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Komatsu Pc200 210 220 250lc 6le Excavator Manual – PDF – Download
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Description
Komatsu Pc200 210 220 250lc 6le Excavator Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:878
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU PC200 210 220 250LC 6LE EXCAVATOR MANUAL – PDF – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under— standing of the product and by showing him the correct way to perform repairs and make judgements.
- Make sure you under- stand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL
- This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
- This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. This section also inlcudes material for the maintenance standards.
TESTING, ADJUSTING AND TROUBLESHOOTING
- This section explains checks to be made before and after performing repairs, as well as adjustments to be nrade at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
- This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
TABLE OF CONTENTS:
Komatsu Pc200 210 220 250lc 6le Excavator Manual
MAIN MENU................................................................................................................. 0 COVER..................................................................................................................... 1 CONTENTS.................................................................................................................. 2 FOREWORD.................................................................................................................. 15 SAFETY................................................................................................................ 15 SAFETY NOTICE..................................................................................................... 15 IMPORTANT SAFETY NOTICE....................................................................................... 15 GENERAL PRECAUTIONS........................................................................................... 15 PREPARATIONS FOR WORK......................................................................................... 15 PRECAUTIONS DURING WORK....................................................................................... 15 GENERAL............................................................................................................... 17 HOW TO READ THE SHOP MANUAL........................................................................................... 18 VOLUMES........................................................................................................... 18 DISTRIBUTION AND UPDATING......................................................................................... 18 FILING METHOD..................................................................................................... 18 REVISED EDITION MARK.............................................................................................. 18 REVISIONS......................................................................................................... 18 SYMBOLS........................................................................................................... 18 HOISTING INSTRUCTIONS................................................................................................. 19 HOISTING.......................................................................................................... 19 WIRE ROPES........................................................................................................ 19 PUSH PULL COUPLER..................................................................................................... 20 TYPE 1............................................................................................................ 20 DISCONNECTION................................................................................................. 20 CONNECTION.................................................................................................... 20 TYPE 2............................................................................................................ 21 DISCONNECTION................................................................................................. 21 CONNECTION.................................................................................................... 21 TYPE 3............................................................................................................ 22 DISCONNECTION................................................................................................. 22 CONNECTION.................................................................................................... 22 COATING MATERIALS..................................................................................................... 23 STANDARD TIGHTENING TORQUE............................................................................................ 25 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...................................................................... 25 TIGHTENING TORQUE OF HOSE NUTS.................................................................................... 26 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS........................................................................... 26 TIGHTENING TORQUE FOR FLARED NUTS................................................................................. 26 ELECTRIC WIRE CODE.................................................................................................... 27 CLASSIFICATION BY THICKNESS....................................................................................... 27 CLASSIFICATION BY COLOR AND CODE.................................................................................. 27 CONVERSION TABLES..................................................................................................... 28 METHOD OF USING THE CONVERSION TABLE.............................................................................. 28 01 GENERAL................................................................................................................ 35 GENERAL ASSEMBLY DRAWING.............................................................................................. 36 PC200LC-6LE, PC210LC-6LE.......................................................................................... 36 PC220LC-6LE, PC250LC-6LE.......................................................................................... 38 SPECIFICATIONS........................................................................................................ 41 PC200LC-6LE....................................................................................................... 41 PC210LC-6LE....................................................................................................... 43 PC220LC-6LE....................................................................................................... 45 PC250LC-6LE....................................................................................................... 47 WEIGHT TABLE.......................................................................................................... 49 PC200LC-6LE....................................................................................................... 49 PC210LC-6LE....................................................................................................... 50 PC220LC-6LE, PC250LC-6LE.......................................................................................... 51 FUEL COOLANT AND LUBRICANTS........................................................................................... 52 10 STRUCTURE AND FUNCTION................................................................................................. 53 ENGINE RELATED PARTS.................................................................................................. 55 RADIATOR - OIL COOLER - AFTERCOLLER................................................................................... 56 PC200LC-6LE, PC210LC-6LE.......................................................................................... 56 PC220LC-6LE, PC250LC-6LE.......................................................................................... 57 POWER TRAIN........................................................................................................... 58 FINAL DRIVE........................................................................................................... 59 PC200LC-6LE, PC210LC-6LE, PC220LC- 6LE............................................................................ 59 PC250LC-6LE....................................................................................................... 63 SWING CIRCLE.......................................................................................................... 