Komatsu PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Galeo Excavator Shop Manual PDF

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Komatsu PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Galeo Excavator Shop Manual YEBM200301 – PDF DOWNLOAD

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Komatsu PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Galeo Excavator Shop Manual YEBM200301 – PDF DOWNLOAD 

Language : English
Pages : 631
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Galeo Excavator Shop Manual YEBM200301 – PDF DOWNLOAD 

COVER 1
SUB-COVER 2
CONTENTS 3
SAFETY 4
FOREWORD 6
GENERAL 6
HOW TO READ THE SHOP MANUAL 7
HOISTING INSTRUCTIONS 8
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 9
COATING MATERIALS 11
STANDARD TIGHTENING TORQUE 13
ELECTRIC WIRE CODE 16
UNITS 17
01 GENERAL 18
SPECIFICATION DIMENSION DRAWINGS 19
PC200-7, PC200LC-7 19
DIMENSIONS 19
WORKING RANGES 19
DIMENSIONS 20
WORKING RANGES 20
PC210-7, PC210LC-7 21
DIMENSIONS 21
WORKING RANGES 21
DIMENSIONS 22
WORKING RANGES 22
PC220-7, PC220LC-7 23
DIMENSIONS 23
WORKING RANGES 23
DIMENSIONS 24
WORKING RANGES 24
SPECIFICATIONS 25
PC200-7, PC200LC-7 25
PC210-7, PC210LC-7 27
PC220-7, PC220LC-7 29
WEIGHT TABLE 31
PC200-7, PC200LC-7 31
PC210-7, PC210LC-7 33
PC220-7, PC220LC-7 35
FUEL, COOLANT, AND LUBRICANTS 37
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 38
ENGINE RELATED PARTS 39
RADIATOR·OIL COOLER·AFTERCOOLER 40
POWER TRAIN 41
FINAL DRIVE 42
SWING MACHINERY 44
PC200/210(LC)-7 44
PC220(LC)-7 46
SWING CIRCLE 48
PC200/210(LC)-7 48
PC220(LC)-7 49
TRACK FRAME·RECOIL SPRING 50
IDLER 52
CARRIER ROLLER 54
TRACK ROLLER 55
TRACK SHOE 56
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE 56
TRIPLE GROUSER SHOE 59
SWAMP SHOE 59
HYDRAULIC EQUIPMENT LAYOUT DRAWING 60
HYDRAULIC TANK 62
HYDRAULIC PUMP 63
HPV95+95 63
LS VALVE 68
PC VALVE 68
FUNCTION 69
OPERATION 70
LS(PC)-EPC VALVE 81
FUNCTION 82
OPERATION 82
CONTROL VALVE 84
CONTROL VALVE 84
PC200/210(LC)-7 84
OUTLINE 84
ARM CONTROL VALVE 90
R H TRAVEL CONTROL VALVE 90
BUCKET CONTROL VALVE 92
SERVICE VALVE 92
SWING CONTROL VALVE 93
BOOM CONTROL VALVE 93
L H TRAVEL CONTROL VALVE 93
PC220(LC)-7 97
OUTLINE 97
ARM CONTROL VALVE 103
R H TRAVEL CONTROL VALVE 103
BUCKET CONTROL VALVE 105
SERVICE VALVE 105
SWING CONTROL VALVE 106
BOOM CONTROL VALVE 106
L H TRAVEL CONTROL VALVE 106
MAIN RELIEF VALVE 110
FUNCTION 110
OPERATION 110
VARIABLE PRESSURE COMPENSATION VALVE 111
CLSS 112
OUTLINE OF CLSS 112
FEATURES 112
STRUCTURE 112
SELF PRESSURE REDUCING VALVE 115
FUNCTION 115
OPERATION 115
SWING MOTOR 118
SPECIFICATIONS 118
RELIEF VALVE PORTION 122
REVERSE PREVENTION VALVE 123
CENTER SWIVEL JOINT 125
TRAVEL MOTOR 126
OPERATION OF MOTOR 129
OPERATION OF PARKING BRAKE 131
OPERATION OF BRAKE VALVE 132
TRAVEL JUNCTION VALVE 135
FUNCTION 135
OPERATION 135
TRAVEL PPC SHUTTLE VALVE 137
FUNCTION 137
OPERATION 137
OPERTION SYSTEM 139
WORK EQUIPMENT·SWING PPC VALVE 140
OPERATION 142
TRAVEL PPC VALVE 144
OPERATION 147
SERVICE PPC VALVE 153
OPERATION 154
WHEN OPERATED 154
SOLENOID VALVE 156
OPERATION 157
WHEN SOLENOID IS TURNED OFF 157
WHEN SOLENOID IS TURNED ON 157
PPC ACCUMULATOR 158
SPECIFICATIONS 158
RETURN OIL FILTER 159
FOR BREAKER 159
SPECIFICATIONS 159
BOOM HYDRAULIC DRIFT PREVENTION VALVE 160
FUNCTION 161
LIFT CHECK VALVE 163
FUNCTION 163
OPERATION 163
ATTACHMENT CIRCUIT SELECTOR VALVE 164
FUNCTION 164
OPERATION 165
HYDRAULIC CYLINDER 166
PC200/210(LC)-7 166
BOOM CYLINDER 166
ARM CYLINDER 166
BUCKET CYLINDER 166
100 HOURS GREASING 167
500 HOURS GREASING 167
PC220(LC)-7 168
BOOM CYLINDER 168
ARM CYLINDER 168
BUCKET CYLINDER 168
100 HOURS GREASING 169
500 HOURS GREASING 169
WORK EQUIPMENT 170
PC200/210(LC)-7 171
100 HOURS GREASING 171
500 HOURS GREASING 171
PC220(LC)-7 172
100 HOURS GREASING 172
500 HOURS GREASING 172
1 DIMENSION OF ARM 173
2 DIMENSION OF BUCKET 175
AIR CONDITIONER 177
AIR CONDITIONER PIPING 177
ENGINE CONTROL 178
1 OPERATION OF SYSTEM 179
1 COMPONENT 180
GOVERNOR MOTOR 181
GOVERNOR AND PUMP CONTROLLER 182
