.$21.95Current price is: $21.95.
Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual
SERIAL NUMBERS:
PC200, 200LC-2 15001 and up
PC220, 220LC-2 11001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual
FILE DETAILS:
Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200-2, PC200LC-2, PC220-2, PC220LC-2
Serial Number: 15001 and up, 11001 and up
Book Code: SEBM0205B04
Language: English
Pages: 552
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual
1 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 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.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in 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:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
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 PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual
COVER................................................................................................................................................................................................................................. 1 CONTENTS.............................................................................................................................................................................................................................. 2 10 ENGINE............................................................................................................................................................................................................................. 15 12 TESTING AND ADJUSTING.......................................................................................................................................................................................................... 15 STANDARD VALUE TABLE.......................................................................................................................................................................................................... 16 TOOL LIST FOR TESTING AND ADJUSTING........................................................................................................................................................................................... 17 ADJUSTING VALVE CLEARANCE..................................................................................................................................................................................................... 18 MEASURING COMPRESSION PRESSURE................................................................................................................................................................................................ 19 MEASURING BLOW-BY PRESSURE.................................................................................................................................................................................................... 20 TESTING AND ADJUSTING FUEL INJECTION TIMING................................................................................................................................................................................... 21 BLEEDING AIR FROM FUEL INJECTION PUMP......................................................................................................................................................................................... 22 ADJUSTING OF ENGINE STOP MOTOR................................................................................................................................................................................................ 23 MEASURING EXHAUST COLOR....................................................................................................................................................................................................... 24 TESTING AND ADJUSTING FAN BELT TENSION........................................................................................................................................................................................ 26 ADJUSTING TENSION OF ALTERNATOR DRIVE BELT.................................................................................................................................................................................... 26 MEASURING ENGINE OIL PRESSURE AND TEMPERATURE................................................................................................................................................................................. 27 13 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................... 28 STARTING MOTOR................................................................................................................................................................................................................ 29 REMOVAL................................................................................................................................................................................................................... 29 INSTALLATION.............................................................................................................................................................................................................. 29 ALTERNATOR.................................................................................................................................................................................................................... 30 REMOVAL................................................................................................................................................................................................................... 30 INSTALLATION.............................................................................................................................................................................................................. 30 ENGINE OIL COOLER............................................................................................................................................................................................................. 31 REMOVAL................................................................................................................................................................................................................... 31 INSTALLATION.............................................................................................................................................................................................................. 31 NOZZLE HOLDER................................................................................................................................................................................................................. 32 REMOVAL................................................................................................................................................................................................................... 32 INSTALLATION.............................................................................................................................................................................................................. 32 FUEL INJECTION PUMP........................................................................................................................................................................................................... 33 REMOVAL................................................................................................................................................................................................................... 33 INSTALLATION.............................................................................................................................................................................................................. 34 AIR COMPRESSOR................................................................................................................................................................................................................ 35 REMOVAL................................................................................................................................................................................................................... 35 INSTALLATION.............................................................................................................................................................................................................. 35 WATER PUMP.................................................................................................................................................................................................................... 36 REMOVAL................................................................................................................................................................................................................... 36 INSTALLATION.............................................................................................................................................................................................................. 36 AFTERCOOLER................................................................................................................................................................................................................... 37 REMOVAL................................................................................................................................................................................................................... 37 INSTALLATION.............................................................................................................................................................................................................. 39 TURBOCHARGER.................................................................................................................................................................................................................. 41 REMOVAL................................................................................................................................................................................................................... 41 INSTALLATION.............................................................................................................................................................................................................. 41 CYLINDER HEAD................................................................................................................................................................................................................. 42 REMOVAL................................................................................................................................................................................................................... 42 INSTALLATION.............................................................................................................................................................................................................. 47 ENGINE........................................................................................................................................................................................................................ 52 REMOVAL................................................................................................................................................................................................................... 52 INSTALLATION.............................................................................................................................................................................................................. 56 RADIATOR...................................................................................................................................................................................................................... 60 REMOVAL................................................................................................................................................................................................................... 60 INSTALLATION.............................................................................................................................................................................................................. 63 20 POWER TRAIN........................................................................................................................................................................................................................ 66 21 STRUCTURE AND FUNCTION......................................................................................................................................................................................................... 66 GENERAL....................................................................................................................................................................................................................... 