66 SWING MACHINERY....................................................................................................... 69 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE............................................................................. 69 PC250LC-6LE....................................................................................................... 73 TRACK FRAME........................................................................................................... 76 TRACK FRAME - RECOIL SPRING....................................................................................... 76 IDLER............................................................................................................. 78 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE......................................................................... 78 PC250LC-6LE................................................................................................... 80 CARRIER ROLLER.................................................................................................... 82 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE......................................................................... 82 PC250LC-6LE................................................................................................... 83 TRACK ROLLER...................................................................................................... 84 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE......................................................................... 84 PC250LC-6LE................................................................................................... 85 TRACK SHOE........................................................................................................ 87 STANDARD SHOE................................................................................................. 87 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE......................................................................... 88 PC250LC-6LE................................................................................................... 90 TRIPLE GROUSER SHOE........................................................................................... 92 SWAMP SHOE.................................................................................................... 93 HYDRAULIC PIPING DRAWING.............................................................................................. 94 HYDRAULIC CIRCUIT DIAGRAM............................................................................................. 97 HYDRAULIC TANK........................................................................................................ 99 HYDRAULIC PUMP........................................................................................................100 LS AND PC VALVE...................................................................................................107 LS VALVE..........................................................................................................108 PC VALVE..........................................................................................................113 IN-LINE OIL FILTER....................................................................................................120 CONTROL VALVE.........................................................................................................122 VARIABLE PRESSURE COMPENSATION VALVE..................................................................................134 SAFETY-SUCTION VALVE FOR SERVICE VALVE................................................................................135 SELF-REDUCING PRESSURE VALVE..........................................................................................137 CLSS (CLOSED CENTER LOAD SENSING SYSTEM)..............................................................................143 OPERATION OF CLSS SYSTEM AS A WHOLE...............................................................................173 SWING MOTOR...........................................................................................................192 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE.............................................................................192 PC250LC-6LE.......................................................................................................196 SWING LOCK VALVE..................................................................................................200 RELIEF VALVE PORTION..............................................................................................201 REVERSE PREVENTION VALVE..........................................................................................202 CENTER SWIVEL JOINT...................................................................................................204 4-PORT SWIVEL.....................................................................................................204 6-PORT SWIVEL.....................................................................................................206 TRAVEL MOTOR..........................................................................................................208 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE.............................................................................208 PC250LC-6LE.......................................................................................................212 MOTOR OPERATION...................................................................................................216 PARKING BRAKE OPERATION...........................................................................................218 BRAKE VALVE OPERATION.............................................................................................219 VALVE CONTROL.........................................................................................................222 WORK EQUIPMENT - SWING PPC VALVE......................................................................................223 TRAVEL PPC VALVE......................................................................................................230 SERVICE PPC VALVE.....................................................................................................235 SAFETY LOCK VALVE.....................................................................................................239 PPC ACCUMULATOR.......................................................................................................239 STRUCTURE-TRAVEL SYSTEM...............................................................................................240 EPC SOLENOID VALVE....................................................................................................241 BOOM LOCK VALVE.......................................................................................................244 ADDITIONAL FILTER FOR BREAKER.........................................................................................248 WORK EQUIPMENT........................................................................................................249 DIMENSION.........................................................................................................250 ARM PORTION...................................................................................................250 BUCKET PORTION................................................................................................252 CLEARANCE.........................................................................................................254 HYDRAULIC CYLINDER....................................................................................................256 PC200LC-6LE, PC210-6LE............................................................................................256 BOOM CYLINDER.................................................................................................256 ARM CYLINDER..................................................................................................256 BUCKET CYLINDER...............................................................................................256 PC220LC-6LE, PC250LC-6LE..........................................................................................258 BOOM CYLINDER.................................................................................................258 ARM CYLINDER..................................................................................................258 BUCKET CYLINDER...............................................................................................258 AIR CONDITIONER.......................................................................................................260 ELECTRICAL CIRCUIT NIPPON DENSO AIR CONDITIONER...................................................................262 