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Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual SEBM024314 – PDF DOWNLOAD
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Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
MACHINE MODEL SERIAL NUMBER
PC200-7 200001 and up
PC200LC-7 200001 and up
PC220-7 60001 and up
PC220LC-7 60001 and up
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Description
FILE DETAILS:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200-7, PC200LC-7, PC220-7, PC220LC-7
Serial Number: 200001 and up, 60001 and up
Book Code: SEBM024314
Language: English
Pages: 840
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC200-7, PC200LC-7, PC220-7, PC220LC-7 Excavator Shop Manual
COVER................................................................................................................................. 1
CONTENTS.............................................................................................................................. 2
01 GENERAL............................................................................................................................ 36
SPECIFICATION DIMENSION DRAWINGS ................................................................................................. 37
PC200-7, PC200LC-7............................................................................................................ 37
PC220-7, PC220LC-7............................................................................................................ 39
SPECIFICATIONS.................................................................................................................... 41
PC200-7, PC200LC-7............................................................................................................ 41
PC220-7, PC220LC-7............................................................................................................ 43
WEIGHT TABLE...................................................................................................................... 45
PC200-7, PC200LC-7............................................................................................................ 45
PC220-7, PC220LC-7............................................................................................................ 47
FUEL, COOLANT, AND LUBRICANTS..................................................................................................... 49
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD...................................................................................... 50
ENGINE RELATED PARTS.............................................................................................................. 51
RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................... 52
POWER TRAIN....................................................................................................................... 53
FINAL DRIVE....................................................................................................................... 54
SWING MACHINERY................................................................................................................... 56
PC200-7, PC200LC-7............................................................................................................ 56
PC220-7, PC220LC-7............................................................................................................ 58
SWING CIRCLE...................................................................................................................... 60
PC200-7, PC200LC-7............................................................................................................ 60
PC220-7, PC220LC-7............................................................................................................ 61
TRACK FRAME・RECOIL SPRING......................................................................................................... 62
IDLER............................................................................................................................. 64
CARRIER ROLLER.................................................................................................................... 66
TRACK ROLLER...................................................................................................................... 67
TRACK SHOE........................................................................................................................ 68
HYDRAULIC EQUIPMENT LAYOUT DRAWING................................................................................................ 72
HYDRAULIC TANK.................................................................................................................... 74
HYDRAULIC PUMP.................................................................................................................... 75
CONTROL VALVE..................................................................................................................... 96
PC200-7, PC200LC-7............................................................................................................ 96
PC220-7, PC220LC-7............................................................................................................109
CLSS..............................................................................................................................125
SELF PRESSURE REDUCING VALVE......................................................................................................128
SWING MOTOR.......................................................................................................................131
REVERSE PREVENTION VALVE..........................................................................................................136
CENTER SWIVEL JOINT...............................................................................................................138
TRAVEL MOTOR......................................................................................................................139
TRAVEL JUNCTION VALVE.............................................................................................................148
STROKE REGULATION WHEN TRAVELLING.................................................................................................150
VALVE CONTROL.....................................................................................................................152
WORK EQUIPMENT・SWING PPC VALVE....................................................................................................153
TRAVEL PPC VALVE..................................................................................................................157
SERVICE PPC VALVE.................................................................................................................166
SOLENOID VALVE....................................................................................................................169
PPC ACCUMULATOR...................................................................................................................171
RETURN OIL FILTER ................................................................................................................172
BOOM HYDRAULIC DRIFT PREVENTION VALVE.............................................................................................173
LIFT CHECK VALVE..................................................................................................................176
ATTACHMENT CIRCUIT SELECTOR VALVE.................................................................................................177
HYDRAULIC CYLINDER................................................................................................................179
PC200-7, PC200LC-7............................................................................................................179
PC220-7, PC220LC-7............................................................................................................181
WORK EQUIPMENT....................................................................................................................183
AIR CONDITIONER...................................................................................................................190
ENGINE CONTROL....................................................................................................................191
ELECTRONIC CONTROL SYSTEM ........................................................................................................197
MULTI MONITOR SYSTEM..............................................................................................................221
7-SEGMENT MONITOR SYSTEM..........................................................................................................241
SENSOR............................................................................................................................248
20 TESTING AND ADJUSTING..............................................................................................................251
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....................................................................................252
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....................................................................................254
TESTING AND ADJUSTING.............................................................................................................269
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................................270
INSPECTION AND ADJUSTING OF ENGINE RPM........................................................................................272
MEASUREMENT OF EXHAUST GAS COLOR..............................................................................................274
ADJUSTMENT OF VALVE CLEARANCE.................................................................................................275