67 DRIVE SHAFT................................................................................................................................................................................................................... 68 OUTPUT SHAFT.................................................................................................................................................................................................................. 69 POWER TRAIN HYDRAULIC PIPING.................................................................................................................................................................................................. 72 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS...................................................................................................................................................................................... 74 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................................... 75 TORQUE CONVERTER.............................................................................................................................................................................................................. 76 TORQUE CONVERTER VALVE........................................................................................................................................................................................................ 78 TRANSMISSION.................................................................................................................................................................................................................. 85 TRANSMISSION CONTROL VALVE.................................................................................................................................................................................................... 92 TORQUE CONVERTER AND TRANSMISSION PUMP........................................................................................................................................................................................103 RETARDER COOLING PUMP.........................................................................................................................................................................................................104 REAR AXLE.....................................................................................................................................................................................................................105 DIFFERENTIAL..................................................................................................................................................................................................................106 FRONT BRAKE...................................................................................................................................................................................................................111 REAR BRAKE....................................................................................................................................................................................................................114 PARKING BRAKE.................................................................................................................................................................................................................116 FINAL DRIVE SYSTEM............................................................................................................................................................................................................117 FRONT WHEELS..................................................................................................................................................................................................................119 REAR WHEELS...................................................................................................................................................................................................................121 22 TESTING AND ADJUSTING..........................................................................................................................................................................................................122 TABLE OF JUDGEMENT STANDARD...................................................................................................................................................................................................123 TOOL LIST FOR TESTING AND ADJUSTING...........................................................................................................................................................................................125 MEASURING OF ACCELERATOR PEDAL................................................................................................................................................................................................126 MEASURING OF OPERATING FORCE OF AUTOMATIC SHIFT CONTROL LEVER.................................................................................................................................................................126 PROCEDURE FOR ADJUSTING MANUAL SHIFT CONSOLE..................................................................................................................................................................................127 MEASURING OF TRANSMISSION OIL TEMPERATURE.....................................................................................................................................................................................130 OIL PRESSURE MEASURING PORT OF POWER TRAIN....................................................................................................................................................................................131 MEASURING OF TORQUE CONVERTER OIL PRESSURE....................................................................................................................................................................................132 MEASURING OF TRANSMISSION OIL PRESSURE........................................................................................................................................................................................134 ADJUSTING OF MODULATING OIL PRESSURE (CLUTCH CIRCUIT OIL PRESSURE)............................................................................................................................................................138 MEASURING TORQUE CONVERTER STALL..............................................................................................................................................................................................139 TESTING PERFORMANCE OF SERVICE BRAKE..........................................................................................................................................................................................140 TESTING BRAKING DISTANCE......................................................................................................................................................................................................140 ADJUSTING OF FRONT BRAKE AND BLEEDING AIR.....................................................................................................................................................................................141 TESTING BRAKE OIL PRESSURE....................................................................................................................................................................................................142 TESTING AND ADJUSTING OF PARKING BRAKE........................................................................................................................................................................................143 23 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................144 OUTPUT SHAFT..................................................................................................................................................................................................................145 REMOVAL...................................................................................................................................................................................................................145 INSTALLATION..............................................................................................................................................................................................................147 DISASSEMBLY...............................................................................................................................................................................................................149 ASSEMBLY..................................................................................................................................................................................................................149 TORQUE CONVERTER AND TRANSMISSION.............................................................................................................................................................................................150 REMOVAL...................................................................................................................................................................................................................150 INSTALLATION..............................................................................................................................................................................................................154 DISCONNECTING.............................................................................................................................................................................................................159 CONNECTING................................................................................................................................................................................................................159 TORQUE CONVERTER AND PTO......................................................................................................................................................................................................160 DISASSEMBLY...............................................................................................................................................................................................................160 ASSEMBLY..................................................................................................................................................................................................................164 TRANSMISSION..................................................................................................................................................................................................................170 DISASSEMBLY...............................................................................................................................................................................................................170 ASSEMBLY..................................................................................................................................................................................................................184 TORQUE CONVERTER CONTROL VALVE................................................................................................................................................................................................200 REMOVAL...................................................................................................................................................................................................................200 INSTALLATION..............................................................................................................................................................................................................200 DISASSEMBLY...............................................................................................................................................................................................................201 ASSEMBLY..................................................................................................................................................................................................................201 TRANSMISSION CONTROL VALVE....................................................................................................................................................................................................202 