AIR CONDITIONING (GENERAL)........................................................................................263 BASIC INFORMATION ON AIR CONDITIONERS.........................................................................263 CONDENSER.........................................................................................................272 COMPRESSOR........................................................................................................275 RECEIVER WITH SIGHT GLASS (LIQUID TANK)...........................................................................276 AIR CONDITIONER UNIT..............................................................................................278 ELECTRICAL WIRING DIAGRAM.............................................................................................280 ELECTRICAL CIRCUIT DIAGRAM............................................................................................284 ENGINE CONTROL SYSTEM.................................................................................................285 ELECTRONIC CONTROL SYSTEM.............................................................................................295 TOTAL SYSTEM DIAGRAM..............................................................................................296 COMPONENTS OF SYSTEM..............................................................................................320 MACHINE MONITOR SYSTEM................................................................................................324 SENSORS...............................................................................................................331 20 TESTING, ADJUSTING AND TROUBLESHOOTING.................................................................................335 STANDARD VALUE TABLE FOR ENGINE.......................................................................................337 FOR ENGINE - PC200/210LC-6LE......................................................................................337 FOR ENGINE - PC220/250LC-6LE......................................................................................338 STANDARD VALUE TABLE FOR CHASSIS......................................................................................339 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.............................................................................348 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING......................................................................356 ENGINE................................................................................................................357 FUEL..............................................................................................................357 BLEEDING AIR FROM FUEL CIRCUIT................................................................................357 FUEL PRESSURE.................................................................................................357 HANDLING FUEL SYSTEM DEVICES..................................................................................357 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE........................................................................357 RELEASING RESIDUAL FUEL SYSTEM PRESSURE.......................................................................357 ADJUSTING ENGINE SPEED SENSOR.....................................................................................357 ADJUSTING VALVE CLEARANCE.........................................................................................357 BLOW-BY PRESSURE..................................................................................................357 COMPRESSION PRESSURE..............................................................................................357 ENGINE OIL PRESSURE...............................................................................................357 ENGINE SPEED SENSOR...............................................................................................357 EXHAUST GAS COLOR.................................................................................................357 EXHAUST TEMPERATURE...............................................................................................357 INTAKE AIR PRESSURE (BOOST PRESSURE)..............................................................................357 FAN BELT TENSION......................................................................................................358 BELT TENSION FOR AIR CONDITIONER COMPRESSOR...........................................................................358 SPEED SENSOR..........................................................................................................359 GOVERNOR MOTOR LEVER STROKE...........................................................................................360 HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT.......................................................361 PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)................................................................364 LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE AND LS DIFFERENTIAL PRESSURE)...................................365 CONTROL CIRCUIT OIL PRESSURE..........................................................................................367 SOLENOID VALVE OUTPUT PRESSURE........................................................................................368 PPC VALVE OUTPUT PRESSURE.............................................................................................370 WORK EQUIPMENT l SWING PPC VALVE......................................................................................372 TRAVEL DEVIATION......................................................................................................373 WORK EQUIPMENT - HYDRAULIC DRIFT......................................................................................374 OIL LEAKAGE...........................................................................................................376 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....................................................................378 SWING CIRCLE BEARING CLEARANCE........................................................................................378 TRACK SHOE TENSION....................................................................................................379 BLEEDING AIR..........................................................................................................380 TROUBLESHOOTING GENERAL...............................................................................................383 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................385 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................387 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................388 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...........................................................388 HANDLING WIRING HARNESSES AND CONNECTORS..................................................................388 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES..........................................390 HANDLING CONTROL BOX......................................................................................393 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS.....................................................394 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT..........................................................394 CHECKS BEFORE TROUBLESHOOTING.....................................................................................396 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................398 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................402 T-BRANCH BOX AND T-BRANCH TABLE...................................................................................424 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM............................................................428 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.............................................................429 METHOD OF USING JUDGEMENT TABLE...................................................................................437 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING......................................................................439 CLASSIFICATION OF TROUBLESHOOTING.............................................................................439 STEPS FOR TROUBLESHOOTING.....................................................................................439 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..........................................................439 SERVICE CODE TABLE................................................................................................444 