ELECTRONIC CONTROL SYSTEM 184
MACHINE CONTROL SYSTEM DIAGRAM 185
1 ENGINE AND PUMP CONTROL FUNCTION 187
FUNCTION 188
MODE E / MODE B/(MODE L) 190
2 PUMP/VALVE CONTROL FUNCTION 192
FUNCTION 192
3 ONE-TOUCH POWER MAXIMIZING FUNCTION 194
FUNCTION 194
4 AUTO-DECELERATION FUNCTION 196
FUNCTION 196
OPERATION 197
WHEN CONTROL LEVERS ARE SET IN NEUTRAL 197
WHEN ANY CONTROL LEVER IS OPERATED 197
5 AUTO-WARM-UP/OVERHEAT PREVENTION 198
FUNCTION 198
6 SWING CONTROL FUNCTION 200
FUNCTION 200
7 TRAVEL CONTROL FUNCTION 202
FUNCTION 202
8 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION(OPTION) 204
FUNCTION 204
9 SYSTEM COMPONENT PARTS 205
FUNCTION 205
MULTI MONITOR SYSTEM 208
1 MONITOR PANEL 209
OUTLINE 209
MONITOR CONTROL, DISPLAY PORTION 211
MONITOR PORTION 211
MONITOR ITEMS AND DISPLAY 212
SWITCHES 216
FLOW RATE ADJUSTMENT FUNCTION 219
METHOD OF USE 219
MAINTENANCE FUNCTION 222
METHOD OF CHECKING STATUS MAINTENANCE ITEMS 223
MAINTENANCE OPERATION 223
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION 224
ADJUSTMENT METHOD 224
SERVICE METER CHECK FUNCTION 225
DISPLAY LCD CHECK FUNCTION 225
USER CODE DISPLAY FUNCTION 226
20 TESTING AND ADJUSTING 228
TESTING AND ADJUSTING 246
INSPECTION AND ADJUSTMENT OF ENGINE RPM 247
MEASUREMENT OF EXHAUST GAS COLOR 249
ADJUSTMENT OF VALVE CLEARANCE 250
MEASUREMENT OF COMPRESSION PRESSURE 252
MEASUREMENT OF BLOW-BY PRESSURE 253
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 254
MEASUREMENT OF ENGINE OIL PRESSURE 256
ADJUSTMENT OF ENGINE SPEED SENSOR 257
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION 257
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM 258
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 259
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION 260
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL 261
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE 265
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE 266
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE 269
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE 273
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE 276
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE 277
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT 278
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 279
MEASUREMENT OF OIL LEAKAGE AMOUNT 280
AIR BLEEDING OF VARIOUS PARTS 282
INSPECTION PROCEDURES FOR DIODE 284
SPECIAL FUNCTION OF MULTI-MONITOR PANEL 285
MONITOR PANEL FUNCTIONS-COVENTIONAL AND SPECIAL 286
OPERATION OF OPERATOR’S MENU AND DISPLAY (OUTLINE) 287
TABLE FOR SERVICE AND FAILURE CODE NOS 292
OPERATION AND DISPLAY OF SERVICE MENU 294
TABLE FOR MONITORING ITEMS 297
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM 309
PM-TUNE UP SERVICE (PC200,200LC-7) 310
PM-TUNE UP SERVICE (PC220,220LC-7) 314
TROUBLESHOOTING 318
POINTS TO REMEMBER WHEN TROUBLESHOOTING 319
SEQUENCE OF EVENTS IN TROUBLESHOOTING 320
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 321
CHECKS BEFORE TROUBLESHOOTING 329
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 330
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM 334
CONNECTOR LOCATION STEREOGRAM 340
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) 345
GOVERNOR CONTROL SYSTEM CIRCUIT DIAGRAM (G GIRCUIT) OF GOVERNOR-PUMP CONTROLLER 347
PUMP CONTROL SYSTEM CIRCUIT DIAGRAM(P CIRCUIT) OF GOVERNOR-PUMP CONTROLLER 349
CONNECTON TABLE FOR CONNECTOR PIN NUMBERS 351
X TYPE CONNECTOR 351
SWP TYPE CONNECTOR 352
M TYPE CONNECTOR 354
S TYPE CONNECTOR 355
MIC TYPE CONNECTOR 357
AMP040 TYPE CONNECTOR 359
L TYPE CONNECTOR 361
CONNECTOR FOR PA 361
BENDIX MS CONNECTOR 361
KES 1 (AUTOMOBILE) CONNECTOR 362
CONNECTOR FOR RELAY (SOCKET TYPE) 363
F TYPE CONNECTOR 364
HD30 SERIES CONNECTOR 365
DT SERIES CONNECTOR 370
DTM SERIES CONNECTOR 372
DTHD SERIES CONNECTOR 372
TROUBLESHOOTING WHEN SERVICE CODE 373
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 375
SERVICE CODE IN ELECTRICAL SYSTEM E101(ABNORMAL DATA IN ERROR HISTORY) 377
SERVICE CODE IN ELECTRICAL SYSTEM E112(SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 379