REMOVAL...................................................................................................................................................................................................................202 INSTALLATION..............................................................................................................................................................................................................202 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................203 TRANSMISSION PUMP.............................................................................................................................................................................................................208 REMOVAL...................................................................................................................................................................................................................208 INSTALLATION..............................................................................................................................................................................................................208 PARKING BRAKE SHOE............................................................................................................................................................................................................209 REMOVAL...................................................................................................................................................................................................................209 INSTALLATION..............................................................................................................................................................................................................209 DIFFERENTIAL GEAR.............................................................................................................................................................................................................210 REMOVAL...................................................................................................................................................................................................................210 INSTALLATION..............................................................................................................................................................................................................213 DISASSEMBLY...............................................................................................................................................................................................................215 ASSEMBLY..................................................................................................................................................................................................................226 PLANETARY CARRIER (FINAL DRIVE)...............................................................................................................................................................................................255 REMOVAL...................................................................................................................................................................................................................255 INSTALLATION..............................................................................................................................................................................................................257 FINAL DRIVE...................................................................................................................................................................................................................259 DISASSEMBLY...............................................................................................................................................................................................................259 ASSEMBLY..................................................................................................................................................................................................................262 REAR WHEEL BRAKE..............................................................................................................................................................................................................265 REMOVAL...................................................................................................................................................................................................................265 INSTALLATION..............................................................................................................................................................................................................266 DISASSEMBLY...............................................................................................................................................................................................................268 ASSEMBLY..................................................................................................................................................................................................................270 REAR WHEEL....................................................................................................................................................................................................................273 REMOVAL...................................................................................................................................................................................................................273 INSTALLATION..............................................................................................................................................................................................................274 FRONT WHEEL...................................................................................................................................................................................................................276 REMOVAL...................................................................................................................................................................................................................276 INSTALLATION..............................................................................................................................................................................................................277 FRONT BRAKE SHOE..............................................................................................................................................................................................................278 REMOVAL...................................................................................................................................................................................................................278 INSTALLATION..............................................................................................................................................................................................................279 FRONT BRAKE CYLINDER..........................................................................................................................................................................................................281 DISASSEMBLY...............................................................................................................................................................................................................281 ASSEMBLY..................................................................................................................................................................................................................283 FRONT CALIPER.................................................................................................................................................................................................................286 REMOVAL...................................................................................................................................................................................................................286 INSTALLATION..............................................................................................................................................................................................................286 CALIPER.......................................................................................................................................................................................................................287 DISASSEMBLY...............................................................................................................................................................................................................287 ASSEMBLY..................................................................................................................................................................................................................287 FRONT WHEEL HUB...............................................................................................................................................................................................................288 DISASSEMBLY...............................................................................................................................................................................................................288 ASSEMBLY..................................................................................................................................................................................................................290 FRONT DRIVE SHAFT.............................................................................................................................................................................................................293 REMOVAL...................................................................................................................................................................................................................293 INSTALLATION..............................................................................................................................................................................................................293 REAR DRIVE SHAFT..............................................................................................................................................................................................................294 REMOVAL...................................................................................................................................................................................................................294 INSTALLATION..............................................................................................................................................................................................................294 DRIVE SHAFT SPIDER............................................................................................................................................................................................................295 DISASSEMBLY...............................................................................................................................................................................................................295 ASSEMBLY..................................................................................................................................................................................................................295 24 MAINTENANCE STANDARD...........................................................................................................................................................................................................296 OUTPUT SHAFT..................................................................................................................................................................................................................297 TORQUE CONVERTER..............................................................................................................................................................................................................299 TORQUE CONVERTER VALVE........................................................................................................................................................................................................301 TRANSMISSION..................................................................................................................................................................................................................303 TRANSMISSION CONTROL