Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM0l0202 PDF

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Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM0l0202  – PDF DOWNLOAD

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Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM0l0202  – PDF DOWNLOAD

Language : English
Pages : 540
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200LC-6 Hydraulic Excavator Shop Manual SEBM0l0202  – PDF DOWNLOAD

• SERIAL NUMBERS PC200LC-6Z – C10827 and up

MAIN MENU 0
COVER 1
CONTENTS . 2
01 GENERAL . 3
SPECIFICATION DIMENSION DRAWINGS . 4
SPECIFICATIONS . 5
WEIGHT TABLE . 7
FUEL, COOLANT AND LUBRICANTS . 9
10 STRUCTURE AND FUNCTION 10
ENGINE RELATED PARTS . 11
RADIATOR OIL COOLER AFTERCOOLER 12
ENGINE CONTROL . 13
POWER TRAIN 14
FINAL DRIVE 15
SWING CIRCLE . 16
SWING MACHINERY 17
TRACK FRAME RECOIL SPRING . 18
TRACK SHOE . 19
HYDRAULIC PIPING DRAWING . 20
HYDRAULIC CIRCUIT DIAGRAM 21
HYDRAULIC TANK . 22
HYDRAULIC PUMP . 23
IN-LINE FILTER . 42
CONTROL VALVE 43
SELF-REDUCING PRESSURE VALVE . 51
CLSS . 56
SWING MOTOR 90
CENTER SWIVEL JOINT 94
TRAVEL MOTOR . 96
VALVE CONTROL 104
WORK EQUIPMENT SWING PPC VALVE .105
TRAVEL PPC VALVE .109
SERVICE PPC VALVE 113
ACCUMULATOR 116
STRAIGHT-TRAVEL SYSTEM .117
EPC SOLENOID VALVE .118
BOOM HOLDING VALVE .120
ADDITIONAL FILTER FOR BREAKER 123
WORK EQUIPMENT .124
ACTUAL ELECTRICAL WIRING DIAGRAM .125
ELECTRIC CIRCUIT SYSTEM 127
ELECTRIC CONTROL SYSTEM 129
MACHINE MONITOR SYSTEM .135
SENSORS 138
20 TESTING AND ADJUSTING .140
STANDARD VALVE TABLE FOR ENGINE RELATED PARTS 141
STANDARD VALVE TABLE FOR ENGINE CHASSIS RELATED PARTS 142
STANDARD VALVE TABLE FOR ENGINE ELECTRICAL SYSTEM 150
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 153
MEASURING ENGINE SPEED .154
MEASURING EXHAUST COLOR 155
ADJUSTING VALVE CLEARANCE 156
MEASURING COMPRESSION PRESSURE .157
MEASURING BLOW BY PRESSURE .157
TESTING AND ADJUSTING FUEL INJECTION TIMING 158
MEASURING ENGINE OIL PRESSURE 159
TESTING AND ADJUSTING FAN BELT TENSION .160
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 160
ADJUSTING ENGINE SPEED SENSOR 161
ADJUSTING FUEL CONTROL LEVER .162
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 164
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 167
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 168
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE .171
TESTING SOLENOID VALVE OUTPUT PRESSURE .172
MEASURING PPC VALVE PUTPUT PRESSURE 173
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 175
TESTING TRAVEL DEVIATION .176
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 177
MEASURING OIL LEAKAGE 179
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 181
TESTING CLEARANCE OF SWING CIRCLE BEARING 182
TESTING AND ADJUSTING TRACK SHOE TENSION .183
BLEEDING AIR .184
TROUBLESHOOTING 186
POINTS TO REMEMBER WHEN TROUBLESHOOTING 187
SEQUENCE OF EVENTS IN TROUBLESHOOTING 188
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 189
CHECKS BEFORE TROUBLESHOOTING 197
CONNECTOR TYPES AND MOUNTING LOCATIONS .198
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .203
METHOD OF USING TROUBLESHOOTING CHARTS .213
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 215
METHOD OF USING TROUBLESHOOTING CHARTS .216
S-1 STARTING PERFORMANCE IS POOR (ALWAYS TAKES TIME) .220
S-2 ENGINE DOES NOT START 221
(1) ENGINE DOES NOT RUN 221
