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KOMATSU Pc200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & Up) – PDF Download
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- KOMATSU Pc200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- Serial Number:A82001 & Up
- Publication Number:CEBMOOOI 02
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KOMATSU Pc200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & Up)
KOMATSU PC200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & UP) – PDF DOWNLOAD:
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KOMATSU Pc200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & Up)
- 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 the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & Up)
MAIN MENU...................................................................................................................................... 0 COVER.......................................................................................................................................... 1 CONTENTS....................................................................................................................................... 2 01 GENERAL..................................................................................................................................... 25 GENERAL ASSEMBLY DRAWING (PC200-6, PC2OOLC-6, PC210LC-6)................................................................................... 26 GENERAL ASSEMBLY DRAWING (PC220LC-6, PC250LC-6)............................................................................................ 28 SPECIFICATIONS (PC200-6, PC200LC-6)........................................................................................................ 31 SPECIFICATIONS (PC210LC-6)................................................................................................................. 33 SPECIFICATIONS (PC220LC-6)................................................................................................................. 35 SPECIFICATIONS (PC250LC-6)................................................................................................................. 37 WEIGHT TABLE (PC200-6, PC200LC-6).......................................................................................................... 39 WEIGHT TABLE (PC210LC-6)................................................................................................................... 41 WEIGHT TABLE (PC220LC-6, PC250LC-6)........................................................................................................ 43 FUEL, COOLANTS AND LUBRICANTS.............................................................................................................. 45 10 STRUCTURE AND FUNCTION...................................................................................................................... 48 ENGINE RELATED PARTS....................................................................................................................... 49 RADIATOR, OIL COOLER, AFTERCOOLER.......................................................................................................... 50 POWER TRAIN................................................................................................................................ 51 FINAL DRIVE................................................................................................................................ 52 SWING CIRCLE............................................................................................................................... 54 SWING MACHINERY............................................................................................................................ 55 TRACK FRAME, RECOIL SPRING................................................................................................................. 56 TRACK SHOE................................................................................................................................. 57 HYDRAULIC PIPING DRAWING................................................................................................................... 59 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 60 HYDRAULIC TANK............................................................................................................................. 62 HYDRAULIC PUMP............................................................................................................................. 63 CONTROL VALVE.............................................................................................................................. 85 CLSS....................................................................................................................................... 94 SWING MOTOR................................................................................................................................138 CENTER SWIVEL JOINT........................................................................................................................141 TRAVEL MOTOR...............................................................................................................................142 VALVE CONTROL..............................................................................................................................153 WORK EQUIPMENT, SWING PPC VALVE............................................................................................................154 TRAVEL PPC VALVE...........................................................................................................................158 SERVICE PPC VALVE..........................................................................................................................162 SAFETY LOCK VALVE..........................................................................................................................165 PPC ACCUMULATOR............................................................................................................................165 PPC SHUTTLE, TRAVEL JUNCTION VALVE.........................................................................................................166 EPC, SOLENOID VALVE........................................................................................................................173 HYDRAULIC CYLINDER.........................................................................................................................181 ADDITIONAL FILTER FOR BREAKER..............................................................................................................182 OVERLOAD WARNING DEVICE....................................................................................................................183 HOSE BURST PROTECTION VALVE (BOOM).........................................................................................................187 WORK EQUIPMENT.............................................................................................................................190 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................. 