VALVE....................................................................................................................................................................................................306 TORQUE CONVERTER AND TRANSMISSION PUMP........................................................................................................................................................................................308 RETARDER COOLING PUMP.........................................................................................................................................................................................................309 DIFFERENTIAL..................................................................................................................................................................................................................310 FRONT BRAKE...................................................................................................................................................................................................................313 REAR BRAKE....................................................................................................................................................................................................................315 PARKING BRAKE.................................................................................................................................................................................................................317 FINAL DRIVE...................................................................................................................................................................................................................318 WHEEL.........................................................................................................................................................................................................................319 40 STEERING AND SUSPENSION SYSTEM.....................................................................................................................................................................................................320 41 STRUCTURE AND FUNCTION.........................................................................................................................................................................................................320 STEERING SYSTEM...............................................................................................................................................................................................................321 SUSPENSION SYSTEM.............................................................................................................................................................................................................323 42 TESTING AND ADJUSTING..........................................................................................................................................................................................................327 TABLE OF JUDGEMENT STANDARD...................................................................................................................................................................................................328 MEASURING OF STEERING WHEEL...................................................................................................................................................................................................329 TESTING AND ADJUSTING OF SUSPENSION CYLINDER..................................................................................................................................................................................330 43 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................334 STEERING VALVE................................................................................................................................................................................................................335 REMOVAL...................................................................................................................................................................................................................335 INSTALLATION..............................................................................................................................................................................................................335 DISASSEMBLY...............................................................................................................................................................................................................337 ASSEMBLY..................................................................................................................................................................................................................341 FRONT SUSPENSION CYLINDER.....................................................................................................................................................................................................347 REMOVAL...................................................................................................................................................................................................................347 INSTALLATION..............................................................................................................................................................................................................349 FRONT SUSPENSION CYLINDER ROD.................................................................................................................................................................................................351 REMOVAL...................................................................................................................................................................................................................351 INSTALLATION..............................................................................................................................................................................................................352 REAR SUSPENSION...............................................................................................................................................................................................................353 REMOVAL...................................................................................................................................................................................................................353 INSTALLATION..............................................................................................................................................................................................................354 SUSPENSION CYLINDER...........................................................................................................................................................................................................355 DISASSEMBLY...............................................................................................................................................................................................................355 ASSEMBLY..................................................................................................................................................................................................................356 44 MAINTENANCE STANDARD...........................................................................................................................................................................................................357 SUSPENSION CYLINDER...........................................................................................................................................................................................................358 STEERING LINKAGE..............................................................................................................................................................................................................359 50 AIR SYSTEM.........................................................................................................................................................................................................................360 51 STRUCTURE AND FUNCTION.........................................................................................................................................................................................................360 AIR PIPING....................................................................................................................................................................................................................361 AIR CIRCUIT DIAGRAM...........................................................................................................................................................................................................363 CHARGING CIRCUIT..............................................................................................................................................................................................................368 AUTO RETARDER BRAKE CIRCUIT (ENGINE OVERRUN PREVENTION SYSTEM)................................................................................................................................................................370 AIR GOVERNOR..............................................................................................................................................................................................................371 SAFETY VALVE..............................................................................................................................................................................................................372 CHECK VALVE...............................................................................................................................................................................................................373 LOW-PRESSURE BUZZER SWITCH................................................................................................................................................................................................374 BRAKE VALVES..............................................................................................................................................................................................................375 HAND BRAKE VALVES (RETARDER CONTROL VALVE)................................................................................................................................................................................380 CHAMBER CYLINDER (FRONT)..................................................................................................................................................................................................384 CHAMBER CYLINDER (REAR)...................................................................................................................................................................................................388 RELAY VALVE...............................................................................................................................................................................................................390 QUICK-RELEASE VALVE.......................................................................................................................................................................................................392 DOUBLE-CHECK VALVE........................................................................................................................................................................................................394 2-WAY CONTROL VALVE.......................................................................................................................................................................................................395 ENGINE OVERRUNNING PREVENTIVE SOLENOID VALVE..............................................................................................................................................................................398 STOP LAMP SWITCH..........................................................................................................................................................................................................399 HORN VALVE................................................................................................................................................................................................................400 52 TESTING AND ADJUSTING..........................................................................................................................................................................................................401 