MEASUREMENT OF COMPRESSION PRESSURE...........................................................................................277
MEASUREMENT OF BLOW-BY PRESSURE...............................................................................................278
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING............................................................................279
MEASUREMENT OF ENGINE OIL PRESSURE............................................................................................281
ADJUSTMENT OF ENGINE SPEED SENSOR.............................................................................................282
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION......................................................................282
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM.........................................................................283
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.............................................................................284
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...............................................................................285
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL.................286
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.....................................................................290
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE.............................................................291
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE.............................................................294
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.................................................................................299
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE......................................................................................302
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE..............................................................................303
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................304
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................305
MEASUREMENT OF OIL LEAKAGE AMOUNT.............................................................................................306
AIR BLEEDING OF VARIOUS PARTS.................................................................................................308
INSPECTION PROCEDURES FOR DIODE...............................................................................................310
SPECIAL FUNCTION OF MULTI-MONITOR PANEL.......................................................................................311
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL.................................................................................336
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM............................................................................353
TROUBLESHOOTING...................................................................................................................363
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................364
SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................365
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................366
CHECKS BEFORE TROUBLESHOOTING ................................................................................................374
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..................................................................................375
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.............................................................379
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................417
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.......................................................................................454
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE.....................................................................................457
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED......................464
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................466
SERVICE CODE IN ELECTRICAL SYSTEM [E101] (ABNORMAL DATA IN ERROR HISTORY).................................................468
SERVICE CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....470
SERVICE CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....472
SERVICE CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................474
SERVICE CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...............................................478
SERVICE CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................480
SERVICE CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................482
SERVICE CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................486
SERVICE CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE / DIVIDE SOLENOID)....................................490
SERVICE CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................494
SERVICE CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................498
SERVICE CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................502
SERVICE CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................506
SERVICE CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF MERGE / DIVIDE SOLENOID).......................................510
SERVICE CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................514
SERVICE CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................518
SERVICE CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)............................................522
SERVICE CODE IN ELECTRICAL SYSTEM [E218] (DISCONNECTION OF S-NET SIGNAL)..................................................526
SERVICE CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................528
SERVICE CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................529
SERVICE CODE IN ELECTRICAL SYSTEM [E224] (ABNORMALITY IN F PUMP PRESSURE SENSOR)..........................................530
SERVICE CODE IN ELECTRICAL SYSTEM [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR)..........................................532
SERVICE CODE IN ELECTRICAL SYSTEM [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)....................................534
SERVICE CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................536
SERVICE CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................537
SERVICE CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................538
SERVICE CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................540
SERVICE CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................542
SERVICE CODE IN ELECTRICAL SYSTEM [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC).....................544
SERVICE CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)(MULTI-MONITOR ONLY)....545
SERVICE CODE IN ELECTRICAL SYSTEM [E256] (INCORRECT NONVOLATILE MEMORY DATA)..............................................546
SERVICE CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................547
SERVICE CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FULE DIAL).......................................................549
SERVICE CODE IN ELECTRICAL SYSTEM [E315] (SHORT-CIRCUITING IN BATTERY RELAY)..............................................551
SERVICE CODE IN ELECTRICAL SYSTEM [E316] (STEP-OUT IN GOVERNOR MOTOR).....................................................553
SERVICE CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................554
SERVICE CODE IN ELECTRICAL SYSTEM [E318] (SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B).........................556
SERVICE CODE IN ELECTRICAL SYSTEM [E501] ("MODEL SELECTION" FUNCTION NOT PROVIDED YET)....................................558
SERVICE CODE IN ELECTRICAL SYSTEM [E502] (MODEL SELECTING SIGNAL FAULT)...................................................559
FAILURE CODE IN MECHANICAL SYSTEM [A000N1] (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLE).....................................560
FAILURE CODE IN MECHANICAL SYSTEM [A000N2] (OUT-OF-RATE ENGINE ROTATION AT LOW IDLE)......................................560
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIR CLEANER CLOGGING).........................................................561
FAILURE CODE IN MECHANICAL SYSTEM [ABOOKE] (ABNORMALLY LOWERED CHARGING VOLTAGE)..........................................562
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ABNORMALLY LOWERED ENGINE OIL PRESSURE).......................................565
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ABNORMALLY LOWERED ENGINE OIL LEVEL)..........................................566
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENGINE COOLANT OVERHEATING)...................................................567
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ABNORMALLY LOWERED RADIATOR COOLANT LEVEL)....................................568
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDRAULIC OIL OVERHEATING)....................................................569
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................570
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................571
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE.............................................................................572
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)........................................................................573
E-2 ENGINE STOPS WHILE IN OPERATION.......................................................................................577
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING........................................................................578
E-4 ENGINE DOES NOT STOP..................................................................................................581
