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KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER: SEBM010106
- SERIAL NUMBER:
PC200, 200LC-6 STD – 96514 and up
PC200, ZOOLC-6 HYPER GX – 96514 and up
P0210, 210LC-6 STD – 30980 and up
PC220, 220LC-6 STD – 52852 and up
PC230, 230LC-6 STD – 10177 and up
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Description
KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL
KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judge- ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur- ther divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte nance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes“ are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing. installing, disassembling and assembling each com- ponent, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and Options together.
TABLE OF CONTENTS:
KOMATSU PC200, 200LC-6 PC210,210LC-6 PC220,220LC-6 PC230, 230LC-6 SERVICE REPAIR MANUAL
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 SAFETY................................................................................................................................... 11 Safety Notice........................................................................................................................ 11 FOREWORD................................................................................................................................. 13 General.............................................................................................................................. 13 How to Read the Shop Manual.......................................................................................................... 14 Hoisting Instructions................................................................................................................ 15 Method of Disassembling, Connecting Push-Pull Type Coupler........................................................................... 16 Coating Materials.................................................................................................................... 18 Standard Tightening Torque........................................................................................................... 20 Electric Wire Code................................................................................................................... 23 Conversion Table..................................................................................................................... 24 Units................................................................................................................................ 30 01 GENERAL................................................................................................................................. 31 Specification Dimension Drawings......................................................................................................... 32 Specifications........................................................................................................................... 40 Weight Table............................................................................................................................. 62 Fuel, Coolant and Lubricants............................................................................................................. 82 10 STRUCTURE AND FUNCTION.................................................................................................................. 85 Engine Related Parts..................................................................................................................... 86 Radiator, Oil Cooler, Aftercooler........................................................................................................ 88 Power Train.............................................................................................................................. 91 Final Drive.............................................................................................................................. 92 Swing Circle............................................................................................................................. 93 Swing Machinery.......................................................................................................................... 94 Track Frame, Recoil Spring............................................................................................................... 95 Track Shoe............................................................................................................................... 96 Hydraulic Piping Drawing................................................................................................................. 98 Hydraulic Circuit Diagram................................................................................................................ 102 Hydraulic Tank........................................................................................................................... 106 Hydraulic Pump........................................................................................................................... 107 Line Oil Filter.......................................................................................................................... 139 Control Valve............................................................................................................................ 140 Self-reducing Pressure Valve............................................................................................................. 154 CLSS..................................................................................................................................... 159 Swing Motor.............................................................................................................................. 222 Center Swivel Joint...................................................................................................................... 228 Travel Motor............................................................................................................................. 230 Valve Control............................................................................................................................ 238 Work Equipment, Swing PPC Valve.......................................................................................................... 240 Travel PPC Valve......................................................................................................................... 248 Service PPC Valve........................................................................................................................ 252 Safety Lock Valve........................................................................................................................ 256 PPC Accumulator.......................................................................................................................... 256 Straight-Travel System................................................................................................................... 257 Solenoid Valve........................................................................................................................... 258 Boom Holding Valve....................................................................................................................... 260 Additional Filter for Breaker............................................................................................................ 263 Swivel Joint for Arm Rotation............................................................................................................ 265 Arm Rotation Motor....................................................................................................................... 266 Work Equipment........................................................................................................................... 268 Air Conditioner.......................................................................................................................... 269 Actual Electric Wiring Diagram........................................................................................................... 270 Electrical Circuit Diagram............................................................................................................... 278 PC220-6 STD Serial No.: 96514 - 102228............................................................................................... 278 PC210-6 STD Serial No.: 30980 - 31424................................................................................................ 278 PC220-6 STD Serial No.: 52852 - 53561................................................................................................ 278 PC230-6 STD Serial No.: 10177 - 10246................................................................................................ 278 Engine Control System.................................................................................................................... 292 Electronic Control System for STD........................................................................................................ 301 Electronic Control System for Hyper GX................................................................................................... 341 Machine Monitor System................................................................................................................... 400 Sensors.................................................................................................................................. 411 Front Window Auto Pull-up System......................................................................................................... 414 20 TESTING AND ADJUSTING................................................................................................................... 417 TABLE OF JUDGEMENT STANDARD VALUE........................................................................................................ 420 TESTING AND ADJUSTING.................................................................................................................... 445 Tools for Testing, Adjusting, and Troubleshooting.................................................................................... 445 Measuring Engine Speed............................................................................................................... 446 Measuring Exhaust Gas Color.......................................................................................................... 447 Adjusting Valve Clearance............................................................................................................ 448 Measuring Compression Pressure....................................................................................................... 449 Measuring Blow-by Pressure........................................................................................................... 449 Testing and Adjusting Fuel Injection Timing.......................................................................................... 450 Measuring Engine Oil Pressure........................................................................................................ 451 Testing and Adjusting Alternator Belt Tension........................................................................................ 452 Testing and Adjusting Belt Tension for Air Conditioner Compressor.................................................................... 452 Measuring Speed Sensor............................................................................................................... 453 Testing and Adjusting Governor Motor Lever Stroke.................................................................................... 454 Testing and Adjusting Hydraulic Pressure in Work Equipment, Swing, Travel Circuit.................................................... 455 Testing and Adjusting PC Valve Output Pressure (Servo Piston Input Pressure)......................................................... 458 Testing and Adjusting LS Valve Output Pressure (Servo Piston Input Pressure) and LS Differential Pressure............................ 460 Testing and Adjusting Control Circuit Oil Pressure................................................................................... 