0 ENGINE CONTROL SYSTEM......................................................................................................................195 ELECTRONIC CONTROL SYSTEM..................................................................................................................200 MACHINE MONITOR SYSTEM.....................................................................................................................225 20 TESTING AND ADJUSTING.......................................................................................................................232 TABLE OF JUDGEMENT STANDARD VALUE..........................................................................................................233 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................................................245 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTNG............................................................................................254 MEASURING ENGINE SPEED.....................................................................................................................255 MEASURING INTAKE MANIFOLD PRESSURE.........................................................................................................256 MEASURING INTAKE AIR RESTRICTION...........................................................................................................257 MEASURING LUBRICATING OIL PRESSURE.........................................................................................................258 MEASURING FUEL (FILTER) INLET RESTRICTION..................................................................................................259 MEASURING BLOWBY PRESSURE..................................................................................................................260 MEASURING ENGINE BACK PRESSURE.............................................................................................................261 MEASURING EXHAUST COLOR....................................................................................................................262 MEASURING COOLANT TEMPERATURE..............................................................................................................263 MEASURING VALVE CLEARANCE..................................................................................................................264 CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.........................................................................265 ADJUSTING ENGINE SPEED SENSOR..............................................................................................................266 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE..........................................................................................267 TESTING CLEARANCE OF SWING CIRCLE BEARING..................................................................................................268 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................................269 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT..........................................................270 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)..............................................................273 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE..................................275 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....................................................................................278 TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE..........................................................................................280 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE..........................................................................282 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE..................................................................................................284 ADJUSTING TRAVEL LEVER.....................................................................................................................285 TESTING TRAVEL DEVIATION...................................................................................................................286 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................................287 MEASURING OIL LEAKAGE......................................................................................................................289 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................................290 TROUBLESHOOTING............................................................................................................................293 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................294 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................295 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..............................................................................................296 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................303 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................304 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................308 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.................................................................................321 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL..................................................................................322 METHOD OF USING JUDGEMENT TABLE........................................................................................................331 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...............................................................................335 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)..........................................................................340 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM..........................................341 ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM..................................................................................342 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................344 JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS............................................................345 E-1 Abnormality in engine throttle controller power source system (engine speed stays at low idling)...............................346 E-2 [E3:08] Abnormality in fuel control dial input value is displayed..............................................................347 E-3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayed................................................348 E-4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed................................................349 E-5 [E3:01] Abnormality in network reception system is displayed...................................................................350 E-6 [E3:05] Abnormality in model code is displayed.................................................................................352 E-7 [E3:06] Abnormality in governor potentiometer system is displayed..............................................................353 E-8 [E3:07] Abnormality in pump controller throttle system is displayed............................................................354 E-9 [E3:15] Abnormality (short circuit) in battery relay output system is displayed................................................354 E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed..........................................................355 E-11 Engine does not start.........................................................................................................356 E-12 Engine speed is irregular.....................................................................................................358 a) Idling speed is irregular...................................................................................................358 b) There is hunting............................................................................................................360 E-13 Lack of output (engine high idling speed is too low)..........................................................................362 E-14 Engine does not stop..........................................................................................................364 E-15 Defective operation of battery relay system (engine does not stop)............................................................366 TROUBLESHOOTING OF ENGINE (S MODE).....................................................................................................367 METHOD OF USING TROUBLESHOOTING CHART..............................................................................................368 S-1 Starting performance is poor (Starting always takes time)......................................................................372 S-2 Engine does not start..........................................................................................................373 1) Engine does not