E-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................584
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK..............................................................................585
E-7 PREHEATER DOES NOT WORK...............................................................................................586
E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE......................................................................588
E-9 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK.....................................................................590
E-10 NO DISPLAY IN MONITOR PANEL AT ALL ..................................................................................591
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING..........................................................................592
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL..............................................................592
E-13 FULE LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING........................................................593
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.........................................................594
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...........................................................595
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY................................................................................596
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY........................................................................597
E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS..............................................................599
E-19 WINDSHIELD WIPER DOES NOT WORK.......................................................................................600
E-20 ALARMING BUZZER CANNOT BE CANCELLED..................................................................................602
E-21 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................603
E-22 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................604
E-23 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................605
E-24 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................606
E-25 "BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................607
E-26 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................608
E-27 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...............................................................609
E-28 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION .............................................................611
E-29 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................613
E-30 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.............................................................615
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM...........................................................................617
E-32 TRAVEL ALARM DOES NOT SOUND..........................................................................................629
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...................................................................630
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS.........................................................................631
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................633
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW....................................................634
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...........................................................................635
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE ..............................................................................636
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP....................................................................636
H-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................637
H-6 FINE CONTROL MODE DOES NOT FUNCTION...................................................................................637
H-7 BOOM MOVES SLOWLY OR LACKS POWER......................................................................................638
H-8 ARM MOVES SLOWLY OR LACKS POWER.......................................................................................639
H-9 BUCKET MOVES SLOWLY OR LACKS POWER....................................................................................640
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION.................................................................640
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT....................................................................641
H-12 WORK EQUIPMENT HAS BIG TIME LAG .....................................................................................642
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT.............................................................642
H-14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE.........................................................................642
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGE LOAD MOVES SLOWLY...................................................643
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...................................................................643
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY........................................................................643
H-18 MACHINE SWERVES IN TRAVEL............................................................................................644
H-19 MACHINE TRAVELS SLOWLY...............................................................................................645
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER......................................................................646
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST...............................................................647
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)..........................................................................648
H-23 MACHINE DOES NOT SWING...............................................................................................649
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...................................................................650
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................651
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING...............................................................................652
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...............................................................652
H-28 SWING NATURAL DRIFT IS TOO BIG.......................................................................................653
TROUBLESHOOTING OF ENGINE (S-MODE)............................................................................................654
METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................655
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................659
S-2 ENGINE DOES NOT START.................................................................................................661
(1) ENGINE DOES NOT TURN..............................................................................................661
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)..........................................662
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).........................................663
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................664
S-4 ENGIEN STOPS DURING OPERATIONS ......................................................................................665
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..............................................................................666
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................667
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................668
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...............................................................669
S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................670
S-10 FUEL CONSUMPTION IS EXCESSIVE .......................................................................................671
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN................................................672
S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)................................................................673
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)...............................................................................674
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................675
S-15 ABNORMAL NOISE IS MADE...............................................................................................676
S-16 VIBRATION IS EXCESSIVE...............................................................................................677
30 DISASSEMBLY AND ASSEMBLY...........................................................................................................678
HOW TO READ THIS MANUAL...........................................................................................................680
COATING MATERIALS LIST............................................................................................................682
SPECIAL TOOL LIST.................................................................................................................685
SKETCHES OF SPECIAL TOOLS.........................................................................................................689
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY...............................................................................693
REMOVAL.......................................................................................................................693