463 Testing Solenoid Valve Output Pressure............................................................................................... 465 Measuring PPC Valve Output Pressure.................................................................................................. 467 Measuring EPC Solenoid Valve Output Pressure and Checking EPC Shuttle Valve.......................................................... 469 Adjusting Work Equipment, Swing PPC Valve............................................................................................ 471 Testing Travel Deviation............................................................................................................. 472 Testing Locations Causing Hydraulic Drift of Work Equipment.......................................................................... 473 Measuring Oil Leakage................................................................................................................ 475 Releasing Remaining Pressure in Hydraulic Circuit.................................................................................... 477 Testing Clearance of Swing Circle Bearing............................................................................................ 478 Testing and Adjusting Track Shoe Tension............................................................................................. 479 Bleeding Air......................................................................................................................... 480 Input/Output Structure of GX Controller.............................................................................................. 483 Basic Operation and GX Function...................................................................................................... 484 Special Functions on GX Panel (Background Mode)...................................................................................... 486 Check Procedure when Operation of GX Automatic Function is Defective................................................................. 509 Adjusting Swing Back Prevention Function (Swing Teaching Mode)....................................................................... 511 Bucket Dimension Input Mode when Using Custom Bucket................................................................................. 513 Procedure for Replacing Sensor....................................................................................................... 516 TROUBLESHOOTING.......................................................................................................................... 522 Points to Remember When Troubleshooting.............................................................................................. 523 Sequence of Events in Troubleshooting................................................................................................ 524 Precautions When Carrying Out Maintenance............................................................................................ 525 Checks Before Troubleshooting........................................................................................................ 533 Connector Types and Mounting Locations............................................................................................... 535 Connection Table for Connector Pin Numbers........................................................................................... 543 Explanation of Control Mechanism for Electrical System............................................................................... 555 Display Method and Special Functions of Monitor Panel................................................................................ 557 Method of Using Judgement Table...................................................................................................... 567 Method of Using Troubleshooting Charts............................................................................................... 569 Details of Troubleshooting and Troubleshooting Procedure............................................................................. 571 Troubleshooting of Communication Abnormality System ( N Mode)........................................................................ 578 N-1 (E218) Communications Abnormality........................................................................................... 579 Troubleshooting of Engine Throttle - Pump Controller (Govenor Control System) (E Mode)............................................... 582 Points to Remember When Carrying Out Troubleshooting of Engine Throttle - Pump Controller System................................. 583 Action Taken by Controller When Abnormality Occurs and Problems on Machine....................................................... 585 Judgement Table for Engine Throttle - Pump Controller (Govenor Control System) and Engine Related Parts.......................... 589 Electrical Circuit Diagram for E Mode System..................................................................................... 591 E-1 Abnormality in Engine Throttle - Pump Controller Power Source (controller LED is OFF).................................... 593 E-2 (E308) Abnormality in Fuel Control Dial Imput Value is Displayed......................................................... 594 E-3 (E317) Abnormality (disconnection) in Motor Drive System is Displayed.................................................... 595 E-4 (E318) Abnormality (short circuit) in Motor Drive System is Displayed.................................................... 596 E-5 (E306) Abnormality in Feedback Potentionmeter System is Displayed........................................................ 597 E-6 (E315) Abnormality (short circuit) in Battery Relay Output System is Displayed........................................... 598 E-7 (E316) Abnormality (step-out) in Motor is Displayed...................................................................... 599 E-8 Engine Does Not Start.................................................................................................... 601 E-9 Engine Speed is Irregular................................................................................................ 605 a) Idling Speed is Irregular............................................................................................. 605 b) There is Hunting...................................................................................................... 607 E-10 Lack of Output (engine high idling speed is too low).................................................................... 609 E-11 Engine Does Not Stop.................................................................................................... 611 E-12 Defective Operation of Battery Relay System (engine does not stop)...................................................... 613 Troubleshooting of Engine System (S Mode)............................................................................................ 616 Method of Using Troubleshooting Charts........................................................................................... 617 S-1 Starting Performance is Poor (starting always takes time).................................................................... 621 S-2 Engine Does Not Start........................................................................................................ 622 (1) Engine Does Not Turn..................................................................................................... 622 (2) Engine Turns But no Exhaust Smoke Comes Out (fuel is not being injected)................................................. 623 (3) Exhaust Smoke Comes Out but Engine Does Not Start (fuel is being injected)............................................... 624 S-3 Engine Does Not Pick Up Smoothly (follow-up is poor)......................................................................... 625 S-4 Engine Stops During Operation................................................................................................ 626 S-5 Engine Does Not Rotate Smoothly (hunting).................................................................................... 627 S-6 Engine Lacks Output ( no power).............................................................................................. 628 S-7 Exhaust Smoke is Black (incomplete combustion)............................................................................... 629 S-8 Oil Consumption is Excessive (or exhaust smoke is blue)...................................................................... 630 S-9 Oil Becomes Contaminated Quickly............................................................................................. 631 S-10 Fuel Consumption is Excessive............................................................................................... 632 S-11 Oil is in Cooling Water, or Water Spurts Back, or Water Level Goes Down..................................................... 633 S-12 Oil Pressure Caution Lamp Lights Up (drop in oil pressure).................................................................. 634 S-13 Oil Level Rises (water, fuel in oil)........................................................................................ 635 S-14 Water Temperature Becomes Too High (overheating)............................................................................ 636 S-15 Abnormal Noise is Made...................................................................................................... 637 S-16 Vibration is Excessive...................................................................................................... 638 Troubleshooting of Engine Throttle - Pump Controller (Pump Control System) (C Mode).................................................. 640 Points to Remember When Troubleshooting Pump Controller System................................................................... 641 Action Taken by Controller When Abnormality Occurs and Problems on Machine....................................................... 643 Judgement Table for Engine Throttle - Pump Controller (pump control system) and Hydraulic Related Parts.......................... 651 Electrical Circuit Diagram for C Mode............................................................................................ 653 C-1 Abnormality in Controller Power Source System (controller LED is OFF).................................................... 657 C-2 (E232) Short Circuit in PC-EPC Solenoid System is Displayed.............................................................. 658 C-3 (E233) Disconnection in PC-EPC Solenoid System is Displayed.............................................................. 659 C-4 (E203) Short Circuit in Swing Brake Solenoid System is Displayed......................................................... 660 C-5 (E213) Disconnection in Swing Brake Solenoid System is Displayed......................................................... 662 C-6 (E204) Short Circuit in Pump Merge/Divider Solenoid System is Displayed.................................................. 664 C-7 (E214) Disconnection in Pump Merge/Divider Solenoid System is Displayed.................................................. 665 C-8 (E207) Short Circuit In Active Mode Solenoid System is Displayed......................................................... 666 C-9 (E208) Disconnection in Active Mode Solenoid System is Displayed......................................................... 667 C-10 (E206) Short Circuit in Travel Speed Solenoid System is Displayed....................................................... 668 C-11 (E216) Disconnection in Travel Speed Solenoid System is Displayed....................................................... 669 C-12 (E205) Short Circuit in 2-Stage Relief Solenoid System is Displayed..................................................... 670 C-13 (E215) Disconnection in 2-State Relief Solenoid System is Displayed..................................................... 671 C-14 (E217) Model Selection Input Error is Displayed......................................................................... 672 C-15 (E222) Short Circuit in LS-EPC Solenoid System is Displayed............................................................. 674 C-16 (E223) Disconnection in LS-EPC Solenoid System is Displayed............................................................. 