SERVICE CODE IN ELECTRICAL SYSTEM E113(SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 381
SERVICE CODE IN ELECTRICAL SYSTEM E114(SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM) 383
SERVICE CODE IN ELECTRICAL SYSTEM E115(ABNORMAL WINDSHIELD WIPER MOTION) 385
SERVICE CODE IN ELECTRICAL SYSTEM E116(ABNORMALITY IN RETRACTING WINDSHIELD WIPER) 387
SERVICE CODE IN ELECTRICAL SYSTEM E201 (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID) 389
SERVICE CODE IN ELECTRICAL SYSTEM E203 (SHORT-CIRCUITING IN SWING AND PARKING BRAKE SOLENOID-IN GOVERNOR·PUMP CONTROLLER SYSTEM 391
SERVICE CODE IN ELECTRICAL SYSTEM E204 (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID) 393
SERVICE CODE IN ELECTRICAL SYSTEM E205 (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID) 395
SERVICE CODE IN ELECTRICAL SYSTEM E206 (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID) 397
SERVICE CODE IN ELECTRICAL SYSTEM E211(DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID) 399
SERVICE CODE IN ELECTRICAL SYSTEM E213(DISCONNECTION IN SWING PARKING BRAKE SOLENOID) 401
SERVICE CODE IN ELECTRICAL SYSTEM E214 (DISCONNECTION OF MERGE/DIVIDE SOLENOID) 403
SERVICE CODE IN ELECTRICAL SYSTEM E215(DISCONNECTION IN 2-STAGE RELIEF SOLENOID) 405
SERVICE CODE IN ELECTRICAL SYSTEM E216(DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID) 407
SERVICE CODE IN ELECTRICAL SYSTEM E217 (ABNORMALITY IN INPUTTING MODEL CODE) 409
PC200/210(LC)-7 409
PC220(LC)-7 411
SERVICE CODE IN ELECTRICAL SYSTEM E218 (DISCONNECTION OF S-NET SIGNAL) 413
SERVICE CODE IN ELECTRICAL SYSTEM E222(SHORT-CIRCUITING IN LS-EPC SOLENOID) 415
SERVICE CODE IN ELECTRICAL SYSTEM E223(DISCONNECTION IN LS-EPC SOLENOID SYSTEM) 416
SERVICE CODE IN ELECTRICAL SYSTEM E224(ABNORMALITY IN F PUMP PRESSURE SENSOR) 417
SERVICE CODE IN ELECTRICAL SYSTEM E225(ABNORMALITY IN R PUMP PRESSURE SENSOR) 419
SERVICE CODE IN ELECTRICAL SYSTEM E226(ABNORMALITY IN PRESSURE SENSOR POWER SOURCE) 421
SERVICE CODE IN ELECTRICAL SYSTEM E227 (ABNORMALITY IN ENGINE ROTATION SENSOR IN GOVERNOR·PUMP CONTROLLER SYSTEM) 423
SERVICE CODE IN ELECTRICAL SYSTEM E228 (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY) 424
SERVICE CODE IN ELECTRICAL SYSTEM E232(SHORT-CIRCUITING IN PC-EPC SOLENOID) 425
SERVICE CODE IN ELECTRICAL SYSTEM E233(DISCONNECTION IN PC-EPC SOLENOID SYSTEM) 427
SERVICE CODE IN ELECTRICAL SYSTEM E238(DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY) 429
SERVICE CODE IN ELECTRICAL EQUIOMENT E245(SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY) 431
SERVICE CODE IN ELECTRICAL SYSTEM E246(DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY) 432
SERVICE CODE IN ELECTRICAL SYSTEM E256 (INCORRECT NONVOLATILE MEMORY DATA) 433
SERVICE CODE IN ELECTRICAL SYSTEM E306 (ABNORMALITY IN GOVERNOR POTENTIOMETER) 434
SERVICE CODE IN ELECTRICAL SYSTEM E308(ABNORMALITY IN FUEL DIAL) 436
SERVICE CODE IN ELECTRICAL SYSTEM E315 (SHORT-CIRCUITING IN BATTERY RELAY) 438
SERVICE CODE IN ELECTRICAL SYSTEM E316(STEP-OUT IN GOVERNOR MOTOR) 440
SERVICE CODE IN ELECTRICAL SYSTEM E317(DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B) 441
SERVICE CODE IN ELECTRICAL SYSTEM E318(SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PHASE B) 443
SERVICE CODE IN ELECTRICAL SYSTEM E501(“MODEL SELECTION” FUNCTION NOT PROVIDED YET) 445
SERVICE CODE IN ELECTRICAL SYSTEM E502(MODEL SELECTING SIGNAL FAULT) 446
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING) 447
FAILURE CODE IN MECHANICAL SYSTEM A000N2 (OUT-OF-RATE ENGINE ROTATION AT LOW IDLING) 447
FAILURE CODE IN MECHANICAL SYSTEM AA10NX(AIR CLEANER CLOGGING) 448
FAILURE CODE IN MECHANICAL SYSTEM AB00KE(ABNORMALLY LOWERED CHARGING VOLTAGE) 449
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ABNORMALLY LOWERED ENGINE OIL PRESSURE) 451
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK(ABNORMALLY LOWERED ENGINE OIL LEVEL) 452
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS(ENGINE COOLING WATER OVERHEATING) 453