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) .222
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES START (FUEL IS BEING INJECTED) 223
S-3 ENGINE DOES NOT PICK SMOOTHY (FOLLOW-UP IS POOR) .224
S-4 ENGINE STOPS DURING OPERATIONS .225
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 226
S-6 ENGINE LACKS OUTPUT (NO POWER) .227
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION 228
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 229
S-9 OIL BECOMES CONTAMINATED QUICKLY .230
S-10 FUEL CONSUMPTION IS EXCESSIVE .231
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN .232
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 233
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 234
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 235
S-15 ABNORMAL NOISE IS MADE 236
S-16 VIBRATION IS EXCESSIVE 237
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 238
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS 239
ELECTRICAL CIRCUIT DIAGRAM FOR SYSTEM 241
FAILURE CODES 242
E-1 ABNORMALITY IN PC-EPC CONTROL SYSTEM .242
A) ENGINE STOPS EVEN WHEN THROTTLE LEVER IS NOT RETURNED TO STOP POSITION. WHEN SUDDEN LOAD IS APPLIED, ENGINE STALLS 242
B) LACKS POWER WHEN THROTTLT LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW .243
E-2 ABNORMALITY IN TRAVEL SPEED SELECTOR SYSTEM (TRAVEL SPEED DOES NOT SWITCH) .245
E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM .246
A) SWING HOLDING BRAKE SOLENOID IS NOT ACTUATED (CANNOT SWING) .246
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED) 247
E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM .248
A) SOLENOID IS NOT ACTUATED (SAFETY LOCK IS NOT CANCELED) 248
B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED) 249
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 250
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 253
TABLE OF FAILURE MODES AND CAUSES 254
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACKS POWER 258
H-2 THERE IS NOT EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 260
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 261
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) .261
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR .262
H-6 BOOM IS SLOW OR LACKS POWER 263
H-7 ARM IS SLOW OR LACKS POWER .265
H-8 BUCKET IS SLOW OR LACKS POWER 267
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL 267
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) .268
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) .269
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED .269
H-13 IN COMPUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS LOW .269
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW .270
H-15 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY .270
H-16 TRAVEL DEVIATION 271
A) DEVIATION IS EXCESSIVE IN NORMAL TRAVEL .271
B) DEVIATION IS EXCESSIVE WHEN STARTING 271
H-17 TRAVEL SPEED IS SLOW 272
H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER 273
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 274
H-20 TRAVEL SPEED DOES NOT SWITCH 274
H-21 DOES NOT SWING 275
A) DOES NOT SWING TO EITHER LEFT OR RIGHT 275
B) DOES NOT SWING IN ONE DIRECTION .275
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS LOW 276
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING .278
A) ONE DIRECTION ONLY 278
B) BOTH DIRECTIONS .278
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 279