TABLE OF JUDGEMENT STANDARD...................................................................................................................................................................................................402 MEASURING OF BRAKE PEDAL......................................................................................................................................................................................................403 MEASURING OF RETARDER CONTORL LEVER...........................................................................................................................................................................................403 TESTING AND ADJUSTING AIR PRESSURE............................................................................................................................................................................................404 53 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................405 SLACK ADJUSTING...............................................................................................................................................................................................................406 REMOVAL...................................................................................................................................................................................................................406 INSTALLATION..............................................................................................................................................................................................................406 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................407 PARKING BRAKE SPRING CYLINDER.................................................................................................................................................................................................408 REMOVAL...................................................................................................................................................................................................................408 INSTALLATION..............................................................................................................................................................................................................408 DISASSEMBLY...............................................................................................................................................................................................................409 ASSEMBLY..................................................................................................................................................................................................................410 BRAKE VALVE...................................................................................................................................................................................................................411 REMOVAL...................................................................................................................................................................................................................411 INSTALLATION..............................................................................................................................................................................................................411 DISASSEMBLY...............................................................................................................................................................................................................412 ASSEMBLY..................................................................................................................................................................................................................414 FRONT BRAKE CHAMBER...........................................................................................................................................................................................................416 REMOVAL...................................................................................................................................................................................................................416 INSTALLATION..............................................................................................................................................................................................................416 DISASSEMBLY...............................................................................................................................................................................................................417 ASSEMBLY..................................................................................................................................................................................................................420 REAR BRAKE CHAMBER............................................................................................................................................................................................................427 REMOVAL...................................................................................................................................................................................................................427 INSTALLATION..............................................................................................................................................................................................................427 DISASSEMBLY...............................................................................................................................................................................................................428 ASSEMBLY..................................................................................................................................................................................................................428 AIR GOVERNOR..................................................................................................................................................................................................................433 REMOVAL...................................................................................................................................................................................................................433 INSTALLATION..............................................................................................................................................................................................................433 DISASSEMBLY...............................................................................................................................................................................................................434 ASSEMBLY..................................................................................................................................................................................................................434 54 MAINTENANCE STANDARD...........................................................................................................................................................................................................435 AIR GOVERNOR..................................................................................................................................................................................................................436 60 HYDRAULIC SYSTEM...................................................................................................................................................................................................................437 61 STRUCTURE AND FUNCTION.........................................................................................................................................................................................................437 HYDRAULIC PIPING..............................................................................................................................................................................................................438 HYDRAULIC SYSTEM..............................................................................................................................................................................................................440 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................................................................................................................441 HYDRAULIC TANK................................................................................................................................................................................................................442 HYDRAULIC AND STEERING PUMP...................................................................................................................................................................................................443 DEMAND VALVE..................................................................................................................................................................................................................444 HOIST CONTROL VALVE...........................................................................................................................................................................................................448 HOIST CONTROL SYSTEM..........................................................................................................................................................................................................452 STEERING CONTROL VALVE........................................................................................................................................................................................................453 CROSSOVER RELIEF VALVE........................................................................................................................................................................................................457 STEERING CYLINDER.............................................................................................................................................................................................................458 HOIST CYLINDER................................................................................................................................................................................................................459 SLOW RETURN VALVE.............................................................................................................................................................................................................460 62 TESTING AND ADJUSTING..........................................................................................................................................................................................................462 TABLE OF JUDGEMENT STANDARD...................................................................................................................................................................................................463 MEASURING OF HOIST LEVER......................................................................................................................................................................................................464 MEASURING OF HYDRAULIC TANK OIL TEMPERATURE...................................................................................................................................................................................464 TESTING AND ADJUSTING OIL PRESSURE IN STEERING AND HOIST CIRCUIT..............................................................................................................................................................465 MEASURING OF RAISING SPEED OF DUMP BODY.......................................................................................................................................................................................467 MEASURING OF HYDRAULIC DRIFT OF HOIST CYLINDER................................................................................................................................................................................467 MEASURING OF HYDRAULIC PUMP PERFORMANCE.......................................................................................................................................................................................468 AIR BLEEDING FROM STEERING CYLINDER...........................................................................................................................................................................................469 