INSTALLATION..................................................................................................................693
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY..........................................................................694
SPECIAL TOOLS.................................................................................................................694
REMOVAL.......................................................................................................................694
INSTALLATION..................................................................................................................696
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.....................................................................................698
SPECIAL TOOLS.................................................................................................................698
REMOVAL.......................................................................................................................698
INSTALLATION..................................................................................................................698
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL......................................................................................700
REMOVAL.......................................................................................................................700
INSTALLATION..................................................................................................................701
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................702
SPECIAL TOOLS.................................................................................................................702
REMOVAL.......................................................................................................................702
INSTALLATION..................................................................................................................705
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY.....................................................................................708
REMOVAL.......................................................................................................................708
INSTALLATION..................................................................................................................709
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.........................................................................710
REMOVAL.......................................................................................................................710
INSTALLATION..................................................................................................................711
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES..................................................................712
SPECIAL TOOLS.................................................................................................................712
REMOVAL.......................................................................................................................712
INSTALLATION..................................................................................................................716
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY..................................................................................718
REMOVAL.......................................................................................................................718
INSTALLATION..................................................................................................................718
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..................................................................................719
SPECIAL TOOLS.................................................................................................................719
DISASSEMBLY...................................................................................................................719
ASSEMBLY......................................................................................................................721
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................726
REMOVAL.......................................................................................................................726
INSTALLATION..................................................................................................................726
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................728
SPECIAL TOOLS.................................................................................................................728
DISASSEMBLY...................................................................................................................728
ASSEMBLY......................................................................................................................730
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................735
SPECIAL TOOLS.................................................................................................................735
DISASSEMBLY...................................................................................................................735
ASSEMBLY......................................................................................................................737
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY...............................................................................749
SPECIAL TOOLS.................................................................................................................749
ASSEMBLY......................................................................................................................749
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.................................................................................750
SPECIAL TOOLS.................................................................................................................750
ASSEMBLY......................................................................................................................750
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY........................................................................................751
SPECIAL TOOLS.................................................................................................................751
DISASSEMBLY...................................................................................................................751
ASSEMBLY......................................................................................................................752
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................................................................................754
SPECIAL TOOLS.................................................................................................................754
DISASSEMBLY...................................................................................................................754
ASSEMBLY......................................................................................................................755
REMOVAL AND INSTALLATION OF SPROCKET..............................................................................................756
REMOVAL.......................................................................................................................756
INSTALLATION..................................................................................................................756
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY...................................................................................757
SPECIAL TOOLS.................................................................................................................757
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON)...........................................................................757
INSTALLATION..................................................................................................................758
REMOVAL AND EXPANSION OF ROAD LINERS..........................................................................................759
INSTALLATION OF ROAD LINERS...................................................................................................760
REMOVAL AND INSTALLATION OF SWING CIRCUIT ASSEMBLY................................................................................761
REMOVAL.......................................................................................................................761
INSTALLATION..................................................................................................................761
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY..............................................................................762
REMOVAL.......................................................................................................................762
INSTALLATION..................................................................................................................763
REMOVAL AND INSTALLATION OF CENTER SWIVEL JIONT ASSEMBLY..........................................................................764
REMOVAL.......................................................................................................................764
INSTALLATION..................................................................................................................765
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY..........................................................................766
SPECIAL TOOLS.................................................................................................................766
DISASSEMBLY...................................................................................................................766
