Komatsu PC200,200LC-5 PC200,200LC-5 MIGHTY PC220,22OLC-5 Shop Manual PDF

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Komatsu PC200,200LC-5 PC200,200LC-5 MIGHTY PC220,22OLC-5 Shop Manual SEBMA2050508 – PDF DOWNLOAD

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Komatsu PC200,200LC-5 PC200,200LC-5 MIGHTY PC220,22OLC-5 Shop Manual SEBMA2050508 – PDF DOWNLOAD

Language : English
Pages :696
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC200,200LC-5 PC200,200LC-5 MIGHTY PC220,22OLC-5 Shop Manual SEBMA2050508 – PDF DOWNLOAD

MACHINE MODEL
PC2004
PC2004 MIGHTY
PC2OOLC-5
PC2OOLC-5 MIGHTY
PC220-5
PC22OLC-5
SERIAL NO.
45001 and up
A70001 and up
58019 and up
45001 and up
A70001 and up
58019 and up
35001 and up
35001 and up
A70001 and uP

FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of
components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu PC200 200LC-5 PC200 200LC-5 MIGHTY PC220 22OLC-5 Shop Manual SEBMA2050508 – PDF DOWNLOAD

MACHINE MODEL
PC2004
PC2004 MIGHTY
PC2OOLC-5
PC2OOLC-5 MIGHTY
PC220-5
PC22OLC-5
SERIAL NO.
45001 and up
A70001 and up
58019 and up
45001 and up
A70001 and up
58019 and up
35001 and up
35001 and up
A70001 and uP