turn........................................................................................................373 2) Engine turns but no exhaust gas comes out (Fuel is not being injected)......................................................374 3) Exhaust gas comes out but engine does not start (Fuel is being injected)....................................................375 S-3 Engine does not pick up smoothly (Follow-up is poor)...........................................................................376 S-4 Engine stops during operations.................................................................................................377 S-5 Engine does not rotate smoothly................................................................................................378 S-6 Engine lacks output (no power).................................................................................................379 S-7 Exhaust gas is black (incomplete combustion)...................................................................................380 S-8 Oil consumption is excessive (or exhaust gas is blue)..........................................................................381 S-9 Oil becomes contaminated quickly...............................................................................................382 S-10 Fuel consumption is excessive.................................................................................................383 S-11 Oil is in cooling water, or water spurts back, or water level goes down.......................................................384 S-12 Oil pressure lamp lights up (drop in oil pressure)............................................................................385 S-13 Oil level rises...............................................................................................................386 S-14 Water temperature becomes too high (overheating)..............................................................................387 S-15 Abnormal noise is made........................................................................................................388 S-16 Vibration is excessive........................................................................................................389 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).....................................................................................390 POINTS TO REMEMNBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM....................................................................391 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................392 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS....................................................................396 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM.............................................................................................397 C-1 Abnormality in pump controller power source system (swing brake is not canceled, ect.).........................................398 C-2 [E2:32] Short circuit in front pump TVC solenoid system is displayed...........................................................399 [E2:36] Short circuit in rear pump TVC solenoid system is displayed............................................................399 C-3 [E2:33] Disconnection in front pump TVC solenoid system is displayed...........................................................401 [E2:37] Disconnection in rear pump TVC solenoid system is displayed............................................................401 C-4 [E2:03] Short circuit in swing brake solenoid system is displayed..............................................................403 C-5 [E2:13] Disconnection in swing brake solenoid system is displayed..............................................................405 C-6 [E2:02] Short circuit in LS select solenoid system is displayed................................................................407 [E2:04] Short circuit in pump merge-divider solenoid system is displayed.......................................................407 [E2:05] Short circuit in 2-stage relief solenoid system is displayed...........................................................407 [E2:06] Short circuit in travel speed solenoid system is displayed.............................................................407 C-7 [E2:12] Disconnection in LS select solenoid system is displayed................................................................409 [E2:14] Disconnection in pump merge-divider solenoid system is displayed.......................................................409 [E2:15] Disconnection in 2-stage relief solenoid system is displayed...........................................................409 [E2:16] Disconnection in travel speed solenoid system is displayed.............................................................409 C-8 [E2:17] Model selection input error is displayed...............................................................................411 C-9 [E2:18] Network response overtime error is displayed...........................................................................412 C-10 [E2:22] Short circuit in LS control EPC solenoid system is displayed..........................................................414 C-11 [E2:23] Disconnection in LS control EPC solenoid system is displayed..........................................................415 C-12 [E2:24] Abnormality in front pump pressure sensor system is displayed.........................................................416 [E2:25] Abnormality in rear pump pressure sensor system is displayed...........................................................416 C-13 [E2:26] Abnormality in pump pressure sensor power source system is displayed..................................................418 C-14 [E2:27] Abnormality in engine speed sensor system is displayed................................................................419 C-15 [E2:28] Abnormality in auto-deceleration output system is displayed...........................................................420 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)........................................................................421 F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up.................................................................422 F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up................................................................423 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up............................................................424 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up............................................................425 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up................................................................426 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up...............................................................427 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up...........................................................428 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up...........................................................429 F-9 Bit pattern 21-(3) Swing lock switch does not light up.........................................................................430 F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system)...............................431 F-12 Bit pattern 22-(6) L.H. knob switch does not light up.........................................................................432 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)............................................................................433 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM..............................................................434 PUMP MERGE-DIVIDER LOGIC...........................................................................................................436 All work equipment, travel, swing..................................................................................................437 H-1 Speeds of all work equipment, swing, travel are slow or lack