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 279
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING 280
A) WHEN SWING LOCK IS ON .280
B) WHEN SWING LOCK IS OFF 280
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) .281
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM 282
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) .283
M-2 WHEN THE STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 283
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 284
A) NO GAUGE LAMP LIGHTS UP (CAUTION LAMPS LIGHT UP .284
B) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP) 284
C) CHARGE CAUTION LAMP DOES NOT LIGHT UP 284
D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 284
M-4 WHEN POWER IS ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 285
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .285
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP .286
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP .286
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL) 287
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING .287
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 288
A) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE 288
B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE .288
C) COOLANT TEMPERATURE GAUGE GOES OUT 288
M-11 ABNORMALITY IN FUEL GAUGE .289
A) ALL FUEL GAUGE SEGMENTS GO OUT 289
B) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL .289
C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL .289
M-12 DEFECTIVE OPERATION OF ALARM BUZZER .291
A) BUZZER DOES NOT SOUND .291
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP .291
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE 292
A) CHARGE CAUTION LAMP LIGHTS UP 292
B) CHARGE CAUTION LAMP DOES NOT LIGHT UP .292
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 293
A) GAUGE LIGHTING DOES NOT LIGHT UP 293
B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 293
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING 294
A) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED ON 294
B) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED ON .294
M-16 HEATER DOES NOT WORK AT EITHER HI OR LO .296
A) DOES NOT WORK AT EITHER HI OR LO 296
B) DOES NOT WORK AT LO ONLY .296
C) DOES NOT WORK AT HI ONLY .296
30 DISASSEMBLY AND ASSEMBLY 297
METHOD OF USING MANUAL .299
PRECAUTIONS WHEN CARRYING OUT OPERATION 300
SPECIAL TOOL LIST 302
SKETCHES OF SPECIAL TOOLS 306
STARTING MOTOR ASSEMBLY 307
REMOVAL AND INSTALLATION .307
ALTERNATIVE ASSEMBLY .308
REMOVAL AND INSTALLATION .308
AIR CONDITIONER COMPRESSOR ASSEMBLY 309
REMOVAL AND INSTALLATION .309
CONDENSER ASSEMBLY .310
REMOVAL AND INSTALLATION .310
ENGINE OIL COOLER CORE ASSEMBLY 311
REMOVAL AND INSTALLATION .311
FUEL INJECTION PUMP ASSEMBLY .312
REMOVAL 312
INSTALLATION .315
WATER PUMP ASSEMBLY 317
REMOVAL AND INSTALLATION .318
NOZZLE HOLDER ASSEMBLY .319
REMOVAL AND INSTALLATION .319
TURBOCHARGER ASSEMBLY 320
REMOVAL AND INSTALLATION .320
THERMOSTAT ASSEMBLY 321
REMOVAL AND INSTALLATION .322
CYLINDER HEAD ASSEMBLY .323
REMOVAL 323
INSTALLATION .327
RADIATOR – HYDRAULIC COOLER ASSEMBLY .330
REMOVAL 330
INSTALLATION .332
ENGINE – MAIN PUMP ASSEMBLY 333
REMOVAL 333
INSTALLATION .337
DAMPER ASSEMBLY 338
REMOVAL AND INSTALLATION .338
FUEL TANK ASSEMBLY .339
REMOVAL AND INSTALLATION .339
CENTER SWIVEL JOINT ASSEMBLY .340