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM N-MODE............................................................445 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....................................................................447 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.................................................447 USER CODE MEMORY RETENTION FUNCTION...........................................................................447 INFORMATION CONTAINED IN TESTING PROCEDURES.......................................................................448 N-1 [E218] COMMUNICATION ABNORMALITY..............................................................................450 TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE THROTTLE-PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM]....................453 TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).............................454 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER SYSTEM................454 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.................................................455 USER CODE MEMORY RETENTION FUNCTION...........................................................................455 INFORMATION CONTAINED IN TESTING PROCEDURES.......................................................................456 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................458 JUDGEMENT TABLE FOR ENGINE THROTTLE-PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATEDPARTS.............462 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM......................................................................464 E-1 ABNORMALITY IN ENGINE THROTTLE-PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...........................467 E-2 [E308] ABNORMAL FUEL DIAL SIGNALS.............................................................................468 E-3 [E317] OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"...............................................................470 E-4 [E318] SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"..............................................................472 E-5 [E306] ABNORMAL GOVERNOR POTENTIOMETER SIGNALS................................................................474 E-6 [E315] SHORT IN BATTERY RELAY SYSTEM..........................................................................476 E-7 [E316] STEP OUT IN GOVERNOR MOTOR.............................................................................478 E-8 ENGINE WILL NOT CRANK.........................................................................................480 E-9 ENGINE SPEED IRREGULAR, OR HUNTING............................................................................482 IDLING SPEED IS IRREGULAR.....................................................................................482 HUNTING.......................................................................................................483 E-10 ENGINE HIGH IDLING SPEED IS TOO LOW (LACK OF OUTPUT).........................................................484 E-11 ENGINE DOES NOT STOPENGINE DOES NOT STOP.....................................................................486 E-12 BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..................................................................488 TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER C-MODE-............................................................491 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM....................................................493 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................494 JUDGEMENT TABLE FOR ENGINE THROTTLE-PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.............502 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE.............................................................................504 PC200LC-6LE, PC210LC-6LE, PC220LC-6LE, PC250LC-6LE S/N A83001 and UP..........................................504 PC200LC-6LE, PC220LC-6LE S/N A85001 and UP....................................................................506 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).........................................508 C-2 [E232] SHORT IN PC-EPC SOLENOID...............................................................................510 C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID.......................................................................512 C-4 [E213] OPEN IN SWING PARKING BRAKE SOLENOID...................................................................514 C-5 [E203] SHORT IN SWING HOLDING BRAKE SOLENOID SYSTEM...........................................................516 C-6 [E204] SHORT IN MERGE/DIVIDE SOLENOID.........................................................................518 C-7 [E214] OPEN OF MERGE/DIVIDE SOLENOID..........................................................................520 C-8 [E207] SHORT IN ACTIVE MODE SOLENOID..........................................................................522 C-9 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID..................................................................524 C-10 [E206] SHORT IN TRAVEL SPEED SHIFT SOLENOID..................................................................526 C-11 [E216] OPEN IN TRAVEL SPEED SOLENOID.........................................................................528 C-12 [205] SHORT IN 2 STAGE RELIEF SOLENOID.......................................................................530 C-13 [215] OPEN IN 2 STAGE RELIEF SOLENOID........................................................................532 C-14 [E217] ABNORMAL INPUT FOR MODEL CODE - PC200/ 210LC-6LE......................................................534 C-14 [E217] ABNORMAL INPUT FOR MODEL CODE - PC220/ 250LC-67LE.....................................................536 C-15 [E222] SHORT IN LS-EPC SOLENOID..............................................................................538 C-16 [E223] OPEN IN LS-EPC SOLENOID SYSTEM........................................................................540 C-17 [224] ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL.................................................................542 C-18 [225] ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL.................................................................544 C-19 [E226] ABNORMAL PRESSURE SENSOR POWER SUPPLY.................................................................546 C-20 [E227] ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER................................................548 TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER F-MODE.............................................................551 F-1 SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................552 F-2 TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..................................................................554 F-3 BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................556 F-4 BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................558 F-5 ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..................................................................560 F-6 ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.................................................................562 F-7 BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................564 F-8 BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................566 F-9 SWING LOCK SWITCH DOES NOT LIGHT UP...........................................................................568 F-10 KEROSENE MODE CONNECTION DOES NOT LIGHT UP...................................................................570 F-11 LH KNOB SWITCH DOES NOT LIGHT UP.............................................................................572 TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM H-MODE................................................................575 TABLE OF FAILURE MODES AND CAUSES.................................................................................577 PUMP MERGE/DIVIDER LOGIC..........................................................................................581 SOLENOID ACTUATION TABLE..........................................................................................582 INFORMATION CONTAINED IN TESTING TABLES...........................................................................583 H-1 WORK EQUIPMENT LACKS POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...............................................584 H-2 ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS...................................................................585 H-3 NO WORK EQUIPMENT, TRAVEL OR SWING OPERATION..................................................................586 H-4 ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP...................................................................587 H-5 AUTO