675 C-17 (E224) Abnormality in Front Pump Pressure Sensor System is Displayed.................................................... 676 C-18 (E225) Abnormality in Rear Pump Pressure Sensor System is Displayed..................................................... 677 C-19 (E226) Abnormality in Pressure Sensor Power Source System is Displayed.................................................. 678 C-20 (E227) Abnormality in Engine Speed Sensor System is Displayed........................................................... 679 C-21 (E302) Short Circuit in Swing Stroke Limit Solenoid System is Displayed................................................. 680 C-22 (E303) Disconnection in Swing Stroke Limit Solenoid System is Displayed................................................. 681 Troubleshooting of Engine throttle - Pump Controller (Input Signal System) (F Mode).................................................. 682 Electrical Circuit Diagram for F Mode............................................................................................ 683 F-1 Bit Pattern 20-(1) Swing Oil Pressure Switch Does Not Light Up............................................................... 687 F-2 Bit Pattern 20-(2) Travel Oil Pressure Switch Does Not Light Up.............................................................. 688 F-3 Bit Pattern 20-(3) Boom LOWER Oil Pressure Switch Does Not Light Up.......................................................... 689 F-4 Bit Pattern 20-(4) Boom RAISE Oil Pressure Switch Does Not Light Up.......................................................... 690 F-5 Bit Pattern 20-(5) Arm IN Oil Pressure Switch Does Not Light Up.............................................................. 691 F-6 Bit Pattern 20-(6) Arm OUT Oil Pressure Switch Does Not Light Up............................................................. 692 F-7 Bit Pattern 21-(1) Bucket CURL Oil Pressure Switch Does Not Light Up......................................................... 693 F-8 Bit Pattern 21-(2) Bucket DUMP Oil Pressure Switch Does Not Light Up......................................................... 694 F-9 Bit Pattern 21-(3) Swing Lock Switch Does Not Light Up....................................................................... 695 F-10 Bit Pattern 22-(5) Kerosene Mode Connection Does Not Light Up............................................................... 696 F-11 Bit Pattern 22 (6) L.H. Knob Switch Does Not Light Up....................................................................... 697 Troubleshooting of Hydraulic and Mechanical system (H Mode).......................................................................... 698 Table of Failure Modes and Causes for Hydraulic and Mechnaical Systems .......................................................... 699 Pump Merge/Divider Logic......................................................................................................... 703 Solenoid Actuation Table......................................................................................................... 704 Troubleshooting Flow Charts for Each Failure Mode................................................................................ 705 All Work Equipment, Travel, Swing............................................................................................ 705 H-1 Speeds of All Work Equipment, Swing, Travel Are Slow or Lack Power................................................... 705 H-2 There is Excessive Drop in Engine Speed, or Engine Stalls............................................................ 707 H-3 No Work Equipment, Travel, Swing Move................................................................................ 708 H-4 Abnormal Noise Generated (around pump)............................................................................... 708 H-5 Auto-Deceleration Does Not work (PPC shuttle valve is euqipped only in travel PPC valve)............................. 709 H-6 Fine Control Ability is Poor or Response is Poor..................................................................... 709 Work Equipment............................................................................................................... 711 H-7 Boom is Slow or Lacks Power.......................................................................................... 711 H-8 Arm is Slow or Lacks Power........................................................................................... 713 H-9 Bucket is Slow or Lacks Power........................................................................................ 715 H10- Work Equipment (boom, arm, bucket) Does Not Move (but travel and swing are normal).................................. 716 H-11 Excessive Hydraulic Drift........................................................................................... 716 H-12 Excessive Time Lag (engine at low idling)........................................................................... 717 H-13 Other Equipment Moves When Single Circuit is Relieved............................................................... 717 H-14 Lack of Power When Pressure Rises................................................................................... 718 H-15 In L/O, F/O Modes, Work Equipment Speed is Faster Than Specified Speed.............................................. 719 Compound Operations.......................................................................................................... 719 H-16 In Compound Operations, Work Equipment with Larger Load is Slow..................................................... 719 H-17 In Swing + Boom RAISE, Boom RAISE is Slow........................................................................... 720 H-18 In Swing + Travel, Travel Speed Drops Excessively................................................................... 720 Travel System................................................................................................................ 721 H-19 Travel Deviation.................................................................................................... 721 H-20 Travel Speed is Slow................................................................................................ 723 H-21 Steering Does Not Turn Easily or Lacks Power........................................................................ 725 H-22 Travel Speed Does Not Switch or is Faster than Specified Speed...................................................... 727 H-23 Travel Does Not Move (one side only)................................................................................ 727 Swing System................................................................................................................. 728 H-24 Does Not Swing...................................................................................................... 728 H-25 Swing Acceleration is Poor or Swing Speed is Slow................................................................... 729 H-26 Excessive Overrun When Stopping Swing............................................................................... 731 H-27 Excessive Shock When Stopping Swing (one direction only)............................................................ 732 H-28 Excessive Abnormal Noise When Stopping Swing........................................................................ 732 H-29 Excessive Hydraulic Drift of Swing.................................................................................. 733 H-30 Swing Speed is Faster than Specified Speed in L/O and F/O Modes..................................................... 734 H-31 Operation of Automatic Mode is Defective (HYPER specification)...................................................... 734 Troubleshooting of Machine Monitor System (M Mode)................................................................................... 736 Action Taken by Monitor Panel When Abnormality Occurs and Problems on Machine.................................................... 739 Electrical Circuit Diagram for M Mode System..................................................................................... 741 M-1 (E101) Abnormality in Error Data is Displayed................................................................................ 743 M-1 (E102) Error in Clock Data is Displayed...................................................................................... 743 M-2 (E103) Short Circuit in Buzzer Output or Contact of 24V Wiring Harness with Buzzer Drive Harness is Displayed................ 744 M-3 (E104) Air Cleaner Clogging Detected is Displayed............................................................................ 745 M-4 (E108) Engine Water Temperature 105 degrees C Detected is Displayed.......................................................... 745 M-5 When Starting Switch is Turned ON, None of Lamps on Monitor Panel Light Up for 3 Seconds..................................... 746 a) None of Lamps on Monitor Panel Light Up.................................................................................. 746 b) Some of Lamps on Monitor Panel Do Not Light Up........................................................................... 746 M-6 When Starting Switch is Turned ON, Monitor Panel Lamps All Stay Lighted Up and Do Not Go Out................................. 748 M-7 When Starting Switch is Turned ON, Items Lighted Up on Monitor Palen are Different from Actual Machine (Model)............... 748 M-8 When Starting Switch is Turned ON (engine stopped), Basic Check Items Flash.................................................. 749 a) Coolant Level Flashes.................................................................................................... 749 b) Engine Oil Level Flashes................................................................................................. 750 c) Hydraulic Oil Level Flashes.............................................................................................. 751 M-9 Preheating is Not Being Used But Preheating Monitor Lights Up................................................................ 752 M-10 When Starting Switch is Turned ON and Engine is Started, Basic Check Items Flash............................................ 753 a) Alternator System........................................................................................................ 753 b) Engine Oil Pressure System............................................................................................... 754 M-11 When Starting Switch is Turned ON (engine stopped), Caution Items, Emergency Items Flash (battery, engine oil pressure l.... 755 a) Alternator System........................................................................................................ 755 b) Engine Oil Pressure Sensor System........................................................................................ 756 M-12 When Starting Switch is Turned ON and Engine is Started, Caution Items, Emergency Items Flash (when there is no abnormal.... 757 a) Engine Oil Pressure Flashes.............................................................................................. 757 b) Coolant Level Flashes.................................................................................................... 757 c) Battery Charge Flashes................................................................................................... 757 d) Coolant Temperature Flashes.............................................................................................. 758 e) Fuel Level Flashes....................................................................................................... 758 f) Air Cleaner Clogging Flashes............................................................................................. 759 M-13 When Starting Switch is Turned ON (engine stopped), Buzzer Does Not Sound for 1 Second; Caution Item Flashes but Buzzer .... 760 M-14 No Abnormality is Displayed on Monitor but Buzzer Sounds.................................................................... 760 M-15 Night Lighting on Monitor Panel Does Not Light Up (liquid crystal display is normal)........................................ 761 M-16 Coolant Temperature Gauge Does Not Rise..................................................................................... 762 M-17 Coolant Temperature Gauge Does Not Give Any Display (none of gauge lamps light up during operation)......................... 