power.........................................................437 H-2 There is excessive drop in engine speed, or engine stalls..................................................................439 H-3 No work equipment, travel, swing move......................................................................................440 H-4 Abnormal noise generated...................................................................................................440 H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)..........................................................441 H-6 Fine control ability is poor or response is poor...........................................................................441 Work Equipment.....................................................................................................................442 H-7 Boom is slow or lacks power................................................................................................442 H-8 Arm is slow or lacks power.................................................................................................444 H-9 Bucket is slow or lacks power..............................................................................................446 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)........................................447 H-11 Excessive hydraulic drift (boom, arm, bucket).............................................................................447 H-12 Excessive time lag (engine at low idling).................................................................................448 H-13 Lack of power when pressure rises.........................................................................................448 H-14 Other equipment moves when single circuit is relieved ....................................................................448 H-15 In L/O, F/O modes, work equipment speed is faster than specified speed....................................................449 Compound operations................................................................................................................449 H-16 In compound operations, work equipment with larger load is slow...........................................................449 H-17 In swing + boom RAISE, boom RAISE is slow.................................................................................450 H-18 In swing + arm OUT, arm OUT is slow.......................................................................................450 H-19 In swing + travel, travel speed drops excessively.........................................................................450 Travel system......................................................................................................................451 H-20 Travel deviation..........................................................................................................451 H-21 Travel speed is slow......................................................................................................452 H-22 Steering does not turn easily or lacks power..............................................................................454 H-23 Travel speed does not switch or is faster than specified speed............................................................456 H-24 Travel does not move (one side only)......................................................................................456 Swing system.......................................................................................................................457 H-25 Does not swing............................................................................................................457 H-26 Swing acceleration is poor or swing speed is slow (both left and right, one direction only)...............................458 H-27 Excessive overrun when stopping swing.....................................................................................460 H-28 Excessive shock when stopping swing (one direction only)..................................................................461 H-29 Excessive abnormal noise when stopping swing..............................................................................461 H-30 Excessive hydraulic drift of swing........................................................................................462 H-31 Swing speed is faster than specified swing speed..........................................................................463 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................464 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE......................................................465 MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM.............................................................................................466 M-1 [E1:01] Abnormality in error data is displayed.................................................................................467 M-2 [E1:02] Error in clock data is displayed.......................................................................................467 M-3 [E1:03] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed.................467 M-4 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds.......................................468 a) None of the lamps on monitor panel light up.................................................................................468 b) Some of lamps on monitor panel (gauge display, time display) do not light up................................................468 M-5 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out...................................469 M-6 When starting switch is turned ON, items lighted up on monitor panel are different from machine model..........................469 M-7 When starting switch is turned ON (engine stopped), CHECK items flash (Fluid levels for CHECK items are at specified level)....470 a) (coolant level) flashes.....................................................................................................470 b) (engine oil level) flashes..................................................................................................471 c) (hydraulic oil level) flashes...............................................................................................471 M-8 Preheating is not being used but preheating display lights up..................................................................472 M-9 When starting switch is turned ON and engine started, CHECK items flash........................................................473 a) Alternator system...........................................................................................................473 b) Engine oil pressure system..................................................................................................474 M-10 When starting switch is turned ON (engine stopped), CAUTION items flash ......................................................475 a) Alternator system...........................................................................................................475 b) Engine oil pressure sensor system...........................................................................................475 M-11 When starting switch is turned ON and engine is started, CAUTION items flash..................................................476 a) (engine oil pressure) flashes...............................................................................................476 b) (coolant level) flashes.....................................................................................................477 c) (coolant temperature) flashes...............................................................................................477 d) (battery charge) flashes....................................................................................................478 M-12 (a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second, CAUTION...........................479 M-12 (b) No abnormality is displayed on monitor but buzzer sounds..................................................................479 M-13 Liquid crystal night lighting on monitor panel does not light