DECELERATOR DOES NOT WORK................................................................................588 H-6 FINE CONTROL MODE DOES NOT FUNCTION...........................................................................589 H-7 BOOM MOVES SLOWLY OR LACKS POWER..............................................................................590 H-8 ARM MOVES SLOWLY OR LACKS POWER...............................................................................591 H-9 BUCKET MOVES SLOWLY OR LACKS POWER............................................................................592 H-10 WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION...........................................................593 H-11 WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT.................................................................594 H-12 WORK EQUIPMENT EXCESSIVE LAG TIME............................................................................595 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT...................................................596 H-14 LACK OF POWER WHEN PRESSURE RISES............................................................................597 H-15 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED.......................................598 H-16 WORK EQUIPMENT WITH HEAVIER LOADS MOVES SLOWLY...............................................................599 H-17 SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY............................................................600 H-18 SWING AND TRAVEL, TRAVEL SPEED DROPS SHARPLY.................................................................601 H-19 MACHINE TRAVEL DIRECTION VARIES..............................................................................602 H-20 MACHINE TRAVEL IS SLOW.......................................................................................603 H-21 MACHINE CANNOT BE STEERED OR LACKS POWER.....................................................................604 H-22 TRAVEL SPEED IS TOO SLOW OR TOO FAST.........................................................................605 H-23 TRACKS DO NOT TURN (ON ONE SIDE ONLY)........................................................................606 H-24 MACHINE DOES NOT SWING.......................................................................................607 H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...........................................................608 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING........................................................................609 H-27 SUDDEN SHOCK WHEN STOPPING SWING.............................................................................610 H-28 ABNORMAL NOISE WHEN STOPPING SWING...........................................................................611 H-29 SWING HAS EXCESSIVE DRIFT....................................................................................612 H-30 SWING SPEED IS FASTER THAN SPECIFIED SPEED IN L/O AND F/O MODES..............................................613 TROUBLESHOOTING MACHINE MONITOR SYSTEM M-MODE.........................................................................615 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....................................................................617 ABNORMALITY RETURNS TO NORMAL BY ITSELF.......................................................................617 USER CODE MEMORY RETENTION FUNCTION...........................................................................617 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....................................618 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM......................................................................620 M-1 [E101] ABNORMAL DATA IN ERROR HISTORY.........................................................................622 M-1 [E102] ERROR IN CLOCK DATA IS DISPLAYED.......................................................................622 M-2 [E103] SHORT IN BUZZER OUTPUT OR CONTACT 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS.........................623 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED.............................................................624 M-4 [E108] ENGINE COOLANT TEMPERATURE 105°C DETECTED IS DISPLAYED.................................................625 M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS..................626 A. NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP................................................................626 B. SOME OF THE LAMPS ON MONITOR PANEL DO NOT LIGHT UP.........................................................626 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT..................628 M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE MODEL....629 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH...................................630 A. COOLANT LEVEL FLASHES......................................................................................630 B. ENGINE OIL LEVEL FLASHES...................................................................................632 C. HYDRAULIC OIL LEVEL FLASHES................................................................................633 M-9 PREHEATING IS NOT BEING USED, BUT LIGHTS UP...................................................................634 M-10 WHEN STARTING SWITCH IS TURNED ON, ENGINE STARTED, BASIC CHECK ITEMS FLASH...................................635 A. ALTERNATOR SYSTEM..........................................................................................635 B. ENGINE OIL PRESSURE SYSTEM.................................................................................636 M-11 WHEN STARTING SWITCH IS TURNED ON, CAUTION, EMERGENCY ITEMS FLASH............................................637 A. ALTERNATOR SYSTEM..........................................................................................637 B. ENGINE OIL PRESSURE SYSTEM.................................................................................638 M-12 WHEN STARTING SWITCH IS TURNED ON, ENGINE STARTED, CUATION, EMERGENCY ITEMS FLASH............................639 A. ENGINE OIL PRESSURE FLASHES................................................................................639 B. COOLANT LEVEL FLASHES......................................................................................639 C. BATTERY CHARGE FLASHES.....................................................................................639 D. COOLANT TEMPERATURE........................................................................................640 E. FUEL LEVEL FLASHES.........................................................................................641 F. AIR CLEANER CLOGGING FLASHES...............................................................................642 M-13 WHEN STARTING SWITCH IS TURNED ON, ENGINE STOPPED, BUZZER DOES NOT SOUND FOR 1 SECOND........................643 M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS.....................................................644 M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP............................................................645 M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE......................................................................646 M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY..........................................................647 M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL........................................................................648 M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY.......................................................................649 M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT MONITOR DOES NOT LIGHT UP..........................................650 M-21 SWING PROLIX SWITCH IS TURNED ON, BUT MONITOR DOES NOT FLASH.................................................651 M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING.......................................................652 M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED..........653 M-24 DEFECTIVE FUEL LEVER SENSOR SYSTEM...........................................................................654 M-25 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM..................................................................656 M-26 DEFECTIVE ENGINE OIL SENSOR SYSTEM...........................................................................658 M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM........................................................................660 M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM..................................................................662 M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.......................................664 A. WIPER DOES NOT WORK........................................................................................664 B. WIPER SWITCH IS