762 M-18 Fuel Level Gauge Always Displays FULL....................................................................................... 763 M-19 Fuel Level Gauge Does Not Give Display...................................................................................... 763 M-20 Swing Lock Switch is Turned ON (LOCK) but Swing Lock Monitor Does Not Light Up.............................................. 764 M-21 Swing Prolix Switch is Turned ON (prolix), but Swing Lock Monitor Does Not Flash............................................ 764 M-22 Service Meter Does Not Advance While Engine is Running...................................................................... 765 M-23 When Starting Switch is at OFF and Time Switch is Pressed, Time and Service Meter Are Not Displayed......................... 765 M-24 Defective Fuel Level Sensor System.......................................................................................... 766 M-25 Defective Coolant Temperature Sensor System................................................................................. 767 M-26 Defective Engine Oil Level Sensor System.................................................................................... 768 M-27 Defective Coolant Level Sensor System....................................................................................... 769 M-28 Defective Hydraulic Oil Level Sensor System................................................................................. 770 M-29 Wiper Does Not Work, or Switch is Not Being Used but Wiper is Actuated...................................................... 771 a) Wiper Does Not Work...................................................................................................... 771 b) Wiper Switch is Not Being Operated but Wiper is Actuated................................................................. 774 M-30 Washer Motor Does Not Work, or Switch is Not Being Used but Washer Motor is Actuated.................................... 776 a) Washer Motor Does Not Work........................................................................................... 776 b) Switch is Not Being Operated but Washer is Actuated.................................................................. 777 Troubleshooting of GX Controller System (A Mode)..................................................................................... 778 Points to Remember When Troubleshooting GX Controller System..................................................................... 780 Procedure for Troubleshooting Hyper GX........................................................................................... 781 Operation of GX Error Code Display Mode and Content of Display................................................................... 784 Action Taken by Controller When Abnormality Occurs, and Problems on Machine...................................................... 787 Electrical Wiring Diagram for GX Controller...................................................................................... 795 A-1 E6:01, E6:02, E6:03, and E6:04 are Displayed at the Same Time................................................................ 797 A-2 E6:01 (GX panel 011, 012) [Abnormality in Boom (RAISE) Pressure Sensor System] is Displayed.................................. 799 A-3 E6:01 (GX panel 013, 014) [Abnormality in Boom (LOWER) Pressure Sensor System] is Displayed.................................. 801 A-4 E6:02 (GX panel 021, 022) [Abnormality in Arm (IN) Pressure Sensor System] is Displayed...................................... 803 A-5 E6:02 (GX panel 023, 024) [Abnormality in Arm (OUT) Pressure Sensor System] is Displayed..................................... 805 A-6 E6:03 (GX panel 031, 032) [Abnormality in Bucket (CURL) Pressure Sensor System] is Displayed................................. 807 A-7 E6:03 (GX panel 033, 034) [Abnormality in Bucket (DUMP) Pressure Sensor System] is Displayed................................. 809 A-8 E6:04 (GX panel 041, 042) [Abnormality in Swing (RIGHT) Pressure Sensor System] is Displayed................................. 811 A-9 E6:04 (GX panel 043, 044) [Abnormality in Swing (LEFT) Pressure Sensor System] is Displayed.................................. 813 A-10 E6:06 (GX panel 061, 063) [Abnormality in Clinometer Input Valve] is Displayed.............................................. 815 A-11 E6:07 and E6:08 [Abnormality in Potentiometer Power Source] are Displayed at the Same Time.................................. 817 A-12 E6:07 (GX panel 071, 072) [Abnormality in Boom Potentionmeter System] is Displayed.......................................... 819 A-13 E6:08 (GX panel 081, 082) [Abnormality in Arm Potentiometer System] is Displayed............................................ 821 A-14 E6:11 (GX panel 111, 112) [Abnormality in Boom Variable Angle] is Displayed................................................. 823 A-15 E6:12 (GX panel 121, 122) [Abnormality in Arm Variable Angle] is Displayed.................................................. 825 A-16 E6:13 (GX panel 131, 132) [Abnormality in Bucket Variable Angle] is Displayed............................................... 828 A-17 E6:14 (GX panel 141) [Abnormality in Comparision of Two Boom Sensor Signals] is Displayed................................... 829 A-18 E6:15 (GX panel 151) [Abnormality in Comparision of Two Arm Sensor Singals] is Displayed.................................... 830 A-19 E6:16 (GX panel 163) [No Change in Signal When Work Equipment Should Move] is Displayed..................................... 831 A-20 E6:17 (GX panel 171, 172) [Cutting Edge Position Out of Range] is Displayed................................................. 832 A-21 E6:18 (GX panel 181, 182) [Abnormality in Data ROM] is Displayed............................................................ 832 A-22 E6:21 (GX panel 211, 212, 213, 214) [Abnromality in Engine Pick-up] is Displayed............................................ 833 A-23 E6:22 (GX panel 221) [Change in Wiring Harness After Engine Picks up] is Displayed.......................................... 837 A-23 E6:22 (GX panel 222) [Automatic Operation Disconnection Switch Signal Does Not Match in Valve Controller and GX Control..... 837 A-23 E6:22 (GX panel 223) [Abnormality in Controller Power Source] is Displayed.................................................. 837 A-24 E6:23 (GX panel 231) [Abnormality in Remote Singal] is Displayed............................................................ 841 A-24 E6:23 (GX panel 235) [Abnormality in 12V Power Source (overcurrent detection)] is Displayed................................. 841 A-24 E6:23 (GX panel 236) [Abnormality in 24V Power Source (overcurrent detection)] is Displayed................................. 841 A-25 E6:24 (GX panel 241) [Abnormality in Buzzer Drive System] is Diaplayed...................................................... 844 A-26 E6:25 (GX panel 251, 252) [Impossible to Receive Network (S-NET) Signal] is Displayed....................................... 845 A-26 E6:25 (GX panel 253) [Impossible to Receive Network (HS-NET) Signal] is Displayed........................................... 847 A-27 E6:26 (GX panel 261, 262, 263, 264) [Abnormality in Non-Volatile Memory Data Range] is Displayed............................ 850 A-28 E6:27 [Non-Volatile Read Error] is Displayed................................................................................ 851 A-29 E6:28 [Non-Volatile Write Error] is Displayed............................................................................... 851 A-30 Buzzer Does Not Sound (when there is no abnormal display)................................................................... 852 A-31 Automatic Mode is Not Actuated When Knob Switch is Pressed (when there is no abnormal display............................... 853 Troubleshooting of Valve Controller System (K Mode).................................................................................. 854 Points to Remember When Troubleshooting Valve Controller System.................................................................. 856 Action Taken by Controller When Abnormality Occurs and Problems on Machine....................................................... 857 Judgement Table for Valve Controller System...................................................................................... 875 Electrical Circuit Diagram of Valve Controller System............................................................................ 877 K-1 [LED OFF] Controller Power Source System..................................................................................... 880 K-2 [E4:02] L.H. Knob Switch OFF System is Displayed............................................................................. 881 K-3 [E4:07] Abnormality in Model Code Input is Displayed......................................................................... 882 K-4 [E4:51] Abnormality in S-NET Communication is Displayed...................................................................... 883 1. Disconnection Related.................................................................................................... 883 2. Short Circuit Related.................................................................................................... 885 K-5 [E4:56] Abnormality in Teaching, Playback RAM Data is Displayed.............................................................. 885 K-6 [E4:57] Abnormality in Knob Switch is Displayed.............................................................................. 886 K-7 [E4:01] Abnormality in Control Lever Neutral System is Displayed............................................................. 887 K-8 [E4:04] Abnormality in Control Lever Potentiometer Power Source System is Displayed.......................................... 889 K-9 [E4:11) Short Circuit in EPC Relay 1 Drive Power Source System is Displayed.................................................. 890 K-10 [E4:12] Contact Between Chassis Power Source and EPC Relay 1 Drive Power Source System is Displayed......................... 891 K-11 [E4:13] Short Circuit in EPC Relay 2 Drive Power Source System is Displayed................................................. 892 K-12 [E4:14] Contact Between Chassis Power Source and EPC Relay 2 Drive Power Source System is Displayed......................... 893 K-13 [E4:15] Disconnection in EPC Relay 1,2 Solenoid Power Source System is Displayed............................................ 894 K-14 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed............................. 896 K-14 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed............................. 896 1) When E4:16 is Displayed Independently.................................................................................... 896 2) When E4:16, E4:17 are Displayed Simultaneously........................................................................... 896 K-15 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed............................. 898 K-15 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed............................. 898 1) When E4:17 is Displayed Independently.................................................................................... 898 2) When E4:16, E4:17 are Displayed Simultaneously........................................................................... 898 K-16 [E4:18] Abnormality in Lever Signal Input Delay Circuit System is Displayed................................................. 900 K-17 [E4:21] Abnormality 1 in Drive Circuit System for Boom LOWER EPC Valve is Displayed......................................... 901 K-17 [E4:25] Abnormality 1 in Drive Circuit System for Boom RAISE EPC Valve is Displayed......................................... 901 K-17 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed............................... 903 K-17 [E4:25] [E4:35] Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed............................... 903 K-18 [E4:31 Abnormality 2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed.......................................... 905 K-18 [E4:35] Abnormality 2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed......................................... 905 K-18 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed............................... 907 K-18 [E4:25] [E4:35} Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed............................... 907 K-19 [E4:32} Abnormality 2 in Drive Circuit System for Arm IN EPC Valve is Displayed............................................. 