REMOVAL AND INSTALLATION .341
DISASSEMBLY AND ASSEMBLY .342
FINAL DRIVE ASSEMBLY .343
REMOVAL AND INSTALLATION .343
DISASSEMBLY 344
ASSEMBLY .347
SPROCKET 352
REMOVAL AND INSTALLATION .352
SWIMG MOTOR, SWING MACHINERY .353
REMOVAL AND INSTALLATION .354
DISASSEMBLY 355
ASSEMBLY .359
REVOLVING FRAME ASSEMBLY 364
REMOVAL 364
INSTALLATION .365
SWING CIRCLE ASSEMBLY 366
REMOVAL 366
INSTALLATION .367
IDLER – RECOIL SPRING ASSEMBLY .368
REMOVAL AND INSTALLATION .368
RECOIL SPRING ASSEMBLY .369
DISASSEMBLY 369
ASSEMBLY .370
IDLER ASSEMBLY .371
DISASSEMBLY 371
ASSEMBLY .372
TRACK ROLLER ASSEMBLY 374
REMOVAL AND INSTALLATION .374
DISASSEMBLY 375
ASSEMBLY .377
CARRIER ROLLER ASSEMBLY 379
REMOVAL AND INSTALLATION .379
DISASSEMBLY 380
ASSEMBLY .382
TRACK SHOE ASSEMBLY 384
REMOVAL AND INSTALLATION .384
HYDRAULAIC TANK ASSEMBLY .385
REMOVAL 385
INSTALLATION .386
MAIN PUMP ASSEMBLY .387
REMOVAL 387
INSTALLATION .389
MAIN PUMP INPUT SHAFT OIL SEAL .390
REMOVAL AND INSTALLATION .390
CONTROL VALVE ASSEMBLY .391
REMOVAL 391
INSTALLATION .393
DISASSEMBLY 394
ASSEMBLY .399
MAIN RELIEF VALVE ASSEMBLY .405
DISASSEMBLY AND ASSEMBLY .405
PC VALVE ASSEMBLY 406
REMOVAL AND INSTALLATION .407
LS VALVE ASSEMBLY 408
REMOVAL AND INSTALLATION .408
PC-EPC VALVE ASSEMBLY 409
REMOVAL AND INSTALLATION .409
SOLENOID VALVE ASSEMBLY 410
REMOVAL AND INSTALLATION .410
WORK EQUIPMENT – SWING PPC VALVE ASSEMBLY 411
REMOVAL AND INSTALLATION .411
DISASSEMBLY 412
ASSEMBLY .413
TRAVEL PPC VALVE ASSEMBLY 414
REMOVAL AND INSTALLATION .414
DISASSEMBLY AND ASSEMBLY .415
ASSEMBLY .416
BOOM LOCK VALVE ASSEMBLY .417
REMOVAL AND INSTALLATION .417
BOOM CYLINDER ASSEMBLY .418
REMOVAL 418
INSTALLATION .419
ARM CYLINDER ASSEMBLY .420
REMOVAL 420
INSTALLATION .421
BUCKET CYLINDER ASSEMBLY .422
REMOVAL 422
INSTALLATION .423
HYDRAULIC CYLINDER ASSEMBLY 424
DISASSEMBLY 424
ASSEMBLY .427
WORK EQUIPMENT ASSEMBLY 431
REMOVAL 431
INSTALLATION .432
BUCKET ASSEMBLY 433
REMOVAL 433
INSTALLATION .434
ARM ASSEMBLY .435
REMOVAL 435
INSTALLATION .436
BUCKET – ARM ASSEMBLY 437
REMOVAL 437
INSTALLATION .438
BOOM ASSEMBLY 298
REMOVAL 298
INSTALLATION .298
OPERATOR’S CAB ASSEMBLY 439
REMOVAL AND INSTALLATION .439
COUNTERWEIGHT ASSEMBLY .440
REMOVAL AND INSTALLATION .440
MONITOR ASSEMBLY .441
REMOVAL AND INSTALLATION .441
40 MAINTENANCE STANDARD 442
SWING MACHINERY 443
SWING CIRCLE .445
FINAL DRIVE 446
TRACK FRAME – RECOIL SPRING 448
IDLER 449
CARRIER ROLLER .451
TRACK ROLLER .452
TRACK SHOE .453
HYDRAULIC PUMP .458
CONTROL VALVE 459
SELF-REDUCING PRESSURE VALVE .466
SWING MOTOR 467
TRAVEL MOTOR .468
WORK EQUIPMENT – SWING PPC VALVE .469
TRAVEL PPC VALVE .470
SERVICE PPC VALVE 471
CENTER SWIVEL JOINT 472
BOOM HOLDING VALVE .474
HYDRAULIC CYLINDER .475
WORK EQUIPMENT .477
DIMENSION OF WORK EQUIPMENT 479
90 OTHERS 483
HYDRAULIC PIPING DRAWING .484
HYDRAULIC CIRCUIT DIAGRAM 490
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2) .492
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2) .496
ELECTRICAL CIRCUIT DIAGRAM (1/2) .500
ELECTRICAL CIRCUIT DIAGRAM (2/2) .504
OPERATION OF CLSS SYSTEM AS A WHOLE 508
1. WHEN ALL WORK EQUIPMENT IS NEUTRAL 508
2. ONE SIDE ACTUATED, OTHER SIDE NEUTRAL .512
3. ARM OUT, STANDARD MODE RELIEF (CUT-OFF CONTROL) 516
4. BUCKET DUMP, POWER MAX RELIEF .520
5. BOOM RAISE 524
6. SWING OPERATED INDEPENDENTLY 528
7. TRAVEL OPERATED INDEPENDENTLY .532
8. COMPOUND OPERATION 536

G.B 27/12/24