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Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual A86001 and up – PDF DOWNLOAD
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Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual
SERIAL NUMBERS:
PC200LC-7L A86001 and UP
PC220LC-7L A86001 and UP
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Description
Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200LC-7L, PC220LC-7L
Serial Number: A86001 and up
Book Code: CEBM005806
Language: English
Pages: 852
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual
1 GENERAL :
- 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, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure, function and maintenance standard of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made 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.
OTHER:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu PC200LC-7L, PC220LC-7L Hydraulic Excavator Shop Manual
COVER........................................................................... 1 CONTENTS........................................................................ 2 SAFETY.......................................................................... 11 SAFETY NOTICE............................................................... 11 IMPORTANT SAFETY NOTICE................................................. 11 GENERAL PRECAUTIONS..................................................... 11 PREPARATIONS FOR WORK................................................... 11 PRECAUTIONS DURING WORK................................................. 11 GENERAL......................................................................... 13 HOW TO READ THE SHOP MANUAL..................................................... 14 VOLUMES..................................................................... 14 DISTRIBUTION AND UPDATING................................................... 14 FILING METHOD............................................................... 14 REVISED EDITION MARK........................................................ 14 REVISIONS................................................................... 14 SYMBOLS..................................................................... 14 HOISTING INSTRUCTIONS........................................................... 15 HOISTING.................................................................... 15 WIRE ROPES.................................................................. 15 PUSH-PULL TYPE COUPLER.......................................................... 16 COATING MATERIALS............................................................... 18 STANDARD TIGHTENING TORQUE...................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................ 20 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS..................................... 21 TIGHTENING TORQUE FOR FLARED NUTS........................................... 21 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS................... 21 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS........................... 22 TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES............................. 22 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...... 23 ELECTRIC WIRE CODE.............................................................. 24 CLASSIFICATION BY THICKNESS................................................. 24 CLASSIFICATION BY COLOR AND CODE............................................ 24 CONVERSION TABLES............................................................... 25 METHOD OF USING THE CONVERSION TABLE........................................ 25 01 GENERAL...................................................................... 31 SPECIFICATION DIMENSION DRAWINGS............................................ 32 PC200LC-7L, PC220LC-7L.................................................. 32 DIMENSIONS.......................................................... 32 WORKING RANGES...................................................... 33 SPECIFICATIONS.............................................................. 34 WEIGHT TABLE................................................................ 36 FUEL, COOLANT AND LUBRICANTS................................................ 38 10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS.................................. 39 ENGINE RELATED PARTS........................................................ 41 RADIATOR, OIL COOLER AND AFTERCOOLER........................................ 42 POWER TRAIN................................................................. 43 FINAL DRIVE................................................................. 45 SWING MACHINERY............................................................. 48 PC200LC-7............................................................... 48 PC220LC-7............................................................... 50 SWING CIRCLE................................................................ 52 PC200LC-7............................................................... 52 PC220LC-7............................................................... 54 UNDERCARRIAGE............................................................... 56 IDLER....................................................................... 58 CARRIER ROLLER.............................................................. 60 TRACK ROLLER................................................................ 62 TRACK CHAIN AND SHOES....................................................... 64 TRIPLE GROUSER SHOE..................................................... 67 SWAMP SHOE.............................................................. 67 HYDRAULIC EQUIPMENT......................................................... 68 HYDRAULIC TANK.............................................................. 70 HYDRAULIC PUMP.............................................................. 71 HPV95+95................................................................ 71 LS VALVE............................................................ 75 PC VALVE............................................................ 76 LS(PC)-EPC VALVE........................................................ 88 MAIN CONTROL VALVE.......................................................... 