909 K-19 [E4:33] Abnormality 2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed........................................ 909 K-19 [E4:34] Abnormality 2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed......................................... 909 K-19 [E4:36] Abnormality 2 in Drive Circuit System for Arm OUT LEFT EPC Valve is Displayed....................................... 909 K-19 [E4:37] Abnormality 2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed........................................ 909 K-19 [E4:38] Abnormality 2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed........................................ 909 K-19 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed................................... 911 K-19 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed.............................. 911 K-19 [E4: 24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed.............................. 911 K-19 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed.................................. 911 K-19 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed.............................. 911 K-19 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed.............................. 911 K-20 [E4:41] [E4:42] [E4:43] [E4:44} Over-range in Control Lever Potentiometer Signal System is Displayed........................ 913 K-21 [E4:45] [E4:46] [E4:47] [E4:48] Excessive Error in Signal SIG and Switch SIG of Control Lever Potentiometer is Displayed.... 915 K-22 [E4:55] Abnormality in ROM, RAM of CPU is Displayed......................................................................... 917 K-23 [E4:58] Abnormality in Interlock PLD is Displayed........................................................................... 917 K-24 [E4:22] Abnormality 1 in Drive Circuit System for Arm IN EPC Valve is Displayed............................................. 918 K-24 [E4:23] Abnormality 1 in Drive Circuit System for Bucket CURL EPC Valve is Displayed........................................ 918 K-24 [E4:24] Abnormality 1 in Drive Circuit System for Swing LEFT EPC Valve is Displayed......................................... 918 K-24 [E4:26] Abnormality 1 in Drive Circuit System for Arm OUT EPC Valve is Displayed............................................ 918 K-24 [E4:27] Abnormality 1 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed........................................ 918 K-24 [E4:28] Abnormality 1 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed........................................ 918 K-24 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed................................... 920 K-24 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed.............................. 920 K-24 [E4:24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed............................... 920 K-24 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed.................................. 920 K-24 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed.............................. 920 K-24 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed.............................. 920 30 DISASSEMBLY AND ASSEMBLY................................................................................................................ 922 Method of Using Manual................................................................................................................... 924 Precautions When Carrying Out Operation.................................................................................................. 925 Special Tool List........................................................................................................................ 927 Sketches of Special Tools................................................................................................................ 935 Starting Motor........................................................................................................................... 938 Removal of Starting Motor Assembly................................................................................................... 938 Installation of Starting Motor Assembly.............................................................................................. 938 Alternator............................................................................................................................... 939 Removal of Alternator Assembly....................................................................................................... 939 Installation of Alternator Assembly.................................................................................................. 940 Air Conditioner Compressor............................................................................................................... 942 Removal of Air Conditioner Compressor Assembly....................................................................................... 942 Installation of Air Conditioner Compressor Assembly.................................................................................. 942 Condenser................................................................................................................................ 943 Removal of Condenser Assembly........................................................................................................ 943 Installation of Condenser Assembly................................................................................................... 943 Air Conditioner Condenser ............................................................................................................... 944 Removal of Air Conditioner Condenser Assembly........................................................................................ 944 Installation of Air Conditioner Condenser Assembly................................................................................... 944 Dry Receiver............................................................................................................................. 945 Removal of Dry Receiver Assembly..................................................................................................... 945 Installation of Dry Receiver Assembly................................................................................................ 945 Engine Oil Cooler Core................................................................................................................... 946 Removal of Engine Oil Cooler Core Assembly........................................................................................... 946 Installation of Engine Oil Cooler Core Assembly...................................................................................... 946 Fuel Injection Pump...................................................................................................................... 947 Removal of Fuel Injection Pump Assembly.............................................................................................. 947 Installation of Fuel Injection Pump Assembly......................................................................................... 950 Water Pump............................................................................................................................... 957 Removal of Water Pump Assembly....................................................................................................... 957 Installation of Water Pump Assembly.................................................................................................. 958 Nozzle Holder............................................................................................................................ 959 Removal of Nozzle Holder Assembly.................................................................................................... 959 Installation of Nozzle Holder Assembly............................................................................................... 959 Turbocharger............................................................................................................................. 960 Removal of Turbocharger Assembly..................................................................................................... 960 Installation of Turbocharger Assembly................................................................................................ 960 Thermostat............................................................................................................................... 961 Removal of Thermostat Assembly....................................................................................................... 961 Installation of Thermostat Assembly.................................................................................................. 962 Govenor Motor............................................................................................................................ 963 Removal of Govenor Motor Assembly.................................................................................................... 963 Installation of Governor Motor Assembly.............................................................................................. 963 Cylinder Head............................................................................................................................ 964 Removal of Cylinder Head Assembly.................................................................................................... 964 Installation of Cylinder Head Assembly............................................................................................... 970 Hydraulic Oil Cooler..................................................................................................................... 981 Removal of Hydraulic Oil Cooler Assembly............................................................................................. 981 Installation of Hydraulic Oil Cooler Assembly........................................................................................ 981 Radiator - Hydraulic Oil Cooler.......................................................................................................... 983 Removal of Radiator, Hydraulic Oil Cooler Assembly................................................................................... 983 Installation of Radiator, Hydraulic Oil Cooler Assembly.............................................................................. 985 Engine - Main Pump....................................................................................................................... 989 Removal of Engine, Main Pump Assembly................................................................................................ 989 Installation of Engine, Main Pump Assembly........................................................................................... 993 Damper................................................................................................................................... 994 Removal of Damper Assembly........................................................................................................... 994 Installation of Damper Assembly...................................................................................................... 994 Fuel Tank................................................................................................................................ 995 Removal of Fuel Tank Assembly........................................................................................................ 995 Installation of Fuel Tank Assembly................................................................................................... 995 Center Swivel Joint...................................................................................................................... 996 Removal of Center Swivel Joint Assembly.............................................................................................. 996 Installation of Center Swivel Joint Assembly......................................................................................... 997 Disassembly of Center Swivel Joint Assembly.......................................................................................... 