MAIN MENU 0
CONTENTS 2
10 STRUCTURE AND FUNCTION 29
ENGINE RELATED PARTS AND ENGINE MOUNT 30
RADIATOR OIL COOLER AND AFTER-COOLER 31
FUEL TANK AND PIPING 34
POWER TRAIN 36
FINAL DRIVE 37
SWING CIRCLE 39
SWING MACHINERY 40
TRACK FRAME AND RECOIL SPRING 41
IDLER 42
TRACK ROLLER, CARRIER ROLLER 43
TRACK SHOE 44
HYDRAULIC PIPING 47
HYDRAULIC CIRCUIT DIAGRAM 48
HYDRAULIC TANK 54
OLSS (Open center Load Sensing System) 55
HYDRAULIC PUMP 57
CONTROL VALVE 76
SWING MOTOR100
CENTER SWIVEL JOINT 104
TRAVEL MOTOR 106
VALVE CONTROL 113
PPC VALVE 114
ACCUMULATOR 124
SAFETY LOCK VALVE 125
SOLENOID VALVE ASSEMBLY 126
SHUTTLE VALVE 133
BOOM HOLDING VALVE 134
HYDRAULIC CYLINDER 138
ELECTRICAL WIRING DIAGRAM 140
ELECTRICAL CIRCUIT DIAGRAM142
ENGINE CONTROL SYSTEM 153
GOVERNOR MOTOR LINKAGE154
PEMC SYSTEM 166
EMACC201
20 TESTING AND ADJUSTING 209
TABLE OF JUDGEMENT STANDARD VALUE 210
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 226
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 241
ADJUSTING VALVE CLEARANCE 242
MEASURING COMPRESSION PRESSURE243
TESTING AND ADJUSTING FUEL INJECTION TIMING 244
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER 245
INSPECTION OF SWING CIRCLE BEARING CLEARANCE246
ADJUSTING ENGINE SPEED SENSOR 248
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 249
TESTING AND ADJUSTING CHARGING PUMP PRESSURE 252
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE 254
MEASURING STROKE OF SERVO PISTON 261
MEASURING OUTPUT PRESSURE OF PPC VALVE 264
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 266
TESTING PPC SHUTTLE VALVE 268
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE 269
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 270
BLEEDING AIR 272
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT274
TROUBLESHOOTING275
POINTS TO REMEMBER WHEN TROUBLESHOOTING 276
SEQUENCE OF EVENTS IN TROUBLESHOOTING 277
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 278
CHECKS BEFORE TROUBLESHOOTING 285
ELECTRICAL CIRCUIT DIAGRAM 286
POSITION OF CONNECTORS FOR TROUBLESHOOTING 294
CONNECTION TABLE FOR CONNECTOR298
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM308
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER 312
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE316
METHOD OF USING JUDGEMENT TABLE321
METHOD OF USING TROUBLESHOOTING CHARTS 324
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)327
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS328
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM 329
FAILURE MODE 330
SELF-DIAGNOSTIC DISPLAY330
E-1 [Abnormality in power source system or controller] is displayed (All lamps OFF) 330
E-2 [Short circuit in governor motor] is displayed 336
E-3 [Abnormality in battery relay] is displayed 337
E-4 [Disconnection in wiring harness of governor inotor] is displayed 339
E-5 [Abnormality in governor potentiometer] is displayed 340
E-6 [Abnormality in fuel control dial] is displayed 342
E-7 [Abnormality in No 2 throttle signal] is displayed 344
NO SELF-DIAGNOSTIC DISPLAY346
E-8 Engine does not start 346
E-9 Engine rotation is irregular 350
a) Idling rotation is irregular350
b) There is hunting352
E-10 Lack of output power (max engine speed is too low) 358
E-11 Engine does not stop 362
E-12 Automatic warming-up operation is defective 368
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)369
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS370
FAILURE MODE372
C-1 [OFF] Self-diagnostic display of controller does not light up372
C-2 [01] is displayed375
C-3 [03] is displayed376
C-4 [04] is displayed377
C-5 [05] is displayed378
C-6 [07] is displayed379
C-7 [08] is displayed 380
C-8 [09] is displayed 381
C-9 [11] is displayed382
C-10 [13] is displayed383
C-11 [14] is displayed 384
C-12 [15] is displayed385
C-13 [17] is displayed 386
C-14 [18] is displayed 387
C-15 [21] is displayed 388
C-16 [22] is displayed 389
C-17 [23] is displayed 390
C-18 [24] is displayed 392
C-19 [25] is displayed 394
C-20 [26] is displayed 396
C-21 [28] is displayed397
C-22 [29] is displayed 398
C-23 [ ] is displayed 399
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)401
FAILURE MODE402
F-1 Pump controller monitor does not display [P1] 402