up (Liquid crystal display is normal)...........................480 M-14 Coolant temperature gauge does not rise.......................................................................................481 M-15 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)...........................482 M-16 Fuel level gauge always displays FULL.........................................................................................483 M-17 Fuel level gauge does not give display........................................................................................483 M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking display does not light up.....................................484 M-19 Swing lock prolix switch is ON (prolix), but monitor panel parking display does not flash.....................................484 M-20 Defective fuel level sensor system............................................................................................485 M-21 Defective coolant tern perature sensor system.................................................................................486 M-22 Defective engine oil level sensor system......................................................................................487 M-23 Defective coolant level sensor system.........................................................................................488 M-24 Defective hydraulic oil level sensor system...................................................................................489 M-25 Working light, panel lighting do not light up, or switch is not being used but lights light up................................490 a) Working light does not light up.............................................................................................490 b) Panel lighting does not light up............................................................................................490 c) Light switch is not being used but working light lights up..................................................................491 M-26 Wiper does not work or switch is not being used but wiper is actuated.........................................................492 a) Wiper does not work.........................................................................................................492 b) Wiper switch is not being used but wiper is actuated........................................................................494 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................496 METHOD OF USING MANUAL.....................................................................................................................499 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................500 SPECIAL TOOL LIST..........................................................................................................................502 REMOVAL................................................................................................................................506 AIR CONDITIONER COMPRESSOR.................................................................................................................506 INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY....................................................................................506 REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................506 CONDENSER ASSEMBLY.........................................................................................................................507 INSTALLATION OF CONDENSER ASSEMBLY.....................................................................................................507 REMOVAL OF CONDENSER ASSEMBLY..........................................................................................................507 GOVERNOR MOTOR.............................................................................................................................508 INSTALLATION OF GOVERNOR MOTOR ASSEMBLY................................................................................................508 REMOVAL OF GOVERNOR MOTOR ASSEMBLY.....................................................................................................508 HYDRAULIC OIL COOLER.......................................................................................................................509 INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY..........................................................................................509 REMOVAL OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................509 RADIATOR, HYDRAULIC OIL COOLER.............................................................................................................511 INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY................................................................................511 REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY.............................................................................................512 ENGINE, HYDRAULIC PUMP.....................................................................................................................512 INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY........................................................................................515 DAMPER.....................................................................................................................................516 INSTALLATION OF DAMPER ASSEMBLY........................................................................................................516 REMOVAL OF DAMPER ASSEMBLY.............................................................................................................516 FUEL TANK..................................................................................................................................517 INSTALLATION OF FUEL TANK ASSEMBLY.....................................................................................................517 REMOVAL OF FUEL TANK ASSEMBLY..........................................................................................................517 CENTER SWIVEL JOINT........................................................................................................................518 INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY...........................................................................................518 REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY................................................................................................518 ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...............................................................................................519 DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY............................................................................................519 FINAL DRIVE................................................................................................................................520 INSTALLATION OF FINAL DRIVE ASSEMBLY...................................................................................................520 DISASSEMBLY OF FINAL DRIVE ASSEMBLY....................................................................................................521 REMOVAL OF FINAL DRIVE ASSEMBLY........................................................................................................520 ASSEMBLY OF FINAL DRIVE ASSEMBLY.......................................................................................................524 DISASSEMBLY OF FINAL DRIVE ASSEMBLY (PC250LC-6)........................................................................................528 ASSEMBLY OF FINAL DRIVE ASSEMBLY (PC250LC-6)...........................................................................................531 DISASSEMBLY............................................................................................................................536 TRAVEL MOTOR...............................................................................................................................536 ASSEMBLY OF TRAVEL MOTOR