Komatsu PC200-5 Custom PC220-5 Custom Excavator Shop Manual PDF

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Komatsu PC200-5 Custom PC220-5 Custom Excavator Shop Manual SEBM0205C503 – PDF DOWNLOAD

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Komatsu PC200-5 Custom PC220-5 Custom Excavator Shop Manual SEBM0205C503 – PDF DOWNLOAD

Language : English
Pages : 473
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC200-5 Custom PC220-5 Custom Excavator Shop Manual SEBM0205C503 – PDF DOWNLOAD 

MACHINE MODEL
РС200-5
РС220-5
SERIAL NO.
45001 and up
35001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu PC200-5 Custom PC220-5 Custom Excavator Shop Manual SEBM0205C503 – PDF DOWNLOAD 

COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 24
POWER TRAIN 25
FINAL DRIVE 26
SWING CIRCLE 27
SWING MACHINERY 28
TRACK FRAME AND RECOIL SPRING 29
IDLER 30
TRACK ROLLER 31
CARRIER ROLLER 31
TRACK SHOE 32
HYDRAULIC PIPING 34
HYDRAULIC CIRCUIT DIAGRAM 35
HYDRAULIC TANK 36
OLSS 37
HYDRAULIC PUMP 39
CONTROL VALVE 55
SWING MOTOR 78
CENTER SWIVEL JOINT 81
TRAVEL MOTOR 82
VALVE CONTROL 88
PPC VALVE 89
ACCUMULATOR 99
SAFETY LOCK VALVE 99
SWING LOCK SOLENOID VALVE 100
SHUTTLE VALVE 102
HYDRAULIC CYLINDER 103
ELECTRICAL CIRCUIT DIAGRAM 105
ENGINE CONTROL SYSTEM 108
EMACC 119
20 TESTING AND ADJUSTING 127
TABLE OF JUDGEMENT STANDARD VALUE 128
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING 144
ADJUSTING VALVE CLEARANCE 145
MEASURING COMPRESSION PRESSURE 146
TESTING AND ADJUSTING FUEL INJECTION TIMING 147
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER 148
ADJUSTING FUEL CONTROL LEVER 149
INSPECTION OF SWING CIRCLE BEARING CLEARANCE 150
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 151
TESTING AND ADJUSTING CHARGING PUMP PRESSURE 153
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE 155
MEASURING STROKE OF SERVO PISTON 162
TESTING AND ADJUSTING TRAVEL DEVIATION 163
MEASURING OUTPUT PRESSURE OF PPC VALVE 165
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 166
TESTING PPC SHUTTLE VALVE 168
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE 168
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 169
BLEEDING AIR 170
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 172
TROUBLESHOOTING 173
POINTS TO REMEMBER WHEN TROUBLESHOOTING 174
SEQUENCE OF EVENTS IN TROUBLESHOOTING 175
PRECAUTION WHEN CARRYING OUT MAINTENANCE 176
CHECKS BEFORE TROUBLESHOOTING 183
ELECTRICAL CIRCUIT DIAGRAM 184
POSITION OF CONNECTORS FOR TROUBLESHOOTING 190
CONNECTION TABLE FOR CONNECTOR 192
HANDLING CONNECTORS 200
DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER 201
ACTION OF SELF-DIAGNOSTION FUNCTION AND SYMPTOMS ON MACHINE 202
METHOD OF PROCEEDING WITH TROUBLESHOOTING 203
METHOD OF USING JUDGEMENT TABLE 204
METHOD OF USING TROUBLESHOOTING CHARTS 206
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) 208
JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATIVE PARTS 209
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM 210
E- 1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF) 211
E- 2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED 213
E- 3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED 214
E- 4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED 215
E- 5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED 216
E- 6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED 217
E- 7 ENGINE DOES NOT START 218
E- 8 ENGINE ROTATION IS IRREGULAR OR LACK OF OUTPUT POWER (MAX ENGINE SPEED IS TOO LOW) 220
E- 9 ENGINE DOES NOT STOP 222