F-2 Pump controller monitor does not display [P2] 403
F-3 Pump controller monitor does not display [P6] 405
F-4 Pump controller monitor does not display [b5] 406
F-5 Pump controller monitor does not display [Hi or Lo] 407
F-6 Pump controller monitor does not display [Ad]408
F-7 Pump controller monitor does not display [UP]409
F-8 Pump controller monitor does not display [ ] 410
F-9 Pump controller working mode display does not switch 411
F-10 Pump controller power set display does not switch 412
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)413
FAILURE MODE414
WORK EQUIPMENT, TRAVEL, SWING SYSTEM414
H-1 Speeds of work equipment, travel, swing are all slow 414
H-2 There is excessive drop in engine speed, or engine stalls 416
H-3 Work equipment, travel, swing do not move, or speed is extremely slow 418
H-4 Work equipment, travel, swing lack power 420
H-5 Power set selection system does not switch 420
H-6 Abnormal noise generated (from around pump) 421
H-7 Auto-deceleration does not work 421
WORK EQUIPMENT SYSTEM422
H-8 Boom, arm speed is extremely slow 422
H-9 Work equipment (boom, arm, bucket) speed is slow 424
H-10 When boom and arm are operated simultaneously, boom is slow 426
H-11 Work equipment (boom, arm, bucket) lacks power 426
H-12 Excessive hydraulic drift 426
H-13 Excessive time lag 428
H-14 Does not enter finishing operation mode 428
H-15 When arm and swing are operated simultaneously, arm is slow428
TRAVEL SYSTEM430
H-16 When machine is traveling, it deviates naturally to one side 430
a) Deviates in same direction both in forward and reverse430
b) Deviates in different direction in forward and reverse432
H-17 Excessive deviation during compound operations 433
H-18 Excessive deviation when starting 434
H-19 Travel lacks power (or speed is slow) 436
H-20 Travel speed does not switch 436
H-21 Machine does not move (one side only) 437
SWING SYSTEM438
H-22 Does not swing 438
H-23 Swing speed is slow or acceleration is poor 440
H-24 Excessive overrun when stopping swing 441
H-25 Excessive shock when stopping swing441
H-26 Excessive abnormal noise when stopping swing 442
H-27 Excessive hydraulic drift of swing 442
H-28 When operated simultaneously with arm, swing is slow 442
TABLE OF FAILURE MODES AND CAUSES443
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)445
FAILURE MODE446
P-1 Monitor panel lamps do not light up for 3 seconds when starting switch is turned ON 446
a) No monitor panel lamps light up446
b) Some monitor panel lamps do not light up446
P-2 Monitor panel lamps all light up when starting switch is turned ON, but do not go out 447
P-3 When starting switch is turned ON (engine stopped) CHECK items flash (Levels for CHECK items are as specified) 448
a) Coolant level flashes448
b) Engine oil level flashes449
c) Hydraulic oil level flashes450
P-4 Preheating is not being used, but preheating display lights up 451
P-5 When starting switch is turned ON and engine is started, CHECK items flash 452
a) Alternator system452
b) Engine oil pressure system452
P-6 When starting switch is turned ON (engine stopped), CAUTION items flash 453
P-7 When starting switch is turned ON and engine is started, CAUTION items flash (When there is no abnormality in CHECK items or engine) 454
a) Engine oil pressure flashes454
b) Coolant level flashes454
c) Coolant temperature flashes455
d) Charge flashes455
e) Fuel level flashes456
P-8 457
a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second CAUTION item is flashing but buzzer 457
b) There is no abnormality display on the monitor, but the buzzer sounds 457
P-9 Panel lighting of monitor panel does not light up (liquid crystal display is normal) 458
P-10 Coolant temperature shows abnormally low temperature 459
P-11 Coolant temperature gauge gives no display (during operation, no level of gauge is displayed) 459
P-12 Fuel gauge always displays FULL 460
P-13 Fuel gauge gives no display 460
P-14461
a) Lamps do not light 461
b) Lamps light up even when lamp switch is not operated 461
P-15463
a) Wipers do not work 463
b) Wipers work even when wiper switch is not operated 463
P-16 465
a) Fan does not work 465
b) Fan works even when fan switch is not operated 465
P-17 Working mode does not switch 467