ASSEMBLY......................................................................................................541 DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY...................................................................................................536 CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE................................................................................548 SPROCKET...................................................................................................................................549 INSTALLATION OF SPROCKET...............................................................................................................549 REMOVAL OF SPROCKET....................................................................................................................549 SWING MOTOR................................................................................................................................550 INSTALLATION OF SWING MOTOR ASSEMBLY...................................................................................................550 REMOVAL OF SWING MOTOR ASSEMBLY........................................................................................................550 SWING MACHINERY............................................................................................................................551 INSTALLATION OF SWINGMACHINERY ASSEMBLY................................................................................................551 DISASSEMBLY OF SWING MACHINERY ASSEMBLY................................................................................................552 ASSEMBLY OF SWING MACHINERY ASSEMBLY...................................................................................................555 REMOVAL OF SWING MACHINERY ASSEMBLY....................................................................................................551 REVOLVING FRAME............................................................................................................................559 INSTALLATION OF REVOLVING FRAME ASSEMBLY...............................................................................................560 REMOVAL OF REVOLVING FRAME ASSEMBLY....................................................................................................559 SWING CIRCLE...............................................................................................................................561 INSTALLATION OF SWING CIRCLE ASSEMBLY..................................................................................................562 REMOVAL OF SWING CIRCLE ASSEMBLY.......................................................................................................561 IDLER, RECOIL SPRING.......................................................................................................................563 INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY..........................................................................................563 REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY...............................................................................................563 RECOIL SPRING..............................................................................................................................564 ASSEMBLY OF RECOIL SPRING ASSEMBLY.....................................................................................................565 DISASSEMBLY OF RECOIL SPRING ASSEMBLY..................................................................................................564 IDLER......................................................................................................................................566 ASSEMBLY OF IDLER ASSEMBLY.............................................................................................................567 DISASSEMBLY OF IDLER ASSEMBLY..........................................................................................................566 TRACK ROLLER...............................................................................................................................569 INSTALLATION OF TRACK ROLLER ASSEMBLY..................................................................................................569 DISASSEMBLY OF TRACK ROLLER ASSEMBLY...................................................................................................571 ASSEMBLY OF TRACK ROLLER ASSEMBLY......................................................................................................572 REMOVAL OF TRACK ROLLER ASSEMBLY.......................................................................................................569 CARRIER ROLLER.............................................................................................................................574 INSTALLATION OF CARRIER ROLLER ASSEMBLY................................................................................................574 ASSEMBLY OF CARRIER ROLLER ASSEMBLY....................................................................................................576 DISASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................................................575 REMOVAL OF CARRIER ROLLER ASSEMBLY.....................................................................................................574 TRACK SHOE.................................................................................................................................578 INSTALLATION OF TRACK SHOE ASSEMBLY....................................................................................................578 REMOVAL OF TRACK SHOE ASSEMBLY.........................................................................................................578 HYDRAULIC TANK.............................................................................................................................579 INSTALLATION OF HYDRAULIC TANK ASSEMBLY................................................................................................580 REMOVAL OF HYDRAULIC TANK ASSEMBLY.....................................................................................................579 CONTROL PUMP...............................................................................................................................581 REMOVAL OF CONTROL PUMP ASSEMBLY.......................................................................................................581 INSTALLATION OF CONTROL PUMP ASSEMBLY..................................................................................................581 MAIN PUMP..................................................................................................................................582 INSTALLATION OF MAIN PUMP ASSEMBLY.....................................................................................................583 DISASSEMBLY OF MAIN PUMP ASSEMBLY (HPV95 + 95).........................................................................................584 ASSEMBLY OF MAIN PUMP ASSEMBLY (HPV95 + 95)............................................................................................590 REMOVAL OF MAIN PUMP ASSEMBLY..........................................................................................................582 MAIN PUMP INPUT SHAFT OIL SEAL.............................................................................................................606 INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL.........................................................................................606 REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL..............................................................................................606 CONTROL VALVE..............................................................................................................................607 INSTALLATION OF CONTROL VALVE ASSEMBLY.................................................................................................608 REMOVAL OF CONTROL VALVE