Komatsu PC200-6 PC200LC-6 PC220-6 PC220LC-6 Custom Excavator Shop Manual PDF

Description

Komatsu PC200-6 PC200LC-6 PC220-6 PC220LC-6 Custom Excavator Shop Manual SEBM005602 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC200-6 PC200LC-6 PC220-6 PC220LC-6 Custom Excavator Shop Manual SEBM005602 – PDF DOWNLOAD 

Language : English
Pages : 560
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC200-6 PC200LC-6 PC220-6 PC220LC-6 Custom Excavator Shop Manual SEBM005602 – PDF DOWNLOAD 

COVER 1
CONTENTS 2
01 GENERAL 24
GENERAL ASSEMBLY DRAWING 25
SPECIFICATIONS 27
WEIGHT TABLE 33
LIST OF LUBRICANT AND WATER 37
10 STRUCTURE AND FUNCTION 38
ENGINE RELATED PARTS 39
RADIATOR・OIL COOLER・AFTERCOOLER 40
POWER TRAIN 42
FINAL DRIVE 43
SWING CIRCLE 44
SWING MACHINERY 45
TRACK FRAME・RECOIL SPRING 46
TRACK SHOE 47
HYDRAULIC PIPING DRAWING 49
HYDRAULIC CIRCUIT DIAGRAM 50
HYDRAULIC TANK 52
HYDRAULIC PUMP 53
LINE OIL FILTER 84
CONTROL VALVE 85
CLSS 104
SWING MOTOR 132
CENTER SWIVEL JOINT 135
TRAVEL MOTOR 137
VALVE CONTROL 143
WORK EQUIPMENT・SWING PPC VALVE 144
TRAVEL PPC VALVE 148
SERVICE PPC VALVE 152
ACCUMULATOR (FOR PPC VALVE) 155
PPC SHUTTLE・TRAVEL JUNCTION VALVE 156
EPC SOLENOID VALVE 163
LS CONTROL EPC VALVE 165
ADDITIONAL FILTER FOR BREAKER 168
WORK EQUIPMENT 169
ELECTRICAL WIRING DIAGRAM 170
ELECTRICAL CIRCUIT DIAGRAM 172
ENGINE CONTROL SYSTEM 175
ELECTRICAL CONTROL SYSTEM 176
MACHINE MONITOR SYSTEM 183
20 TESTING AND ADJUSTING 188
TABLE OF JUDGEMENT STANDARD VALUE 189
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 199
TESTING AND ADJUSTING 201
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 202
MEASURING ENGINE SPEED 203
MEASURING EXHAUST GAS COLOR 204
ADJUSTING VALVE CLEARANCE 205
MEASURING COMPRESSION PRESSURE 206
MEASURING BLOWBY PRESSURE 206
TESTING AND ADJUSTING FUEL INJECTION TIMING 207
MEASURING ENGINE OIL PRESSURE 208
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION 209
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 209
ADJUSTING FUEL CONTROL LEVER 210
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 212
TESTING AND ADJUSTING TCC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 214
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 216
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 218
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 224
TESTING SOLENOID VALVE OUTPUT PRESSURE 228
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 230
ADJUSTING WORK EQUIPMENT・SWING PPC VALVE 232
TESTING TRAVEL DEVIATION 233
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 234
MEASURING OIL LEAKAGE 235
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 236
TESTING CLEARANCE OF SWING CIRCLE BEARING 237
TESTING AND ADJUSTING TRACK SHOE TENSION 238
BLEEDING AIR 239
TROUBLESHOOTING 241
POINTS TO REMEMBER WHEN TROUBLESHOOTING 242
SEQUENCE OF EVENTS IN TROUBLESHOOTING 243
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 244
CHECKS BEFORE TROUBLESHOOTING 251
CONNECTOR TYPES AND MOUNTING LOCATIONS 252
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 254
METHOD OF USING TROUBLESHOOTING CHARTS 264
TROUBLESHOOTING OF ENGINE (S MODE) 266
METHOD OF USING TROUBLESHOOTING CHARTS 267
S- 1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 271
S- 2 ENGINE DOES NOT START 272
(1) ENGINE DOES NOT TURN 272
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 273
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 274
S- 3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 275