P-18 Power set does not switch 468
P-19 Auto-deceleration does not switch (Does not enter auto-deceleration; auto-deceleration is not canceled) 469
P-20 Travel speed does not switch between Hi and Lo 470
P-21 Warming-up operation is not carried out below 3O”C, or warming-up operation is not canceled even when temperature goes above 30°C 471
P-22 Even when swing lock switch is turned ON (LOCK), swing lock lamp on monitor panel does not light up 472
P-23 Fuel level sensor system defective 473
P-24 Coolant temperature sensor system defective 474
P-25 Defective engine oil level sensor system 475
P-26 Coolant level sensor system defective 476
P-27 Hydraulic oil level sensor system defective 477
30 DISASSEMBLY AND ASSEMBLY 479
METHOD OF USING MANUAL 482
PRECAUTIONS WHEN CARRYING OUT OPERATION 483
SPECIAL TOOL LIST 485
WEIGHT TABLE 487
TIGHTENING TORQUES AND STANDARD VALUES TABLE 489
LUBRICANT AND COOLANT TABLE491
STARTING MOTOR 492
REMOVAL AND INSTALLATION492
ALTERNATOR492
REMOVAL AND INSTALLATION492
ENGINE OIL COOLER494
REMOVAL AND INSTALLATION494
FUEL INJECTION PUMP 494
REMOVAL AND INSTALLATION494
WATER PUMP 496
REMOVAL AND INSTALLATION496
NOZZLE HOLDER 496
REMOVAL AND INSTALLATION496
TURBOCHARGER498
REMOVAL AND INSTALLATION498
THERMOSTAT498
REMOVAL AND INSTALLATION498
ENGINE FRONT SEAL 500
REMOVAL AND INSTALLATION500
ENGINE REAR SEAL 500
REMOVAL AND INSTALLATION500
GOVERNOR MOTOR 502
REMOVAL AND INSTALLATION502
CYLINDER HEAD 504
REMOVAL AND INSTALLATION504
AFTER-COOLER 506
REMOVAL AND INSTALLATION506
HYDRAULIC COOLER506
REMOVAL AND INSTALLATION506
RADIATOR, HYDRAULIC COOLER 508
REMOVAL AND INSTALLATION508
ENGINE, HYDRAULIC PUMP510
REMOVAL AND INSTALLATION510
DAMPER512
REMOVAL AND INSTALLATION 512
CENTER SWIVEL JOINT 512
REMOVAL AND INSTALLATION512
DISASSEMBLY AND ASSEMBLY514
FINAL DRIVE514
REMOVAL AND INSTALLATION514
DISASSEMBLY516
ASSEMBLY518
SPROCKET 524
REMOVAL AND INSTALLATION524
TRAVEL MOTOR526
DISASSEMBLY526
ASSEMBLY530
SWING MOTOR540
REMOVAL AND INSTALLATION540
DISASSEMBLY 541
ASSEMBLY 544
SWING MACHINERY549
REMOVAL AND INSTALLATION 549
DISASSEMBLY550
ASSEMBLY552
REVOLVING FRAME558
REMOVAL AND INSTALLATION558
SWING CIRCLE 560
REMOVAL AND INSTALLATION560
IDLER, RECOIL SPRING560
REMOVAL AND INSTALLATION560
DISASSEMBLY AND ASSEMBLY 562
TRACK ROLLER 564
REMOVAL AND INSTALLATION564
CARRIER ROLLER 564
REMOVAL AND INSTALLATION564
TRACK SHOE566
REMOVAL AND INSTALLATION566
CHARGING PUMP568
REMOVAL AND INSTALLATION 568
HYDRAULIC PUMP568
REMOVAL AND INSTALLATION568
DISASSEMBLY 570
ASSEMBLY575
MAIN PUMP INPUT SHAFT 588
REMOVAL AND INSTALLATION588
CONTROL VALVE588
REMOVAL AND INSTALLATION588
DISASSEMBLY590
ASSEMBLY 592
MAIN RELIEF VALVE594
REMOVAL AND INSTALLATION594
DISASSEMBLY AND ASSEMBLY 594
TVC VALVE596
REMOVAL AND INSTALLATION596
CO-NC VALVE596
REMOVAL AND INSTALLATION 596
SERVO VALVE 596
REMOVAL AND INSTALLATION596
WORK EQUIPMENT PPC VALVE598
REMOVAL AND INSTALLATION598
DISASSEMBLY AND ASSEMBLY 600
TRAVEL PPC VALVE604
REMOVAL AND INSTALLATION604
DISASSEMBLY AND ASSEMBLY 604
BOOM HOLDING VALVE606
REMOVAL AND INSTALLATION 606
DISASSEMBLY AND ASSEMBLY606
PPC SHUTTLE VALVE608
REMOVAL AND INSTALLATION608
BOOM CYLINDER610
REMOVAL AND INSTALLATION610
ARM CYLINDER612
REMOVAL AND INSTALLATION612
BUCKET CYLINDER 614
REMOVAL AND INSTALLATION614
HYDRAULIC CYLINDER616
DISASSEMBLY616
ASSEMBLY 618
WORK EQUIPMENT 620
REMOVAL AND INSTALLATION620
BUCKET622
REMOVAL AND INSTALLATION 622
ARM622
REMOVAL AND INSTALLATION622
ARM, BUCKET624
REMOVAL AND INSTALLATION624
BOOM 626
REMOVAL AND INSTALLATION626
CAB 628
REMOVAL AND INSTALLATION628
COUNTERWEIGHT 628
REMOVAL AND INSTALLATION628
ENGINE THROTTLE CONTROLLER630
REMOVAL AND INSTALLATION 630
PUMP CONTROLLER630
REMOVAL AND INSTALLATION630
MONITOR PANEL630
REMOVAL AND INSTALLATION630
40 MAINTENANCE STANDARD 641
FINAL DRIVE 642
SWING MACHINERY 644
SWING CIRCLE 646
TRACK FRAME AND RECOIL SPRING 647
IDLER 648
TRACK ROLLER 650
CARRIER ROLLER 651
TRACK652
HYDRAULIC PUMP 655
CHARGING PUMP AND RELIEF VALVE 656
CONTROL VALVE 657
SWING MOTOR 682
CENTER SWIVEL JOINT 683
TRAVEL MOTOR 684
PPC VALVE 685
BOOM HOLDING VALVE 688
HYDRAULIC CYLINDER 690
WORK EQUIPMENT 692

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24