92 PC200LC-7L.............................................................. 92 PC220LC-7L..............................................................106 MAIN RELIEF VALVE...........................................................122 VARIABLE PRESSURE COMPENSATION VALVE........................................123 CLSS........................................................................126 OUTLINE OF CLSS.........................................................126 SELF PRESSURE REDUCING VALVE................................................129 SWING MOTOR.................................................................132 SPECIFICATIONS..........................................................132 RELIEF VALVE PORTION....................................................137 REVERSE PREVENTION VALVE....................................................138 CENTER SWIVEL JOINT.........................................................141 TRAVEL MOTOR................................................................142 HMV110-2................................................................142 SPECIFICATIONS..........................................................142 TRAVEL JUNCTION VALVE.......................................................151 TRAVEL PPC SHUTTLE VALVE....................................................153 VALVE CONTROL...............................................................155 WORK EQUIPMENT AND SWING PPC VALVE..........................................157 TRAVEL PPC VALVE............................................................162 SERVICE PPC VALVE...........................................................172 SOLENOID VALVE..............................................................176 PPC ACCUMULATOR.............................................................178 SPECIFICATIONS..........................................................178 BREAKER RETURN OIL FILTER...................................................179 SPECIFICATIONS..........................................................179 BOOM DRIFT PREVENTION VALVE.................................................180 LIFT CHECK VALVE............................................................184 ATTACHMENT SELECTOR VALVE...................................................185 EQUIPMENT CYLINDERS.........................................................188 PC200LC-7L..............................................................188 BOOM CYLINDER.......................................................188 ARM CYLINDER........................................................188 BUCKET CYLINDER.....................................................188 PC220LC-7L..............................................................190 BOOM CYLINDER.......................................................190 ARM CYLINDER........................................................190 BUCKET CYLINDER.....................................................190 WORK EQUIPMENT..............................................................192 PC200LC-7L..............................................................193 PC220LC-7L..............................................................194 ARM DIMENSION...........................................................196 BUCKET DIMENSIONS.......................................................198 AIR CONDITIONER.............................................................200 ENGINE CONTROLS.............................................................201 COMPONENT...............................................................203 FUEL CONTROL DIAL...................................................203 GOVERNOR MOTOR......................................................204 ENGINE THROTTLE AND PUMP CONTROLLER.....................................206 INPUT AND OUTPUT SIGNALS............................................207 ELECTRONIC CONTROL SYSTEM...................................................208 MACHINE CONTROL SYSTEM DIAGRAM..........................................209 ENGINE AND PUMP CONTROL FUNCTION....................................211 PUMP VALVE CONTROL FUNCTION.........................................215 ONE TOUCH POWER MAXIMIZING FUNCTION.................................217 AUTO DECELERATION FUNCTION..........................................218 AUTO WARM UP OVERHEAT PREVENTION....................................220 SWING CONTROL FUNCTION..............................................222 TRAVEL CONTROL FUNCTION.............................................224 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION.........................226 SYSTEM COMPONENT PARTS..................................................227 ENGINE REVOLUTION SENSOR............................................227 PPC OIL PRESSURE SWITCH.............................................228 PUMP PRESSURE SENSOR................................................229 MULTI MONITOR SYSTEM........................................................230 MONITOR PANEL...........................................................231 INPUT AND OUTPUT SIGNALS............................................232 MONITOR CONTROL, DISPLAY PORTION........................................233 MONITOR PORTION.....................................................233 MONITOR ITEMS AND DISPLAY...........................................234 SWITCHES................................................................238 SELECT MODE FUNCTION................................................240 METHOD OF USE.......................................................240 MAINTENANCE FUNCTION................................................243 METHOD OF CHECKING STATUS MAINTENANCE ITEMS.........................244 MAINTENANCE OPERATION...............................................244 BRIGHTNESS CONTRAST ADJUSTMENT FUNCTION.............................245 SERVICE METER CHECK FUNCTION........................................246 DISPLAY LCD CHECK FUNCTION..........................................246 USER CODE DISPLAY FUNCTION..........................................246 SENSORS.....................................................................248 ENGINE OIL LEVEL SENSOR.................................................248 COOLANT TEMPERATURE SENSOR..............................................249 HYDRAULIC OIL TEMPERATURE SENSOR........................................249 ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)...........................249 FUEL LEVEL SENSOR.......................................................250 AIR CLEANER CLOGGING SENSOR.............................................250 20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................251 STANDARD VALUE TABLES.......................................................252 ENGINE PARTS............................................................252 CHASSIS PARTS...........................................................253 FLOW CONTROL CHARACTERISTIC OF PC VALVE.................................262 TESTING AND ADJUSTING.......................................................263 TOOLS FOR TESTING.......................................................265 ENGINE COMPONENTS.......................................................268 ENGINE RPM..........................................................268 EXHAUST GAS COLOR...................................................268 VALVE CLEARANCE.....................................................268 ENGINE COMPRESSION PRESSURE.........................................268 BLOW BY PRESSURE....................................................268 FUEL INJECTION TIMING...............................................268 ENGINE OIL PRESSURE.................................................268 ENGINE SPEED SENSOR.................................................268 AIR CONDITIONER BELT....................................................269 INSPECTION..........................................................269 ADJUSTMENT..........................................................269 ENGINE CONTROL SYSTEM FAILURE...........................................270 SWING CIRCLE BEARINGS...................................................271 TRACK SHOE