ASSEMBLY......................................................................................................607 CONTROL VALVE ASSEMBLY * 7-spool control valve (1 service valve)...........................................................................609 INSTALLATION OF CONTROL VALVE ASSEMBLY.................................................................................................610 DISASSEMBLY OF CONTROL VALVE ASSEMBLY..................................................................................................611 ASSEMBLY OF CONTROL VALVE ASSEMBLY.....................................................................................................613 DISASSEMBLY............................................................................................................................615 PUMP MERGE-DIVIDER VALVE...................................................................................................................615 DISASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY.......................................................................................615 ASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY..........................................................................................615 PRESSURE COMPENSATION VALVE................................................................................................................616 DISASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY....................................................................................616 ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY.......................................................................................616 MAIN RELIEF VALVE..........................................................................................................................617 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..............................................................................................617 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY.................................................................................................618 TVC, LS VALVE ASSEMBLY FOR FRONT PUMP......................................................................................................619 REMOVAL OF TVC, LS VALVE ASSEMBLY FOR FRONT PUMP.......................................................................................619 INSTALLATION OF TVC, LS VALVE ASSEMBLY FOR FRONT PUMP..................................................................................619 TVC, LS VALVE ASSEMBLY FOR REAR PUMP.......................................................................................................620 REMOVAL OF TVC, LS VALVE ASSEMBLY FOR REAR PUMP........................................................................................620 INSTALLATION OF TVC, LS VALVE ASSEMBLY FOR REAR PUMP...................................................................................620 LS CONTROL EPC VALVE.......................................................................................................................621 INSTALLATION OF LS CONTROL EPC VALVE ASSEMBLY..........................................................................................621 REMOVAL OF LS CONTROL EPC VALVE ASSEMBLY...............................................................................................621 SOLENOID VALVE.............................................................................................................................622 INSTALLATION OF SOLENOID VALVE ASSEMBLY................................................................................................622 REMOVAL OF SOLENOID VALVE ASSEMBLY.....................................................................................................622 WORK EQUIPMENT, SWING PDC VALVE............................................................................................................623 ASSEMBLY OF WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY...................................................................................625 INSTALLATION OF WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY...............................................................................623 DISASSEMBLY OF WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY................................................................................624 REMOVAL OF WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY....................................................................................623 TRAVEL PPC VALVE...........................................................................................................................626 ASSEMBLY OF TRAVEL VALVE ASSEMBLY......................................................................................................627 INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY..............................................................................................626 DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...............................................................................................627 REMOVAL OF TRAVEL PPC VALVE ASSEMBLY...................................................................................................626 BOOM LOCK VALVE............................................................................................................................629 INSTALLATION OF BOOM LOCK VALVE ASSEMBLY...............................................................................................629 REMOVAL OF BOOM LOCK VALVE ASSEMBLY....................................................................................................629 BOOM CYLINDER..............................................................................................................................630 INSTALLATION OF BOOM CYLINDER ASSEMBLY.................................................................................................631 REMOVAL OF BOOM CYLINDER ASSEMBLY......................................................................................................630 ARM CYLINDER...............................................................................................................................632 INSTALLATION OF ARM CYLINDER ASSEMBLY..................................................................................................633 REMOVAL OF ARM CYLINDER ASSEMBLY.......................................................................................................632 BUCKET CYLINDER............................................................................................................................634 INSTALLATION OF BUCKET CYLINDER ASSEMBLY...............................................................................................635 REMOVAL OF BUCKET CYLINDER ASSEMBLY....................................................................................................634 HYDRAULIC CYLINDER.........................................................................................................................636 ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY................................................................................................638 DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.............................................................................................636 WORK EQUIPMENT.............................................................................................................................641 INSTALLATION OF WORK EQUIPMENT ASSEMBLY................................................................................................642 REMOVAL OF WORK EQUIPMENT ASSEMBLY.....................................................................................................641 BUCKET.....................................................................................................................................643 INSTALLATION OF BUCKET ASSEMBLY........................................................................................................644 REMOVAL OF BUCKET