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK(ABNORMALLY LOWERED RADIATOR WATER LEVEL) 454
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDRAULIC OIL OVERHEATING) 455
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 456
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 457
E-1 ENGINE DOES NOT START(ENGINE DOES NOT ROTATE) 458
E-2 ENGINE STOPS WHILE IN OPERATION 461
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING 462
E-4 ENGINE DOES NOT STOP 464
E-5 AUTO-DECELERATOR DOES NOT WORK 466
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK 467
E-7 PREHEATER DOES NOT WORK 468
E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE 470
E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK 472
E-10 NO DISPLAY IN MONITOR PANEL AT ALL 473
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING 474
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 474
E-13 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING 475
E-14 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 476
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 477
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY 478
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 479
E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 481
E-19 WINDSHIELD WIPER DOES NOT WORK 482
E-20 ALARMING BUZZER CANNOT BE CANCELLED 484
E-21 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 485
E-22 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 486
E-23 “ARM DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 487
E-24 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 488
E-25 “BUCKET DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 489
E-26 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 490
E-27 “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 491
E-28 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 493
E-29 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 495
E-30 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 497
E-31 AIR CONDITIONER DOES NOT WORK 499
E-32 TRAVEL ALARM DOES NOT SOUND 500
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 502
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 229
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 231
FLOW CONTROL CHARACTERISTIC OF PC VALVE(STD) 245
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 503
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 505
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 506
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS 507
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE 508
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 508
H-5 AUTO-DECELERATOR DOES NOT WORK 509
H-6 FINE CONTROL MODE DOES NOT FUNCTION 509
H-7 BOOM MOVES SLOWLY OR LACKS LACKS POWER 510
H-8 ARM MOVES SLOWLY OR LACKS POWER 511
H-9 BUCKET MOVES SLOWLY OR LACKS POWER 512
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 512
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT 513
H-12 WORK EQUIPMENT HAS BIG TIME LAG 514
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT 514
H-14 ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE 514
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY 515
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY 515
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 515
H-18 MACHINE SWERVES IN TRAVEL 516
H-19 MACHINE TRAVELS SLOWLY 517
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER 518
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST 519
H-22 TRACK SHOE DOES NOT TURN(ON ONE SIDE ONLY) 520
H-23 MACHINE DOES NOT SWING 521
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 522
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING 523
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING 524
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING 524
H-28 SWING NATURAL DRIFT IS TOO BIG 525
30 DISASSEMBLY AND ASSEMBLY 526
HOW TO READ THIS MANUAL 528
REMOVAL AND INSTALLATION OF ASSEMBLIES 528
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES 529
PRECAUTIONS WHEN PERFORMING OPERATION 530