S- 4 ENGINE STOPS DURING OPERATIONS 276
S- 5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 277
S- 6 ENGINE LACKS OUTPUT (NO POWER) 278
S- 7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 279
S- 8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 280
S- 9 OIL BECOMES CONTAMINATED QUICKLY 281
S-10 FUEL CONSUMPTION IS EXCESSIVE 282
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVER GOES DOWN 283
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 284
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 285
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 286
S-15 ABNORMAL NOISE IS MADE 287
S-16 VIBRATION IS EXCESSIVE 288
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 289
CHART FOR DISTINGUISHING IF FAILURE IS IN ELECTRICAL SYSTEM OR IN HYDRAULIC, MECHANICAL SYSTEM 290
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 292
E- 1 ABNORMALITY IN LS-EPC SOLENOID SYSTEM 294
a) IS NOT ACTUATED (ENGINE SPEED DROPS EXCESSIVELY OR ENGINE STALLS WHEN ENGINE IS MIDRANGE SPEED OR BELOW) 294
b) REMAINS ACTUATED (WORK EQUIPMENT SPEED IS SLOW EVEN WHEN ENGINE IS AT MIDRANGE SPEED OR ABOVE) 295
E- 2 ABNORMALITY IN PUMP TVC CONTROL SYSTEM 296
a) ENGINE STALLS WHEN FUEL CONTROL LEVER IS AT FULL (FUEL CONTROL LEVER LIMIT SWITCH OFF) 296
b) ENGINE STALLS AT BELOW MIDRANGE SPEED (FUEL CONTROL LEVER LIMIT SWITCH ON: ENGINE SPEED BELOW 1650 rpm) 297
c) WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER WHEN FUEL CONTROL LEVER IS AT FULL 298
E- 3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM 300
a) SWING HOLDING BRAKE IS NOT ACTUATED (CANNOT SWING) 300
b) SWING HOLDING BRAKE REMAINS ACTUATED (SWING CANNOT BE LOCKED) 301
E- 4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM 302
a) IS NOT ACTUATED (SAFETY LOCK IS NOT RELEASED) 302
b) REMAINS ACTUATED (SAFETY LOCK IS NOT APPLIED) 303
E- 5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 304
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 306
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM 307
PUMP MERGE/DIVIDER LOGIC 309
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 310
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 312
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 313
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 313
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 313
H-6 BOOM IS SLOW OR LACKS POWER 314
H-7 ARM IS SLOW OR LACKS POWER 316
H-8 BUCKET IS SLOW OR LACKS POWER 318
H-9 WORK EQUIPMENT DOES NOT MOVE (BOOM, ARM, BUCKET) (TRAVEL AND SWING ARE NORMAL) 318
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) 319
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 319
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 320
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 320
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 320
H-15 IN SWING + ARM OUT, ARM OUT IS SLOW 321
H-16 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 321
H-17 TRAVEL DEVIATION (EXCESSIVE DURING NORMAL TRAVEL,WHEN STARTING) 321
H-18 TRAVEL SPEED IS SLOW 322
H-19 STEERING DOES NOT TURN OR LACKS POWER 324
H-20 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 326
H-21 DOES NOT SWING (BOTH LEFT AND RIGHT,ONE DIRECTION ONLY) 327
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY) 328
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY) 330
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 331
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 331