NOT BEING OPERATED, BUT WIPER IS ACTUATED..................................................668 M-30 WASHER MOTOR DOES NOT WORK OR SWITCH IS NOT BEING USED, BUT WASHER MOTOR IS ACTUATED.........................671 A. WASHER MOTOR DOES NOT WORK.................................................................................671 A1. WHEN E114 IS DISPLAYED................................................................................671 A2. WHEN E114 IS NOT DIPLAYED.............................................................................672 B. SWITCH IS NOT BEING OPERATED, BUT WASHER IS ACTUATED.......................................................673 30 DISASSEMBLY AND ASSEMBLY...............................................................................................675 METHOD OF USING MANUAL................................................................................................679 PRECAUTIONS DURING OPERATION..........................................................................................680 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK........................................................................680 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...................................................................681 PRECAUTIONS WHEN COMPLETING THE OPERATIONS........................................................................682 OTHER PRECAUTIONS.................................................................................................682 SPECIAL TOOL LIST.....................................................................................................683 SKETCHES OF SPECIAL TOOLS.............................................................................................686 ENGINE................................................................................................................687 AFTERCOOLER CORE..................................................................................................687 ALTERNATOR........................................................................................................687 CYLINDER HEAD.....................................................................................................687 ENGINE FRONT SEAL.................................................................................................687 ENGINE OIL COOLER.................................................................................................687 ENGINE REAR SEAL..................................................................................................687 FUEL INJECTION PUMP...............................................................................................687 NOZZLE HOLDER.....................................................................................................687 STARTING MOTOR....................................................................................................687 THERMOSTAT........................................................................................................687 TURBOCHARGER......................................................................................................687 WATER PUMP........................................................................................................687 CONNECTOR REPAIR PROCEDURES...........................................................................................688 CONTACT TERMINAL REMOVAL (HD30 TYPE)..............................................................................688 STRIPING INSULATION...............................................................................................689 CRIMPING CONTACT TERMINAL (HD30 TYPE).............................................................................690 INSERTION OF CONTACT TERMINAL (HD30 TYPE).........................................................................691 CONTACT TERMINAL REMOVAL (DT TYPE)................................................................................692 STRIPING INSULATION...............................................................................................693 CRIMPING CONTACT TERMINAL (DT TYPE)...............................................................................694 INSERTION OF CONTACT TERMINAL (DT TYPE)...........................................................................695 RADIATOR..............................................................................................................696 HYDRAULIC OIL COOLER..................................................................................................696 REMOVAL...........................................................................................................696 INSTALLATION......................................................................................................697 MAIN PUMP.............................................................................................................698 REMOVAL...........................................................................................................698 INSTALLATION......................................................................................................702 DAMPER................................................................................................................702 REMOVAL...........................................................................................................702 INSTALLATION......................................................................................................702 FUEL TANK.............................................................................................................703 REMOVAL...........................................................................................................703 INSTALLATION......................................................................................................703 CENTER SWIVEL JOINT...................................................................................................705 REMOVAL...........................................................................................................705 INSTALLATION......................................................................................................706 DISASSEMBLY.......................................................................................................706 ASSEMBLY..........................................................................................................706 FINAL DRIVE...........................................................................................................707 REMOVAL...........................................................................................................707 INSTALLATION......................................................................................................707 DISASSEMBLY PC200/210/220LC-6LE...................................................................................708 ASSEMBLY PC200/210/220LC-6LE......................................................................................711 DISASSEMBLY PC250LC-6LE...........................................................................................716 ASSEMBLY PC250LC-6LE..............................................................................................719 SPROCKET..............................................................................................................723 REMOVAL...........................................................................................................723 INSTALLATION......................................................................................................723 SWING MOTOR...........................................................................................................724 REMOVAL PC200/210/220.............................................................................................724 INSTALLATION PC200/210/220........................................................................................724 SWING MACHINERY.......................................................................................................725 REMOVAL PC200/210/220.............................................................................................725 INSTALLATION PC200/210/220........................................................................................725 SWING MOTOR AND MACHINERY.............................................................................................726 REMOVAL PC250.....................................................................................................726 INSTALLATION PC250................................................................................................726 SWING MACHINERY.......................................................................................................727 DISASSEMBLY PC200/210/220.........................................................................................727 