998 Assembly of Center Swivel Joint Assembly............................................................................................. 998 Final Drive.............................................................................................................................. 999 Removal of Final Drive Assembly...................................................................................................... 999 Installation of Final Drive Assembly................................................................................................. 999 Disassembly of Final Drive Assembly..................................................................................................1000 Assembly of Final Drive Assembly.....................................................................................................1003 Travel Motor.............................................................................................................................1008 Disassembly of Travel Motor Assembly.................................................................................................1008 Assembly of Travel Motor Assembly....................................................................................................1014 Sprocket.................................................................................................................................1022 Removal of Sproket...................................................................................................................1022 Installation of Sprocket.............................................................................................................1022 Swing Motor and Swing Machinery..........................................................................................................1023 Removal of Swing Motor, Swing Machinery Assembly.....................................................................................1023 Installation of Swing Motor, Swing Machinery Assembly................................................................................1024 Disassembly of Swing Machinery Assembly..............................................................................................1025 Assembly of Swing Machinery Assembly.................................................................................................1029 Swing Motor..............................................................................................................................1034 Disassembly of Swing Motor Assembly..................................................................................................1034 Assembly of Swing Motor Assembly.....................................................................................................1038 Revolving Frame..........................................................................................................................1046 Removal of Revolving Frame Assembly..................................................................................................1046 Installation of Revolving Frame Assembly.............................................................................................1047 Swing Circle.............................................................................................................................1048 Removal of Swing Circle Assembly.....................................................................................................1048 Installation of Swing Circle Assembly................................................................................................1049 Idler - Recoil Spring....................................................................................................................1050 Removal of Idler - Recoil Spring Assembly............................................................................................1050 Installation of Idler - Recoil Spring Assembly.......................................................................................1050 Recoil Spring............................................................................................................................1051 Disassembly of Recoil Spring Assembly................................................................................................1051 Assembly of Recoil Spring Assembly...................................................................................................1052 Idler....................................................................................................................................1053 Disassembly of Idler Assembly........................................................................................................1053 Assembly of Idler Assembly...........................................................................................................1054 Track Roller.............................................................................................................................1056 Removal of Track Roller Assembly.....................................................................................................1056 Installation of Track Roller Assembly................................................................................................1056 Disassembly of Track Roller Assembly.................................................................................................1057 Assembly of Track Roller Assembly....................................................................................................1059 Carrier Roller...........................................................................................................................1061 Removal of Carrier Roller Assembly...................................................................................................1061 Installation of Carrier Roller Assembly..............................................................................................1061 Disassembly of Carrier Roller Assembly...............................................................................................1062 Assembly of Carrier Roller Assembly..................................................................................................1064 Track Shoe...............................................................................................................................1066 Removal of Track Shoe Assembly.......................................................................................................1066 Installation of Track Shoe Assembly..................................................................................................1066 Hydraulic Tank...........................................................................................................................1067 Removal of Hydraulic Tank Assembly...................................................................................................1067 Installation of Hydraulic Tank Assembly..............................................................................................1068 Main Pump................................................................................................................................1069 Removal of Main Pump Assembly........................................................................................................1069 Installation of Main Pump Assembly...................................................................................................1071 Disassembly of Main Pump Assembly....................................................................................................1073 Assembly of Main Pump Assembly.......................................................................................................1086 Main Pump Input Shaft Oil Seal...........................................................................................................1102 Removal of Main Pump Input Shaft Oil Seal............................................................................................1102 Installation of Main Pump Input Shaft Oil Seal.......................................................................................1102 Control Valve............................................................................................................................1103 Removal of Control Valve Assembly....................................................................................................1103 Installation of Control Valve Assembly...............................................................................................1105 Disassembly of Control Valve Assembly................................................................................................1106 Assembly of Control Valve Assembly...................................................................................................1111 Pump Merge-Divider Valve.................................................................................................................1117 Disassembly of Pump Merge-Divider Valve Assembly.....................................................................................1117 Assembly of Pump Merge-Divider Valve Assembly........................................................................................1117 Main Relief Valve........................................................................................................................1118 Disassembly of Main Relief Valve Assembly............................................................................................1118 Assmebly of Main Relief Valve Assembly...............................................................................................1118 Work Equipment EPC Valve.................................................................................................................1119 Removal of Work Equipment EPC Valve Assembly.........................................................................................1119 Installation of work Equipment EPC Valve Assembly....................................................................................1119 PC Valve.................................................................................................................................1120 Removal of PC Valve Assembly.........................................................................................................1120 Installation of PC Valve Assembly....................................................................................................1121 LS Valve ................................................................................................................................1122 Removal of LS Valve Assembly.........................................................................................................1122 Installation of LS Valve Assembly....................................................................................................1122 PC, LS-EPC Valve.........................................................................................................................1123 Removal of PC, LS-EPC Valve Assembly.................................................................................................1123 Installation of PC, LS-EPC Valve Assembly............................................................................................1123 Solenoid Valve...........................................................................................................................1124 Removal of Solenoid Valve Assembly...................................................................................................1124 Installation of Solenoid Valve Assembly..............................................................................................1124 Work Equipment - Swing PPC Valve.........................................................................................................1125 Removal of Work Equipment - Swing PPC Valve Assembly.................................................................................1125 Installation of Work Equipment - Swing PPC Valve Assembly............................................................................1125 Disassembly of Work Equipment - Swing PPC Valve Assembly.............................................................................1126 Assembly of Work Equipment - Swing PPC Valve