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING (LOCK ON , LOCK OFF) 332
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 333
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM 334
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) 335
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 335
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 336
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 336
b) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP) 336
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 336
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 336
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 337
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 337
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP 338
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP 338
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL) 339
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 339
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 340
a) AFTER ENGINE IS STARTED LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE 340
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 340
c) COOLANT TEMPERATURE GAUGE GOES OUT 340
M-11 ABNORMALITY IN FUEL GAUGE 341
a) ALL FUEL GAUGE SEGMENTS GO OUT 341
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL 341
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL 341
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 343
a) BUZZER DOES NOT SOUND 343
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 343
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE 344
a) CHARGE CAUTION LAMP LIGHTS UP 344
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP 344
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 345
a) GAUGE LIGHTING DOES NOT LIGHT UP 345
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 345
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING 346
a) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED TO ON 346
b) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED TO ON 346
M-16 HEATER DOES NOT WORK 347
a) DOES NOT WORK AT EITHER HI OR LO 347
b) DOES NOT WORK AT LO ONLY 347
c) DOES NOT WORK AT HI ONLY 347
30 DISASSEMBLY AND ASSEMBLY 348
METHOD OF USING MANUAL 350
PRECAUTIONS WHEN CARRYING OUT OPERATION 351
SPECIAL TOOL LIST 353
STARTING MOTOR ASSEMBLY 358
REMOVAL AND INSTALLATION 358
ALTERNATOR ASSEMBLY 358
REMOVAL AND INSTALLATION 358
AIR CONDITIONER COMPRESSOR ASSEMBLY 359
REMOVAL AND INSTALLATION 359
CONDENSER ASSEMBLY 360
REMOVAL AND INSTALLATION 360
ENGINE OIL COOLE CORE ASSEMBLY 361
REMOVAL AND INSTALLATION 361
FUEL INJECTION PUMP ASSEMBLY 362
REMOVAL 362
INSTALLATION 364
WATER PUMP ASSEMBLY 365
REMOVAL AND INSTALLATION 365
NOZZLE HOLDER ASSEMBLY 366
REMOVAL AND INSTALLATION 366
TURBOCHARGER ASSEMBLY 367
REMOVAL AND INSTALLATION 367
THERMOSTAT ASSEMBLY 368
REMOVAL AND INSTALLATION 368
ENGINE FRONT OIL SEAL ASSEMBLY 369
REMOVAL AND INSTALLATION 369
ENGINE REAR OIL SEAL ASSEMBLY 370
REMOVAL AND INSTALLATION 370
CYLINDER HEAD ASSEMBLY 371
REMOVAL 371
INSTALLATION 373
AFTERCOOLER ASSEMBLY 375
REMOVAL AND INSTALLATION 375
HYDRAULIC OIL COOLER ASSEMBLY 376
REMOVAL AND INSTALLATION (PC200-6) 376
REMOVAL AND INSTALLATION (PC220-6) 377
RADIATOR・HYDRAULIC OIL COOLER ASSEMBLY 378
REMOVAL (PC200-6) 378
INSTALLATION (PC200-6) 379
REMOVAL (PC220-6) 380
INSTALLATION (PC220-6) 381
ENGINE・HYDRAULIC PUMP ASSEMBLY 382
REMOVAL 382
INSTALLATION 385