ASSEMBLY PC200/210/220............................................................................................730 DISASSEMBLY PC250.................................................................................................734 ASSEMBLY PC250....................................................................................................737 REVOLVING FRAME.......................................................................................................742 REMOVAL...........................................................................................................742 INSTALLATION......................................................................................................743 SWING CIRCLE..........................................................................................................744 REMOVAL...........................................................................................................744 INSTALLATION......................................................................................................745 IDLER - RECOIL SPRING.................................................................................................746 REMOVAL...........................................................................................................746 INSTALLATION......................................................................................................746 RECOIL SPRING.........................................................................................................747 DISASSEMBLY.......................................................................................................747 ASSEMBLY..........................................................................................................748 IDLER.................................................................................................................749 DISASSEMBLY.......................................................................................................749 ASSEMBLY..........................................................................................................750 TRACK ROLLER..........................................................................................................752 REMOVAL...........................................................................................................752 INSTALLATION......................................................................................................753 DISASSEMBLY.......................................................................................................754 ASSEMBLY..........................................................................................................755 CARRIER ROLLER........................................................................................................758 REMOVAL...........................................................................................................758 INSTALLATION......................................................................................................758 DISASSEMBLY.......................................................................................................759 ASSEMBLY..........................................................................................................760 TRACK SHOE............................................................................................................762 REMOVAL...........................................................................................................762 INSTALLATION......................................................................................................762 HYDRAULIC TANK........................................................................................................764 REMOVAL...........................................................................................................764 INSTALLATION......................................................................................................765 MAIN PUMP.............................................................................................................766 REMOVAL...........................................................................................................766 INSTALLATION......................................................................................................768 MAIN PUMP INPUT SHAFT OIL SEAL........................................................................................769 REMOVAL...........................................................................................................769 INSTALLATION......................................................................................................769 CONTROL VALVE.........................................................................................................770 REMOVAL...........................................................................................................770 INSTALLATION......................................................................................................772 DISASSEMBLY.......................................................................................................773 ASSEMBLY..........................................................................................................778 PUMP MERGE-DIVIDER VALVE..............................................................................................781 DISASSEMBLY.......................................................................................................781 ASSEMBLY..........................................................................................................781 MAIN RELIEF VALVE.....................................................................................................782 DISASSEMBLY.......................................................................................................782 ASSEMBLY..........................................................................................................782 PC VALVE..............................................................................................................783 REMOVAL...........................................................................................................783 INSTALLATION......................................................................................................784 LS VALVE..............................................................................................................785 REMOVAL...........................................................................................................785 INSTALLATION......................................................................................................785 PC, LS-EPC VALVE......................................................................................................786 REMOVAL...........................................................................................................786 INSTALLATION......................................................................................................786 SOLENOID VALVE........................................................................................................787 REMOVAL...........................................................................................................787 INSTALLATION......................................................................................................787 WORK EQUIPMENT - SWING PPC VALVE......................................................................................788 REMOVAL...........................................................................................................788 INSTALLATION......................................................................................................788 DISASSEMBLY.......................................................................................................789 ASSEMBLY..........................................................................................................790 TRAVEL PPC VALVE......................................................................................................791 REMOVAL...........................................................................................................791 INSTALLATION......................................................................................................791 DISASSEMBLY.......................................................................................................792 ASSEMBLY..........................................................................................................793 BOOM LOCK VALVE.......................................................................................................794 REMOVAL...........................................................................................................794 INSTALLATION......................................................................................................794 