ASSEMBLY.............................................................................................................643 ARM........................................................................................................................................645 INSTALLATION OF ARM ASSEMBLY...........................................................................................................646 REMOVAL OF ARM ASSEMBLY................................................................................................................645 BUCKET, ARM................................................................................................................................647 INSTALLATION OF BUCKET, ARM ASSEMBLY...................................................................................................648 REMOVAL OF BUCKET, ARM ASSEMBLY........................................................................................................647 BOOM.......................................................................................................................................649 INSTALLATION OF BOOM ASSEMBLY..........................................................................................................650 REMOVAL OF BOOM ASSEMBLY...............................................................................................................649 OPERATOR’ S CAB............................................................................................................................651 INSTALLATION OF OPERATOR’ S CAB ASSEMBLY...............................................................................................653 REMOVAL OF OPERATOR’ S CAB ASSEMBLY....................................................................................................651 COUNTERWEIGHT..............................................................................................................................654 INSTALLATION OF COUNTERWEIGHT ASSEMBLY.................................................................................................654 REMOVAL OF COUNTERWEIGHT ASSEMBLY......................................................................................................654 ENGINE THROTTLE CONTROLLER.................................................................................................................655 INSTALLATION OF ENGINE THROTTLE CONTROLLER ASSEMBLY....................................................................................655 REMOVAL OF ENGINE THROTTLE CONTROLLER ASSEMBLY.........................................................................................655 PUMP CONTROLLER............................................................................................................................656 INSTALLATION OF PUMP CONTROLLER ASSEMBLY...............................................................................................656 REMOVAL OF PUMP CONTROLLER ASSEMBLY....................................................................................................656 MONITOR....................................................................................................................................657 INSTALLATION OF MONITOR ASSEMBLY.......................................................................................................657 REMOVAL OF MONITOR ASSEMBLY............................................................................................................657 40 MAINTENANCE STANDARD........................................................................................................................658 FINAL DRIVE (PC200-6, PC200LG6, PC210LC-6, PC220LC-6)......................................................................................659 FINAL DRIVE (PC250LC-6)....................................................................................................................661 SWING MACHINERY............................................................................................................................663 SWING CIRCLE...............................................................................................................................665 TRACK FRAME, RECOIL SPRING (PC200-6, PC200LC-6, PC210LC-6, PC220LC-6)......................................................................666 TRACK FRAME, RECOIL SPRING (PC25OLC-6).....................................................................................................667 IDLER (PC200-6, PC200LC-6 PC210LC-6, PC220LC-6)............................................................................................668 IDLER (PC250LC-6)..........................................................................................................................670 CARRIER ROLLER (PC200-6, PC200LC-6 PC210LC-6, PC220LC-6)...................................................................................672 CARRIER ROLLER (PC250LC-6).................................................................................................................673 TRACK ROLLER (PC200-6, PC200LC-6 PC210LC-6, PC220LC-6).....................................................................................674 TRACK ROLLER (PC250LC-6)...................................................................................................................675 TRACK SHOE (PC200-6, PC200LC-6 PC210LC-6, PC220LC-6).......................................................................................676 TRACK SHOE (PC250LC-6).....................................................................................................................678 HYDRAULIC PUMP.............................................................................................................................680 CONTROL VALVE..............................................................................................................................682 SAFETY-SUCTION VALVE FOR SERVICE VALVE.....................................................................................................688 SWING MOTOR................................................................................................................................689 TRAVEL MOTOR (PC200-6, PC200LC-6 PC210LC-6, PC220LC-6).....................................................................................690 TRAVEL MOTOR (PC250LC-6)...................................................................................................................691 WORK EQUIPMENT, SWING PPC VALVE............................................................................................................692 TRAVEL PPC VALVE...........................................................................................................................693 SERVICE PPC VALVE..........................................................................................................................694 PPC SHUTTLE, TRAVEL JUNCTION VALVE.........................................................................................................695 EPC, SOLENOID VALVE........................................................................................................................697 CENTER SWIVEL JOINT........................................................................................................................698 BOOM HOLDING VALVE.........................................................................................................................700 HYDRAULIC CYLINDER (PC200-6, PC200LC-6, PC210LC-6).........................................................................................701 HYDRAULIC CYLINDER (PC220LC-6, PC250LG6)...................................................................................................703 WORK EQUIPMENT.............................................................................................................................705
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for KOMATSU Pc200,200LC-6 PC210LC-6 PC220LC-6 PC250LC-6 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A82001 & Up) – PDF Download
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Mathew Josue –
pretty quick so far