E-10 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE 224
TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE) 225
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM 226
C- 1 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 227
C- 2 DOES NOT SWING (SWING LOCK IS NOT CANCELED) 228
C- 3 SWING LOCK IS NOT ACTUATED 229
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 230
H- 1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW 231
H- 2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 232
H- 3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW 234
H- 4 WORK EQUIPMENT, TRAVEL, SWING LACK POWER 236
H- 5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 236
H- 6 BOOM, ARM SPEED IS EXTREMELY SLOW 237
H- 7 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW 237
H- 8 WHEN BOOM AND ARM ARE OPERATED SIMULTANEOUSLY, BOOM IS SLOW 238
H- 9 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER 238
H-10 EXCESSIVE HYDRAULIC DRIFT 238
H-11 EXCESSIVE TIME LAG 239
H-12 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, ARM IS SLOW 239
H-13 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE 240
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE 240
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE 242
H-14 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS 243
H-15 EXCESSIVE DEVIATION WHEN STARTING 244
H-16 TRAVEL LACKS POWER OR SPEED IS SLOW 246
H-17 MACHINE DOES NOT MOVE (ONE SIDE ONLY) 246
H-18 DOES NOT SWING 247
H-19 SWING SPEED IS SLOW OR ACCELERATION IS POOR 249
H-20 EXCESSIVE OVERRUN WHEN STOPPING SWING 250
H-21 EXCESSIVE SHOCK WHEN STOPPING SWING 250
H-22 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 251
H-23 EXCESSIVE HYDRAULIC DRIFT OF SWING 251
H-24 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW 251
TABLE OF FAILURE MODES AND CAUSES 252
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE) 253
P- 1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON 254
a) NO MONITOR PANEL LAMPS LIGHT UP 254
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP 254
P- 2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT 255
P- 3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 256
a) COOLANT LEVEL FLASHES 256
P- 4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP 257
P- 5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 258
a) ALTERNATOR SYSTEM 258
b) ENGINE OIL PRESSURE SYSTEM 258
P- 6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH 259
P- 7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH 260
a) ENGINE OIL PRESSURE FLASHES 260
b) COOLANT LEVEL FLASHES 260
c) COOLANT TEMPERATURE FLASHES 261
d) CHARGE FLASHES 261
e) FUEL LEVEL FLASHES 262
P- 8 a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND 263
P- 8 b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS 263
P- 9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 264
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE 265
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 265
P-12 FUEL GAUGE ALWAYS FULL 266
P-13 FUEL GAUGE GIVES NO DISPLAY 266
P-14 a) LAMPS DO NOT LIGHT UP 267
P-14 b) LAMPS LIGHT UP EVEN LAMP SWITCH IS NOT OPERATED 267
P-15 a) WIPERS DO NOT WORK 269
P-15 b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED 269
P-16 a) FAN DOES NOT WORK 271
P-16 b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED 271
P-17 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30゜C,OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30゜C 273
P-18 DEFECTIVE SWING LOCK 274
P-19 FUEL LEVEL SENSOR SYSTEM DEFECTIVE 275
P-20 COOLANT TEMPERATURE SYSTEM DEFECTIVE 276