ASSEMBLY......................................................................................................................766
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...............................................................................767
REMOVAL.......................................................................................................................767
INSTALLATION..................................................................................................................768
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY................................................................................769
REMOVAL.......................................................................................................................769
INSTALLATION..................................................................................................................771
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY................................................................................772
SPECIAL TOOLS.................................................................................................................772
ASSEMBLY......................................................................................................................773
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY...............................................................................775
SPECIAL TOOLS.................................................................................................................775
REMOVAL.......................................................................................................................775
INSTALLATION..................................................................................................................777
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT................................................................778
SPECIAL TOOLS.................................................................................................................778
REMOVAL.......................................................................................................................778
INSTALLATION..................................................................................................................778
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................779
DISASSEMBLY...................................................................................................................779
ASSEMBLY......................................................................................................................779
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................781
DISASSEMBLY...................................................................................................................781
ASSEMBLY......................................................................................................................781
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.............................................................................783
SPECIAL TOOLS.................................................................................................................783
ASSEMBLY......................................................................................................................783
DISASSEMBLY...................................................................................................................783
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.............................................................................785
DISASSEMBLY...................................................................................................................785
SPECIAL TOOLS.................................................................................................................785
ASSEMBLY......................................................................................................................785
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...........................................................................787
SPECIAL TOOLS.................................................................................................................787
DISASSEMBLY...................................................................................................................787
ASSEMBLY......................................................................................................................789
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...............................................................................793
SPECIAL TOOLS.................................................................................................................793
REMOVAL.......................................................................................................................793
INSTALLATION..................................................................................................................794
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.........................................................................796
REMOVAL.......................................................................................................................796
INSTALLATION..................................................................................................................798
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.........................................................................799
REMOVAL.......................................................................................................................799
INSTALLATION..................................................................................................................800
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY................................................................................801
REMOVAL.......................................................................................................................801
INSTALLATION..................................................................................................................801
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...............................................................................802
REMOVAL.......................................................................................................................802
INSTALLATION..................................................................................................................803
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...............................................................................804
REMOVAL.......................................................................................................................804
INSTALLATION..................................................................................................................806
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS).....................................................................807
SPECIAL TOOLS.................................................................................................................808
REMOVAL.......................................................................................................................808
INSTALLATION..................................................................................................................809
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.................................................................................817
REMOVAL.......................................................................................................................817
INSTALLATION..................................................................................................................819
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY......................................................................................822
REMOVAL.......................................................................................................................822
INSTALLATION..................................................................................................................822
REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY....................................................................823
REMOVAL.......................................................................................................................823
INSTALLATION..................................................................................................................823
90 OTHERS.............................................................................................................................824
HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................825
PC200-7, PC200LC-7............................................................................................................825
PC220-7, PC220LC-7............................................................................................................826
ELECTRICAL CIRCUIT DIAGRAM (PC200-7, PC200LC-7 : SERIAL NO. 200001-250000 PC220-7, PC220LC-7 : SERIAL NO. 60001-65000)............827
FOR MULTI MONITOR.............................................................................................................827
FOR 7-SEGMENT MONITOR.........................................................................................................831
ELECTRICAL CIRCUIT DIAGRAM (PC200-7, PC200LC-7 : SERIAL NO. 250001 AND UP, PC220-7, PC220LC-7 : SERIAL NO. 65001 AND UP)..........835
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER....................................................................................839
KOMATSU PC200-7, PC200LC-7, PC220-7, PC220LC-7 EXCAVATOR SHOP MANUAL SEBM024314 – PDF DOWNLOAD:
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