DAMPER ASSEMBLY 386
REMOVAL AND INSTALLATION 386
FUEL TANK ASSEMBLY 387
REMOVAL AND INSTALLATION 387
CENTER SWIVEL JOINT ASSEMBLY 388
REMOVAL AND INSTALLATION 388
DISASSEMBLY AND ASSEMBLY 389
TRAVEL MOTOR, FINAL DRIVE ASSEMBLY 390
REMOVAL AND INSTALLATION 390
FINAL DRIVE ASSEMBLY 391
DISASSEMBLY 391
ASSEMBLY 395
TRAVEL MOTOR ASSEMBLY 401
DISASSEMBLY 401
ASSEMBLY 404
SPROCKET 408
REMOVAL AND INSTALLATION 408
SWING MOTOR ASSEMBLY 409
REMOVAL AND INSTALLATION 409
DISASSEMBLY 410
ASSEMBLY 413
SWING MACHINERY ASSEMBLY 418
REMOVAL AND INSTALLATION 418
DISASSEMBLY 419
ASSEMBLY 422
REVOLVING FRAME ASSEMBLY 426
REMOVAL 426
INSTALLATION 427
SWING CIRCLE ASSEMBLY 428
REMOVAL 428
INSTALLATION 429
IDLER・RECOIL SPRING ASSEMBLY 430
REMOVAL AND INSTALLATION 430
RECOIL SPRING ASSEMBLY 431
DISASSEMBLY 431
ASSEMBLY 432
IDLER ASSEMBLY 433
DISASSEMBLY 433
ASSEMBLY 434
TRACK ROLLER ASSEMBLY 436
REMOVAL AND INSTALLATION 436
DISASSEMBLY 437
ASSEMBLY 438
CARRIER ROLLER ASSEMBLY 440
REMOVAL AND INSTALLATION 440
DISASSEMBLY 441
ASSEMBLY 442
TRACK SHOE ASSEMBLY 444
REMOVAL AND INSTALLATION 444
HYDRAULIC TANK ASSEMBLY 445
REMOVAL 445
INSTALLATION 446
CONTROL PUMP ASSEMBLY 447
REMOVAL AND INSTALLATION 447
MAIN PUMP ASSEMBLY 448
REMOVAL 448
INSTALLATION 449
DISASSEMBLY 452
ASSEMBLY 458
MAIN PUMP INPUT SHAFT OIL SEAL 474
REMOVAL AND INSTALLATION 474
CONTROL VALVE ASSEMBLY 475
REMOVAL 475
INSTALLATION 476
DISASSEMBLY 477
ASSEMBLY 479
PUMP MERGE-DIVIDER VALVE ASSEMBLY 482
DISASSEMBLY AND ASSEMBLY 482
TCC・LS VALVE ASSEMBLY FOR FRONT PUMP 483
REMOVAL AND INSTALLATION 483
TVC・LS VALVE ASSEMBLY FOR FRONT PUMP 484
REMOVAL AND INSTALLATION 484
TCC・LS VALVE ASSEMBLY FOR REAR PUMP 485
REMOVAL AND INSTALLATION 485
TVC・LS VALVE ASSEMBLY FOR REAR PUMP 486
REMOVAL AND INSTALLATION 486
LS CONTROL EPC VALVE ASSEMBLY 487
REMOVAL AND INSTALLATION 487
SOLENOID VALVE ASSEMBLY 488
REMOVAL AND INSTALLATION 488
WORK EQUIPMENT LEFT SIDE PPC VALVE ASSEMBLY 489
REMOVAL AND INSTALLATION 489
WORK EQUIPMENT RIGHT SIDE PPC VALVE ASSEMBLY 490
REMOVAL AND INSTALLATION 490
WORK EQUIPMENT PPC VALVE ASSEMBLY 491
DISASSEMBLY 491
ASSEMBLY 492
TRAVEL PPC VALVE ASSEMBLY 493
REMOVAL AND INSTALLATION 493
DISASSEMBLY AND ASSEMBLY 494
BOOM CYLINDER ASSEMBLY 495
REMOVAL 495
INSTALLATION 496
ARM CYLINDER ASSEMBLY 497
REMOVAL 497
INSTALLATION 498
BUCKET CYLINDER ASSEMBLY 499
REMOVAL 499
INSTALLATION 500
HYDRAULIC CYLINDER ASSEMBLY 501
DISASSEMBLY 501
ASSEMBLY 503
WORK EQUIPMENT ASSEMBLY 506
REMOVAL 506
INSTALLATION 507
BUCKET ASSEMBLY 508
REMOVAL 508
INSTALLATION 509
ARM ASSEMBLY 510
REMOVAL 510
INSTALLATION 511
BUCKET・ARM ASSEMBLY 512
REMOVAL 512
INSTALLATION 513
BOOM ASSEMBLY 514
REMOVAL 514
INSTALLATION 515
OPERATOR’S CAB ASSEMBLY 516
REMOVAL AND INSTALLATION 516
COUNTERWEIGHT ASSEMBLY 517
REMOVAL AND INSTALLATION 517
MONITOR ASSEMBLY 518
REMOVAL AND INSTALLATION 518
40 MAINTENANCE STANDARD 519
SWING MACHINERY 520
SWING CIRCLE 522
FINAL DRIVE 523
TRACK FRAME・RECOIL SPRING 525
IDLER 526
CARRIER ROLLER 528
TRACK ROLLER 529
TRACK SHOE 530
HYDRAUILC PUMP 532
CONTROL VALVE 535
SWING MOTOR 542
TRAVEL MOTOR 543
WORK EQUIPMENT・SWING PPC VALVE 544
SERVICE PPC VALVE 545
PPC SHUTTLE・TRAVEL JUNCTION VALVE 546
LS CONTROL EPC VALVE 548
CENTER SWIVEL JOINT 549
HYDRAULIC CYLINDER 551
WORK EQUIPMENT 555

DESCRIPTION:

Komatsu PC200-6 PC200LC-6 PC220-6 PC220LC-6 Custom Excavator Shop Manual SEBM005602 – PDF DOWNLOAD

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

S.V 24/12/24