P-21 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE 277
30 DISASSEMBLY AND ASSEMBLY 278
METHOD OF USING MANUAL 280
PRECAUTIONS WHEN CARRYING OUT OPERATION 281
SPECIAL TOOL LIST 283
WEIGHT TABLE 285
TIGHTENING TORQUES AND STANDARD VALUES TABLE 286
LUBRICANT AND COOLANT TABLE 289
STARTING MOTOR 290
REMOVAL AND INSTALLATION 290
ALTERNATOR 290
REMOVAL AND INSTALLATION 290
ENGINE OIL COOLER 292
REMOVAL AND INSTALLATION 292
FUEL INJECTION PUMP 292
REMOVAL AND INSTALLATION 292
WATER PUMP 294
REMOVAL AND INSTALLATION 294
NOZZLE HOLDER 294
REMOVAL AND INSTALLATION 294
TURBOCHARGER 296
REMOVAL AND INSTALLATION 296
THERMOSTAT 296
REMOVAL AND INSTALLATION 296
ENGINE FRONT SEAL 298
REMOVAL AND INSTALLATION 298
ENGINE REAR SEAL 298
REMOVAL AND INSTALLATION 298
GOVERNOR MOTOR 300
REMOVAL AND INSTALLATION 300
CYLINDER HEAD 302
REMOVAL AND INSTALLATION 302
AFTER-COOLER 304
REMOVAL AND INSTALLATION 304
HYDRAULIC COOLER 304
REMOVAL AND INSTALLATION 304
RADIATOR, HYDRAULIC COOLER 306
REMOVAL AND INSTALLATION 306
ENGINE, HYDRAULIC PUMP 308
REMOVAL AND INSTALLATION 308
DAMPER 312
REMOVAL AND INSTALLATION 312
CENTER SWIVEL JOINT 312
REMOVAL AND INSTALLATION 312
DISASSEMBLY AND ASSEMBLY 314
TRAVEL MOTOR 316
REMOVAL AND INSTALLATION 316
DISASSEMBLY 328
ASSEMBLY 331
FINAL DRIVE 316
REMOVAL AND INSTALLATION 316
DISASSEMBLY 318
ASSEMBLY 322
SPROCKET 335
REMOVAL AND INSTALLATION 335
SWING MOTOR 337
REMOVAL AND INSTALLATION 337
DISASSEMBLY 339
ASSEMBLY 342
SWING MACHINERY 337
REMOVAL AND INSTALLATION 337
DISASSEMBLY 347
ASSEMBLY 349
REVOLVING FRAME 355
REMOVAL AND INSTALLATION 355
SWING CIRCLE 357
REMOVAL AND INSTALLATION 357
IDLER, RECOIL SPRING 357
REMOVAL AND INSTALLATION 357
DISASSEMBLY AND ASSEMBLY 359
TRACK ROLLER 361
REMOVAL AND INSTALLATION 361
CARRIER ROLLER 361
REMOVAL AND INSTALLATION 361
TRACK SHOE 363
REMOVAL AND INSTALLATION 363
CHARGING PUMP 365
REMOVAL AND INSTALLATION 365
HYDRAULIC PUMP 365
REMOVAL AND INSTALLATION 365
DISASSEMBLY 367
ASSEMBLY 372
MAIN PUMP INPUT SHAFT OIL SEAL 385
REMOVAL AND INSTALLATION 385
CONTROL VALVE 385
REMOVAL AND INSTALLATION 385
DISASSEMBLY 387
ASSEMBLY 389
MAIN RELIEF VALVE 391
REMOVAL AND INSTALLATION 391
DISASSEMBLY AND ASSEMBLY 391
TVC VALVE 393
REMOVAL AND INSTALLATION 393
CO・NC VALVE 393
REMOVAL AND INSTALLATION 393
SERVO VALVE 393
REMOVAL AND INSTALLATION 393
WORK EQUIPMENT PPC VALVE 395
REMOVAL AND INSTALLATION 395
DISASSEMBLY AND ASSEMBLY 395
TRAVEL PPC VALVE 399
REMOVAL AND INSTALLATION 399
DISASSEMBLY AND ASSEMBLY 399
PPC SHUTTLE VALVE 401
REMOVAL AND INSTALLATION 401
BOOM CYLINDER 401
REMOVAL AND INSTALLATION 401
ARM CYLINDER 403
REMOVAL AND INSTALLATION 403
BUCKET CYLINDER 403
REMOVAL AND INSTALLATION 403
HYDRAULIC CYLINDER 405
DISASSEMBLY 405
ASSEMBLY 407
WORK EQUIPMENT 409
REMOVAL AND INSTALLATION 409
BUCKET 411
REMOVAL AND INSTALLATION 411
ARM 411
REMOVAL AND INSTALLATION 411
ARM, BUCKET 413
REMOVAL AND INSTALLATION 413
BOOM 413
REMOVAL AND INSTALLATION 413
CAB 415
REMOVAL AND INSTALLATION 415
COUNTERWEIGHT 415
REMOVAL AND INSTALLATION 415
ENGINE THROTTLE CONTROLLER 417
REMOVAL AND INSTALLATION 417
MONITOR PANEL 417
REMOVAL AND INSTALLATION 417
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT 419
40 MAINTENANCE STANDARD 427
FINAL DRIVE 428
SWING MACHINERY 430
SWING CIRCLE 432
TRACK FRAME AND RECOIL SPRING 433
IDLER 434
TRACK ROLLER 436
CARRIER ROLLER 437
TRACK SHOE 438
HYDRAULIC PUMP 440
CHARGING PUMP AND RELIEF VALVE 441
CONTROL VALVE 442
TRAVEL SHUTTLE VALVE 463
SWING MOTOR 464
CENTER SWIVEL JOINT 465
TRAVEL MOTOR 466
PPC VALVE 467
HYDRAULIC CYLINDER 470
WORK EQUIPMENT 472

S.V 18/12/24