BOOM CYLINDER.........................................................................................................795 REMOVAL...........................................................................................................795 INSTALLATION......................................................................................................796 ARM CYLINDER..........................................................................................................797 REMOVAL...........................................................................................................797 INSTALLATION......................................................................................................798 BUCKET CYLINDER.......................................................................................................799 REMOVAL...........................................................................................................799 INSTALLATION......................................................................................................800 HYDRAULIC CYLINDER....................................................................................................801 DISASSEMBLY.......................................................................................................801 ASSEMBLY..........................................................................................................803 WORK EQUIPMENT........................................................................................................807 REMOVAL...........................................................................................................807 INSTALLATION......................................................................................................808 BUCKET................................................................................................................809 REMOVAL...........................................................................................................809 INSTALLATION......................................................................................................810 ARM...................................................................................................................811 REMOVAL...........................................................................................................811 INSTALLATION......................................................................................................812 BUCKET - ARM..........................................................................................................813 REMOVAL...........................................................................................................813 INSTALLATION......................................................................................................814 BOOM..................................................................................................................815 REMOVAL...........................................................................................................815 INSTALLATION......................................................................................................816 OPERATOR’S CAB........................................................................................................817 REMOVAL...........................................................................................................817 INSTALLATION......................................................................................................818 COUNTERWEIGHT.........................................................................................................819 REMOVAL...........................................................................................................819 INSTALLATION......................................................................................................819 ENGINE THROTTLE - PUMP CONTROLLER.....................................................................................820 REMOVAL...........................................................................................................820 INSTALLATION......................................................................................................820 CONTROL STAND CASE....................................................................................................821 REMOVAL...........................................................................................................821 INSTALLATION......................................................................................................822 MONITOR...............................................................................................................823 REMOVAL...........................................................................................................823 INSTALLATION......................................................................................................823 90 OTHERS.................................................................................................................825 ELECTRICAL - PC200/210/220/250LC-6LE S/N A83001 & UP..................................................................827 ELECTRICAL DIAGRAM PART 1 OF 2 (SHEET 1 OF 3) - S/N A83001 & UP - FOLDOUT 1.......................................827 ELECTRICAL DIAGRAM PART 1 OF 2 (SHEET 2 OF 3) - S/N A83001 & UP - FOLDOUT 2.......................................829 ELECTRICAL DIAGRAM PART 1 OF 2 (SHEET 3 OF 3) - S/N A83001 & UP - FOLDOUT 3.......................................831 ELECTRICAL DIAGRAM PART 2 OF 2 (SHEET 1 OF 2) - S/N A83001 & UP - FOLDOUT 4.......................................833 ELECTRICAL DIAGRAM PART 2 OF 2 (SHEET 2 OF 2) - S/N A83001 & UP - FOLDOUT 5.......................................835 ELECTRICAL - PC200/220LC-6LE S/N A85001 & UP..........................................................................837 ELECTRICAL DIAGRAM PART 1OF 2 (SHEET 1 OF 3) - S/N A85001 & UP - FOLDOUT 6........................................837 ELECTRICAL DIAGRAM PART 1 OF 2 (SHEET 2 OF 3) - S/N A85001 & UP - FOLDOUT 7.......................................839 ELECTRICAL DIAGRAM PART 1 OF 2 (SHEET 3 OF 3) - S/N A85001 & UP - FOLDOUT 8.......................................841 ELECTRICAL DIAGRAM PART 2 OF 2 (SHEET 1 OF 2) - S/N A85001 & UP - FOLDOUT 9.......................................843 ELECTRICAL DIAGRAM PART 2 OF 2 (SHEET 2 OF 2) - S/N A85001 & UP - FOLDOUT 10......................................845 HYDRAULIC - PC200/210/220/250LC-6LE S/N A83001 & UP...................................................................847 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 1 OF 5) - S/N A83001 & UP - FOLDOUT 11.....................................847 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 2 OF 5) - S/N A83001 & UP - FOLDOUT 12.....................................849 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 3 OF 5) - S/N A83001 & UP - FOLDOUT 13.....................................851 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 4 OF 5) - S/N A83001 & UP - FOLDOUT 14.....................................853 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 5 OF 5) - S/N A83001 & UP - FOLDOUT 15.....................................855 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 1 OF 3) - S/N A83001 & UP - FOLDOUT 16.....................................857 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 2 OF 3) - S/N A83001 & UP - FOLDOUT 17.....................................859 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 3 OF 3) - S/N A83001 & UP - FOLDOUT 18.....................................861 HYDRAULIC - PC200/220LC-6LE S/N A85001 & UP...........................................................................863 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 1 OF 5) - S/N A85001 & UP - FOLDOUT 19.....................................863 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 2 OF 5) - S/N A85001 & UP - FOLDOUT 20.....................................865 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 3 OF 5) - S/N A85001 & UP - FOLDOUT 21.....................................867 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 4 OF 5) - S/N A85001 & UP - FOLDOUT 22.....................................869 HYDRAULIC DIAGRAM - PART 1 OF 2 (SHEET 5 OF 5) - S/N A85001 & UP - FOLDOUT 23.....................................871 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 1 OF 3) - S/N A85001 & UP - FOLDOUT 24.....................................873 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 2 OF 3) - S/N A85001 & UP - FOLDOUT 25.....................................875 HYDRAULIC DIAGRAM - PART 2 OF 2 (SHEET 3 OF 3) - S/N A85001 & UP - FOLDOUT 26.....................................877
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