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY 532
REMOVAL 532
INSTALLATION 532
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 533
REMOVAL 533
INSTALLATION 535
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 537
REMOVAL 537
INSTALLATION 537
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 539
REMOVAL 539
INSTALLATION 540
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 541
SPECIAL TOOLS 541
REMOVAL 541
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 547
REMOVAL 547
INSTALLATION 548
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 549
REMOVAL 549
INSTALLATION 550
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES 551
SPECIAL TOOLS 551
REMOVAL 551
INSTALLATION 555
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 557
REMOVAL 557
INSTALLATION 557
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY 558
SPECIAL TOOLS 558
DISASSEMBLY 558
ASSEMBLY 560
SKETCHES OF SPECIAL TOOLS 565
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 566
REMOVAL 566
INSTALLATION 566
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 567
SPECIAL TOOLS 567
DISASSEMBLY 567
ASSEMBLY 569
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 574
SPECIAL TOOLS 574
ASSEMBLY 574
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 575
SPECIAL TOOLS 575
ASSEMBLY 575
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 576
SPECIAL TOOLS 576
DISASSEMBLY 576
ASSEMBLY 577
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 579
SPECIAL TOOLS 579
DISASSEMBLY 579
ASSEMBLY 580
REMOVAL AND INSTALLATION OF SPROCKET 581
REMOVAL 581
INSTALLTION 581
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 582
SPECIAL TOOLS 582
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY(IRON) 582
INSTALLATION 583
REMOVAL AND EXPANSION OF ROAD LINERS 584
INSTALLATION OF ROAD LINERS 585
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY 586
REMOVAL 586
INSTALLATION 586
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY 587
REMOVAL 587
INSTALLATION 588
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 589
REMOVAL 589
INSTALLATION 590
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 591
SPECIAL TOOLS 591
DISASSEMBLY 591
ASSEMBLY 591
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 592
REMOVAL 592
INSTALLATION 593
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSMEBLY 594
REMOVAL 594
INSTALLATION 596
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 597
SPECIAL TOOLS 597
ASSEMBLY 598
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 600
SPECIAL TOOLS 600
REMOVAL 600
INSTALLATION 602
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT 603
SPECIAL TOOLS 603
REMOVAL 603
INSTALLATION 603
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 604
ASSEMBLY 604
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 605
ASSEMBLY 605
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 606
SPECIAL TOOLS 606
DISASSEMBLY 606
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 612
SPECIAL TOOLS 612
REMOVAL 612
INSTALLATION 613
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 615
SPECIAL TOOLS 615
REMOVAL 615
INSTALLATION 617
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY 618
REMOVAL 618
INSTALLATION 618
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 619
REMOVAL 619
INSTALLATION 621
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY 621
REMOVAL 621
INSTALLATION 621
REMOVAL AND INSTALLATION OF GOVERNOR PUMP CONTROLLER ASSEMBLY 622
REMOVAL 622
INSTALLATION 622
90 OTHERS 623
HYDRAULIC CIRCUIT DIAGRAM (PC200,210(LC)-7) 624
HYDRAULIC CIRCUIT DIAGRAM (PC220,220LC-7) 625
ELECTRICAL CIRCUIT DIAGRAM(1/4) 626
ELECTRICAL CIRCUIT DIAGRAM(2/4) 627
ELECTRICAL CIRCUIT DIAGRAM(3/4) 628
ELECTRICAL CIRCUIT DIAGRAM(4/4) 629
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER(PC200,210,220(LC)-7) 630
UNDER COVER 631

DESCRIPTION:

Komatsu PC200-7 PC200LC-7 PC210-7 PC210LC-7 PC220-7 PC220LC-7 Galeo Excavator Shop Manual YEBM200301 – PDF DOWNLOAD 

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 26/12/24