63 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................470 TANDEM PUMP (BRAKE COOLING)...................................................................................................................................................................................................471 REMOVAL...................................................................................................................................................................................................................471 INSTALLATION..............................................................................................................................................................................................................471 TANDEM PUMP (HOIST, STEERING).................................................................................................................................................................................................472 REMOVAL...................................................................................................................................................................................................................472 INSTALLATION..............................................................................................................................................................................................................472 EMERGENCY STEERING MOTOR AND PUMP.............................................................................................................................................................................................473 REMOVAL...................................................................................................................................................................................................................473 INSTALLATION..............................................................................................................................................................................................................473 DEMAND VALVE..................................................................................................................................................................................................................474 REMOVAL...................................................................................................................................................................................................................474 INSTALLATION..............................................................................................................................................................................................................474 DISASSEMBLY...............................................................................................................................................................................................................475 ASSEMBLY..................................................................................................................................................................................................................476 RELIEF VALVE..................................................................................................................................................................................................................475 DISASSEMBLY...............................................................................................................................................................................................................475 ASSEMBLY..................................................................................................................................................................................................................476 HOIST VALVE...................................................................................................................................................................................................................477 REMOVAL...................................................................................................................................................................................................................477 INSTALLATION..............................................................................................................................................................................................................478 DISASSEMBLY...............................................................................................................................................................................................................479 ASSEMBLY..................................................................................................................................................................................................................480 STEERING CYLINDER.............................................................................................................................................................................................................481 REMOVAL...................................................................................................................................................................................................................481 INSTALLATION..............................................................................................................................................................................................................481 DISASSEMBLY...............................................................................................................................................................................................................482 ASSEMBLY..................................................................................................................................................................................................................484 HOIST CYLINDER................................................................................................................................................................................................................487 REMOVAL...................................................................................................................................................................................................................487 INSTALLATION..............................................................................................................................................................................................................488 DISASSEMBLY...............................................................................................................................................................................................................489 ASSEMBLY..................................................................................................................................................................................................................490 64 MAINTENANCE STANDARD...........................................................................................................................................................................................................491 HYDRAULIC AND STEERING PUMP...................................................................................................................................................................................................492 DEMAND VALVE..................................................................................................................................................................................................................493 HOIST VALVE...................................................................................................................................................................................................................494 CROSSOVER RELIEF VALVE........................................................................................................................................................................................................496 STEERING CYLINDER.............................................................................................................................................................................................................497 HOIST CYLINDER................................................................................................................................................................................................................498 HOIST CONTROL SYSTEM..........................................................................................................................................................................................................499 70 WORK EQUIPMENT.....................................................................................................................................................................................................................500 71 STRUCTURE AND FUNCTION.........................................................................................................................................................................................................500 MAIN FRAME, DUMP BODY.........................................................................................................................................................................................................501 73 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................502 DUMP BODY.....................................................................................................................................................................................................................503 REMOVAL...................................................................................................................................................................................................................503 INSTALLATION..............................................................................................................................................................................................................503 74 MAINTENANCE STANDARD...........................................................................................................................................................................................................504 MAIN FRAME....................................................................................................................................................................................................................505 REPAIR OF DUMP BODY BY WELDING................................................................................................................................................................................................507 80 ELECTRICAL AND ELECTRONIC SYSTEM...................................................................................................................................................................................................508 81 STRUCTURE AND FUNCTION.........................................................................................................................................................................................................508 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................................................................................................509 FILTER CLOGGING CAUTION SENSOR................................................................................................................................................................................................510 RADIATOR WATER LEVEL SENSOR...................................................................................................................................................................................................511 INSTRUMENT PANEL..............................................................................................................................................................................................................513 ELECTRONIC VEHICLE MONITORING SYSTEM (E.V.M.S.) (IF EQUIPPED).................................................................................................................................................................514 ELECTRIC CIRCUIT DIAGRAM......................................................................................................................................................................................................517 TRANSMISSION MANUAL SHIFT CONTROL SYSTEM......................................................................................................................................................................................518 TRANSMISSION SELECTOR