Assembly................................................................................1127 Travel PPC Valve.........................................................................................................................1128 Removal of Travel PPC Valve Assembly.................................................................................................1128 Installation of Travel PPC Valve Assembly............................................................................................1128 Disassembly of Travel PPC Valve Assembly.............................................................................................1129 Assembly of Travel PPC Valve Assembly................................................................................................1130 Boom Lock Valve..........................................................................................................................1131 Removal of Boom Lock Valve Assembly..................................................................................................1131 Installation of Boom Lock Valve Assembly.............................................................................................1131 Boom Cylinder............................................................................................................................1132 Removal of Boom Cylinder Assembly....................................................................................................1132 Installation of Boom Cylinder Assembly...............................................................................................1133 Arm Cylinder.............................................................................................................................1134 Removal of Arm Cylinder Assembly.....................................................................................................1134 Installation of Arm Cylinder Assembly................................................................................................1135 Bucket Cylinder..........................................................................................................................1136 Removal of Bucket Cylinder Assembly..................................................................................................1136 Installation of Bucket Cylinder Assembly.............................................................................................1137 Hydraulic Cylinder.......................................................................................................................1138 Disassembly of Hydraulic Cylinder Assembly...........................................................................................1138 Assembly of Hydraulic Cylinder Assembly..............................................................................................1141 Work Equipment...........................................................................................................................1145 Removal of Work Equipment Assembly...................................................................................................1145 Installation of Work Equipment Assembly..............................................................................................1146 Bucket...................................................................................................................................1147 Removal of Bucket Assembly...........................................................................................................1147 Installation of Bucket Assembly......................................................................................................1148 Arm......................................................................................................................................1149 Removal of Arm Assembly..............................................................................................................1149 Installation of Arm Assembly.........................................................................................................1150 Bucket - Arm.............................................................................................................................1151 Removal of Bucket - Arm Assembly.....................................................................................................1151 Installation of Bucket - Arm Assmebly................................................................................................1152 Boom.....................................................................................................................................1153 Removal of Boom Assembly.............................................................................................................1153 Installation of Boom Assembly........................................................................................................1154 Opeator's Cab............................................................................................................................1155 Removal of Operator's Cab Assembly...................................................................................................1155 Installation of Operator's Cab Assembly..............................................................................................1156 Counterweight............................................................................................................................1157 Removal of Counterweight Assembly....................................................................................................1157 Installation of Counterweight Assembly...............................................................................................1157 Work Equipment Electric Lever Unit.......................................................................................................1159 Removal of Work Equipment Electric Lever Unit Assembly...............................................................................1159 Installation of Work Equipment Electric Lever Unit Assembly..........................................................................1159 Engine Throttle - Pump Controller........................................................................................................1160 Removal of Engine Throttle - Pump Controller Assembly................................................................................1160 Installation of Engine Throttle - Pump Controller Assembly...........................................................................1160 Control Stand Case.......................................................................................................................1161 Removal of Control Stand Case........................................................................................................1161 Installation of Control Stand Case...................................................................................................1162 Valve Controller.........................................................................................................................1163 Removal of Valve Controller Assembly.................................................................................................1163 Installation of Valve Controller Assembly............................................................................................1163 Monitor..................................................................................................................................1164 Removal of Monitor Assembly..........................................................................................................1164 Installation of Monitor Assembly.....................................................................................................1164 ITERMS FOR HYPER GX......................................................................................................................1165 Swing Motor..........................................................................................................................1165 Removal of Swing Motor Assembly..................................................................................................1165 Installation of Swing Motor Assembly.............................................................................................1165 Control Valve........................................................................................................................1166 Removal of Control Valve Assembly................................................................................................1166 Installation of Control Valve Assembly...........................................................................................1167 Work Equipment EPC Valve.............................................................................................................1168 Removal of Work Equipment EPC Valve Assembly.....................................................................................1168 Installation of Work Equipment EPC Valve Asembly.................................................................................1168 Boom Cylinder........................................................................................................................1169 Removal of Boom Cylinder Assembly................................................................................................1169 Installation of Boom Cylinder Assembly...........................................................................................1170 Arm Cylinder.........................................................................................................................1171 Removal of Arm Cylinder Assembly.................................................................................................1171 Installation of Arm Cylinder Assembly............................................................................................1172 Bucket Cylinder......................................................................................................................1173 Removal of Bucket Cylinder Assembly..............................................................................................1173 Installation of Bucket Cylinder Assembly.........................................................................................1174 Disassembly of Bucket Cylinder Assembly..........................................................................................1175 Assembly of Bucket Cylinder Assembly.............................................................................................1177 Work Equipment.......................................................................................................................1181 Removal of Work Equipment Assembly...............................................................................................1181 Installation of Work Equipment Assembly..........................................................................................1183 Bucket...............................................................................................................................1184 Removal of Bucket Assembly.......................................................................................................1184 Installation of Bucket Assembly..................................................................................................1185 Arm..................................................................................................................................1186 Removal of Arm Assembly..........................................................................................................1186 Installation of Arm Assembly.....................................................................................................1187 Bucket - Arm.........................................................................................................................1188 Removal of Bucket - Arm Assembly.................................................................................................1188 Installation of Bucket - Arm Assembly............................................................................................1189 Boom.................................................................................................................................1190 