SWITCH..............................................................................................................................................................................................521 DIODE MATRIX..............................................................................................................................................................................................................521 AUTO LOCK-UP CONTROL CIRCUIT..............................................................................................................................................................................................522 AUTO LOCK-UP CONTROLLER...................................................................................................................................................................................................522 AUTOMATIC SHIFT CONTROL SYSTEM (IF EQUIPPED)..................................................................................................................................................................................523 SHIFT INDICATOR...............................................................................................................................................................................................................534 82 TESTING AND ADJUSTING..........................................................................................................................................................................................................537 ELECTRICAL WIRING DIAGRAM.....................................................................................................................................................................................................538 CONNECTION TABLE FOR CONNECTOR PINS...........................................................................................................................................................................................539 MS CONNECTORS.................................................................................................................................................................................................................541 TESTING OF SENSORS............................................................................................................................................................................................................544 TROUBLESHOOTING...............................................................................................................................................................................................................550 TROUBLESHOOTING PROCEDURE.................................................................................................................................................................................................550 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................................................................................551 JUDGEMENT TABLE...........................................................................................................................................................................................................557 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR AUTOMATIC SHIFT TRANSMISSION (E-1. TO E-11.)................................................................................................................................560 E-1 ENGINE DOES NOT START.............................................................................................................................................................................................561 E-2 ENGINE DOES NOT START.............................................................................................................................................................................................570 E-3 MACHINE DOES NOT START............................................................................................................................................................................................572 E-4 ABNORMALITY IN OPERATION OF MACHINE WHEN STARTING.................................................................................................................................................................585 E-5 GEAR SHIFT ABNORMALLY.............................................................................................................................................................................................585 E-6 ABNORMALITY IN OPERATION OF MACHINE DURING TRAVEL.................................................................................................................................................................586 E-7 TRANSMISSION SUDDENLY SHIFTS TO NEUTRAL WHEN TRAVELING............................................................................................................................................................594 E-8 LONG TIME TAKEN TO SHIFT UP.......................................................................................................................................................................................604 E-9 SKIP SHIFT OPERATES ABNORMALLY....................................................................................................................................................................................611 E-10 KICK-DOWN OPERATES ABNORMALLY....................................................................................................................................................................................617 E-11 ABNORMALITY IN MACHINE OPERATION WHEN RETARDER IS OPERATED.......................................................................................................................................................621 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM FOR MANUAL SHIFT TRANSMISSION (E-1. TO E-7.)....................................................................................................................................622 MANUAL SHIFT RELATED WIRING DIAGRAM...................................................................................................................................................................................623 CONNECTOR AND CONNECTOR POSITION......................................................................................................................................................................................624 E-1 ENGINE DOES NOT START.............................................................................................................................................................................................628 E-2 ENGINE DOES NOT START.............................................................................................................................................................................................629 E-3 MACHINE DOES NOT MOVE OR TRANSMISSION SUDDENLY RETURNS TO NEUTRAL.................................................................................................................................................631 E-4 ABNORMALITY GEAR SHIFTING WHEN MACHINE START......................................................................................................................................................................632 E-5 GEAR SHIFTING IS ABNORMAL.........................................................................................................................................................................................633 E-6 ACTION OF MACHINE ABNORMAL WHEN TRAVELING.........................................................................................................................................................................633 E-7 ACTION OF MACHINE ABNORMAL WHEN TRAVELING.........................................................................................................................................................................634 TROUBLESHOOTING TABLE (H-1. TO H-18.).....................................................................................................................................................................................635 H-1 MACHINE DOES NOT MOVE.............................................................................................................................................................................................636 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY..................................................................................................................................................................................638 H-3 CAN NOT DISENGAGE LOCK-UP CLUTCH (ENGINE STALL)...................................................................................................................................................................638 H-4 LARGE SHOCK WHEN STARTING OR SHIFTING.............................................................................................................................................................................639 H-5 DOES NOT SHIFT UP OR SHIFT UP SPEED IS HIGH.......................................................................................................................................................................639 H-6 MACHINE TRAVELS SLOWLY OR LACKS POWER.............................................................................................................................................................................640 H-7 LARGE TIME LAG WHEN STARTING AND GEARSHIFTING.....................................................................................................................................................................645 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..........................................................................................................................................................................646 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW..............................................................................................................................................................................647 H-10 FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONLY ONE SIDE............................................................................................................................................................648 H-11 REAR BRAKE IS INEFFECTIVE OF EFFECTIVE ONLY ONE SIDE.............................................................................................................................................................649 H-12 STEERING WHEEL DRAGS.............................................................................................................................................................................................650 H-13 STEERING WHEEL DOES NOT FUNCTION.................................................................................................................................................................................651 H-14 STEERING WHEEL VIBRATES..........................................................................................................................................................................................651 H-15 HOIST CYLINDER LACKS LIFTING FORCE (LIFTTING SPEED)..............................................................................................................................................................652 H-16 HOIST CYLINDER DOES NOT WORK.....................................................................................................................................................................................653 H-17 EXCESSIVE HYDRAULIC DRIFT OF THE DUMP BODY.......................................................................................................................................................................654 H-18 AIR PRESSURE DOES NOT RISE.......................................................................................................................................................................................655 TROUBLESHOOTING CHART FOR STANDARD PANEL (M-1. TO M-5.)...................................................................................................................................................................656 ELECTRICAL CIRCUIT DIAGRAM FOR STANDARD PANEL.........................................................................................................................................................................657 M-1 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY............................................................................................................................................658 M-2 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY....................................................................................................................................659 M-3 RETARDER OIL TEMPERATURE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY..................................................................................................................................................660 M-4 ENGINE OIL PRESSURE DOES NOT DISPLAY OF DISPLAYS ABNORMALLY.......................................................................................................................................................661 M-5 SERVICE METER DOES NOT OPERATE....................................................................................................................................................................................662 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (OPTION) (M-6. TO M-45.)...................................................................................................................................656 HOW TO CONNECT CHECKER FOR EVMS.......................................................................................................................................................................................663 TROUBLESHOOTING TABLE (EVMS)..........................................................................................................................................................................................665 ELECTRICAL CIRCUIT DIAGRAM FOR EVMS...................................................................................................................................................................................667 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR..........................................................................................................................................668 M-7 ENGINE SPEED DISPLAY DOES NOT APPEAR..............................................................................................................................................................................670 M-8 MACHINE SPEED DISPLAY DOES NOT APPEAR.............................................................................................................................................................................672 M-9 RETARDER OIL TEMPERATURE GAUGE DOES NOT OPERATE...................................................................................................................................................................674 M-10 SERVICE METER DOES NOT OPERATE...................................................................................................................................................................................676 M-11 ODOMETER DOES NOT OPERATE........................................................................................................................................................................................677 M-12 FUEL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES...............................................................................................................................................678 M-13 BRAKE OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES..........................................................................................................................................679 M-14 ENGINE OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES.........................................................................................................................................680 M-15 BATTERY ELECTROLYTE LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES................................................................................................................................682 M-16 COOLANT LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES............................................................................................................................................683 M-17 HYDRAULIC OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES......................................................................................................................................685 M-18 TRANSMISSION OIL LEVEL IS CORRECT, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES...................................................................................................................................686 M-19 LAMP IS NORMAL, BUT CHECK BEFORE STARTING ITEM LAMP FLASHES......................................................................................................................................................687 M-20 FUEL LEVEL IS CORRECT, BUT WARNING ITEM LAMP FLASHES.............................................................................................................................................................688 M-21 FUEL FILTER IS NORMAL, BUT WARNING ITEM LAMP FLASHES.............................................................................................................................................................689 M-22 ENGINE OIL FILTER IS NORMAL, BUT WARNING ITEM LAMP FLASHES.......................................................................................................................................................690 M-23 ALTERNATOR IS NORMAL, BUT WARNING ITEM LAMP FLASHES..............................................................................................................................................................691 M-24 AIR CLEANER IS NORMAL, BUT WARNING ITEM LAMP FLASHES.............................................................................................................................................................692 M-25 HYDRAULIC OIL FILTER IS NORMAL, BUT WARNING ITEM LAMP FLASHES....................................................................................................................................................693 M-26 TRANSMISSION OIL FILTER IS NORMAL, BUT WARNING ITEM LAMP FLASHES.................................................................................................................................................694 M-27 DUMP BODY IS NORMAL, BUT WARNING ITEM LAMP FLASHES...............................................................................................................................................................695 M-28 ENGINE WATER TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.................................................................................................................................................696 M-29 RETARDER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.................................................................................................................................................697 M-30 ENGINE OIL PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES......................................................................................................................................................697 M-31 AIR PRESSURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.............................................................................................................................................................699 M-32 COOLANT LEVEL IS CORRECT, BUT DANGER ITEM LAMP FLASHES...........................................................................................................................................................700 M-33 HYDRAULIC OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES................................................................................................................................................702 M-34 TORQUE CONVERTER OIL TEMPERATURE IS NORMAL, BUT DANGER ITEM LAMP FLASHES.........................................................................................................................................703 M-35 PARKING BRAKE IS NORMAL, BUT DANGER ITEM LAMP FLASHES............................................................................................................................................................704 M-36 WHEN RETARDER OIL TEMPERATURE GAUGE REACHES RED RANGE, WARNING LAMP FOR RETARDER OIL TEMPERATURE IN DANGER MONITOR DOES NOT FLASH; WARNING LAMP FLASHES WHEN RETARDER OIL TEMPERATURE GAUGE IS IN GREEN RANGE....705 M-37 WHEN DANGER ITEM LAMP LIGHTS UP, THE BUZZER DOES NOT SOUND OR THE CENTRAL WARNING LAMP DOES NOT LIGHT UP.........................................................................................................706 M-38 NIGHT LIGHTING DOES NOT LIGHT-UP.................................................................................................................................................................................708 M-39 PILOT LAMP FOR RETARDER DOES NOT LIGHT UP........................................................................................................................................................................710 M-40 PILOT LAMP FOR TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP.........................................................................................................................................................712 M-41 PILOT LAMP FOR TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP........................................................................................................................................................714 M-42 PILOT LAMP FOR HIGH BEAM DOES NOT LIGHT UP.......................................................................................................................................................................716 M-43 PILOT LAMP FOR KICK-DOWN DOES NOT LIGHT UP.......................................................................................................................................................................718 M-44 PILOT LAMP FOR PARKING BRAKE DOES NOT LIGHT UP...................................................................................................................................................................720 M-45 MONITOR LAMP DOES NOT LAMP-CHECK WHEN TURN STARTING SWITCH ON....................................................................................................................................................721 TROUBLESHOOTING OF SHIFT INDICATOR (S-1. TO S-7.).........................................................................................................................................................................722 SHIFT INDICATOR RELATED CIRCUIT DIAGRAM...............................................................................................................................................................................723 SHIFT INDICATOR RELATED CONNECTORS....................................................................................................................................................................................724 S-1 NO DISPLAY IS GIVEN FOR ANY GEAR SPEED............................................................................................................................................................................725 S-2 N IS DISPLAYED FOR EVERY GEAR SPEED...............................................................................................................................................................................726 S-3 E IS DISPLAYED FOR SOME GEAR SPEEDS ONLY..........................................................................................................................................................................727 S-4 SPEED SENSOR SIGNAL DISPLAY LED DOES NOT LIGHT UP.................................................................................................................................................................728 S-5 LOCK-UP OPERATION DISPLAY LED DOES NOT LIGHT UP...................................................................................................................................................................728 S-6 DISPLAY IS GIVEN BUT IT IS NOT CORRECT............................................................................................................................................................................729 S-7 PART OF GEAR SPEED DISPLAY LED DOES NOT LIGHT UP, SO INCOMPLETE NUMBER OR LETTER IS DISPLAYED.....................................................................................................................730 83 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................731 CONSOLE BOX, CONTROL BOX AND SENSOR...........................................................................................................................................................................................732 REMOVAL AND INSTALLATION..................................................................................................................................................................................................732
KOMATSU PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 AND UP EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
4 reviews for Komatsu PC200-2, PC200LC-2, PC220-2, PC220LC-2 15001, 11001 and up Excavator Shop Manual – PDF DOWNLOAD
Add a review
Wesley Andre –
Very satisfied!!! Thank you
Reid Grady –
Ledger Johan –
fast Easy service
Boone Julien –