Removal of Boom Assembly.........................................................................................................1190 Installation of Boom Assembly....................................................................................................1192 Valve Controller.....................................................................................................................1193 Removal of Valve Controller Assembly.............................................................................................1193 Installation of Valve Controller Assembly........................................................................................1193 GX Controller........................................................................................................................1194 Removal of GX Controller Assembly................................................................................................1194 Installation of GX Controller Assembly...........................................................................................1194 GX Panel.............................................................................................................................1195 Removal of GX Panel Assembly.....................................................................................................1195 Installation of GX Panel Assembly................................................................................................1195 40 MAINTENANCE STANDARD....................................................................................................................1196 Swing Machinery..........................................................................................................................1197 Swing Circle.............................................................................................................................1199 Final Drive..............................................................................................................................1201 Track Frame - Recoil Spring..............................................................................................................1203 Idler....................................................................................................................................1205 Carrier Roller...........................................................................................................................1207 Track Roller.............................................................................................................................1208 Track Shoe...............................................................................................................................1209 Hydraulic Pump...........................................................................................................................1215 Control Valve............................................................................................................................1216 Safety-Suction Valve (for Service Valve).................................................................................................1229 Self-Reducing Pressure Valve.............................................................................................................1230 Swing Motor..............................................................................................................................1231 Travel Motor.............................................................................................................................1232 Work Equipment - Swing PPC Valve.........................................................................................................1233 Work Equipment - Swing EPC Valve.........................................................................................................1234 Tavel PPC Valve..........................................................................................................................1235 Service PPC Valve........................................................................................................................1236 EPC Solenoid Valve.......................................................................................................................1237 Center Swivel Joint......................................................................................................................1238 Boom Holding Valve.......................................................................................................................1240 Hydraulic Cylinder.......................................................................................................................1241 Work Equipment...........................................................................................................................1247 Dimension of Work Equipment..............................................................................................................1253 90 OTHER...................................................................................................................................1260 Hydraulic Circuit Diagram (pg. 90-3).....................................................................................................1261 PC200-6 STD Serial No.: 96514 - 102228...............................................................................................1261 PC210-6 STD Serial No.: 30980 - 31424................................................................................................1261 PC220-6 STD Serial No.: 52852 - 53561................................................................................................1261 PC230-6 STD Serial No.: 10177 - 10246................................................................................................1261 Hydraulic Circuit Diagram (pg. 90-5).....................................................................................................1262 PC200-6 STD Serial No.: 102229 and UP................................................................................................1262 PC210-6 STD Serial NO.: 31425 and UP.................................................................................................1262 PC220-6 STD Serial No.: 53562 and UP.................................................................................................1262 PC230-6 STD Serial NO.: 10247 and UP.................................................................................................1262 Hydraulic Circuit Diagram (pg. 90-7).....................................................................................................1263 PC200-6 HYPER GX Serial No.: 96514 - 102228..........................................................................................1263 Hydraulic Circuit Diagram (pg. 90-9).....................................................................................................1264 PC200-6 HYPER GX Serial No.: 102229 and UP...........................................................................................1264 Hydraulic Circuit Diagram (pg. 90-10-1)..................................................................................................1265 For Rotary Arm = PC200, 200LC-6......................................................................................................1265 Electrical Circuit Diagram [ 1/2 ] (pg. 90-11)...........................................................................................1266 PC200-6 STD Serial No.: 96514 - 102228...............................................................................................1266 PC210-6 STD Serial No.: 30980 - 31424................................................................................................1266 PC220-6 STD Serial No.: 52852 - 53561................................................................................................1266 PC230-6 STD Serial No.: 10177 - 10246 ..............................................................................................1266 Electrical Circuit Diagram [ 2/2 ] (pg. 90-13)...........................................................................................1267 PC200-6 STD Serial No.: 96514 - 102228...............................................................................................1267 PC210-6 STD Serial No.: 30980 - 31424................................................................................................1267 PC220-6 STD Serial NO.: 52852 - 53561................................................................................................1267 PC230-6 STD Serial No.: 10177 - 10246................................................................................................1267 Electrical Circuit Diagram [1/2 ] (pg. 90-15)...........................................................................................1268 PC200-6 STD Serial No.: 102229 and UP................................................................................................1268 PC210-6 STD Serial No.: 31425 and UP.................................................................................................1268 PC220-6 STD Serial No.: 53562 and UP.................................................................................................1268 PC230-6 STD Serial No.: 10247 and UP.................................................................................................1268 Electrical Circuit Diagram [ 2/2 ] (pg. 90-17)...........................................................................................1269 PC200-6 STD Serial No.: 102229 and UP................................................................................................1269 PC210-6 STD Serial No.: 31425 and UP.................................................................................................1269 PC220-6 STD Serial No.: 53562 and UP.................................................................................................1269 PC230-6 STD Serial No.: 10247 and UP.................................................................................................1269 Electrical Circuit Diagram [ 1/3 ] (pg. 90-19)...........................................................................................1270 PC200-6 HYPER GX Serial No.: 94999 - 102228..........................................................................................1270 Electrical Circuit Diagram [ 2/3 ] (pg. 90-21)...........................................................................................1271 PC200-6 HYPER GX Serial No.: 94999 - 102228..........................................................................................1271 Electrical Circuit Diagram [ 3/3 ] (pg. 90-23)...........................................................................................1272 PC200-6 HYPER GX Serial No.: 94999 - 102228..........................................................................................1272 Electrical Circuit Diagram (pg. 90-25)...................................................................................................1273 PC200-6 HYPER GX Serial No.: 94999 - 102228..........................................................................................1273 Electrical Circuit Diagram [ 1/3 ] (pg. 90-27)...........................................................................................1274 PC200-6 HYPER GX Serial No.: 102229 and UP...........................................................................................1274 Electrical Circuit Diagram [ 2/3 ] (pg. 90-29)...........................................................................................1275 PC200-6 HYPER GX Serial No.: 102229 and UP...........................................................................................1275 Electrical Circuit Diagram [ 3/3 ] (pg. 90-31)...........................................................................................1276 PC200-6 HYPER GX Serial No.: 102229 and UP...........................................................................................1276 Electrical Circuit Diagram (pg 90-33)....................................................................................................1277 PC200-6 HYPER GX Serial No.: 102229 and UP...........................................................................................1277
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