TENSION......................................................272 INSPECTION..........................................................272 ADJUSTMENT..........................................................272 EQUIPMENT, SWING AND TRAVEL PRESSURES...................................273 MEASUREMENT.........................................................273 PRE MEASUREMENT WORK............................................273 COMBINATION OF PUMP, ACTUATOR AND VALVE.........................274 UNLOAD PRESSURE.................................................274 WORK EQUIPMENT RELIEF PRESSURE..................................274 SWING RELIEF PRESSURE...........................................274 TRAVEL CIRCUIT RELIEF PRESSURE..................................275 ADJUSTMENT..........................................................276 MAIN RELIEF PRESSURE............................................276 SWING RELIEF PRESSURE...........................................277 CONTROL CIRCUIT OIL PRESSURE............................................278 PUMP PC CONTROL CIRCUIT PRESSURE........................................279 TESTING.............................................................279 PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)..........279 PC-EPC OUTPUT PRESSURE..........................................280 ADJUSTMENT..........................................................281 PUMP LS CONTROL CIRCUIT PRESSURE........................................282 MEASUREMENT.........................................................282 LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)..........282 LS DIFFERENTIAL PRESSURE........................................283 LS-EPC VALVE OUTPUT PRESSURE....................................285 ADJUSTMENT..........................................................286 SOLENOID VALVE OUTPUT PRESSURE..........................................287 TESTING.............................................................287 TABLE FOR FUNCTIONING CONDITIONS....................................288 PPC LOCK SOLENOID VALVE.........................................288 SWING AND PARKING BRAKE SOLENOID................................288 TRAVEL INTERCONNECTION SOLENOID VALVE...........................288 TRAVEL SPEED SHIFTING SOLENOID VALVE............................288 2 STAGE RELIEF SOLENOID VALVE...................................289 MERGE DIVIDE SOLENOID VALVE.....................................289 PPC VALVE OUTPUT PRESSURE...............................................290 EQUIPMENT AND SWING PPC VALVE...........................................291 WORK EQUIPMENT DRIFT....................................................292 BOOM AND BUCKET CYLINDERS...........................................292 ARM CYLINDER........................................................292 BOOM LOCK VALVE.....................................................293 PPC VALVE...........................................................293 RELEASE REMAINING PRESSURE..............................................294 OIL LEAKAGE AMOUNT......................................................295 BOOM CYLINDER.......................................................295 ARM CYLINDER........................................................295 BUCKET CYLINDER.................................................296 SWING MOTOR.....................................................296 TRAVEL MOTOR........................................................297 BLEEDING AIR............................................................298 HYDRAULIC PUMP......................................................298 HYDRAULIC CYLINDERS.................................................299 SWING MOTOR.........................................................299 TRAVEL MOTOR........................................................299 INSPECTION PROCEDURES FOR DIODE.........................................300 USING DIGITAL TYPE CIRCUIT TESTER...................................300 USING ANALOG TYPE CIRCUIT TESTER....................................300 MULTI MONITOR PANEL.....................................................301 MONITOR PANEL FUNCTIONS - CONVENTIONAL AND SPECIAL..................302 CONVENTIONAL FUNCTION: OPERATOR'S MENU..........................302 SPECIAL FUNCTION: SERVICE MENU..................................302 OPERATOR'S MENU AND DISPLAY (OUTLINE)...............................303 2. SHOWING KOMATSU LOGO.........................................303 3. MACHINE INSPECTION BEFORE STARTING WORK......................303 4. MACHINE MAINTENANCE..........................................303 5. SHOWING PRECAUTION ITEMS.....................................303 6. CONFIRMING WORKING MODE AND TRAVEL SPEED.....................304 7. DISPLAY OF ORDINARY ITEMS....................................304 8. ADJUSTING DISPLAY LUMINANCE AND CONTRAST.....................304 9. ADJUSTING BREAKER AND ATTACHMENT FLOW RATE...................304 10. CONFIRMING MAINTENANCE INFORMATION..........................305 11. SHOWING SERVICE METER READING...............................305 12. CHECKING DISPLAY LCD........................................305 13. SHOWING OCCURRENCE OF CAUTION ITEM..........................305 14. SHOWING USERS CODE NO.......................................306 15. SHOWING SERVICE CODE AND FAILURE CODE NO....................306 TABLE FOR SERVICE AND FAILURE CODE NOS..............................308 OPERATION AND DISPLAY OF SERVICE MENU...............................310 WAY OF SWITCHING TO SERVICE MENU................................310 TABLE FOR MONITORING ITEMS..........................................313 17. FUNCTION FOR ABNORMALITY RECORD [02]........................315 18. FUNCTION FOR MAINTENANCE RECORD [03]........................317 19. Function for Maintenance Mode Change [04]...................318 20. FUNCTION FOR PHONE NUMBER ENTRY [05]........................319 21. FUNCTION FOR /DEFAULT [06]..................................320 22. FUNCTION FOR ADJUSTMENT [07]................................321 ELECTRICAL SYSTEM PREPARATIONS..........................................324 MONITOR PANEL.......................................................324 GOVERNOR PUMP CONTROLLER............................................324 GOVERNOR PUMP CONTROLLER............................................325 PC200LC-7L..........................................................326 ENGINE TUNE UP..................................................327 HYDRAULIC SYSTEM................................................328 PC220LC-7L..........................................................331 ENGINE TUNE UP..................................................332 HYDRAULIC SYSTEM................................................333 TROUBLESHOOTING.............................................................337 TROUBLESHOOTING POINTS TO REMEMBER......................................338 SEQUENCE OF EVENTS......................................................340 MAINTENANCE POINTS TO REMEMBER..........................................341 WHEN HANDLING ELECTRIC EQUIPMENT....................................341 WHEN TROUBLESHOOTING ELECTRIC CIRCUITS..............................345 WHEN HANDLING HYDRAULIC EQUIPMENT...................................346 CHECKS BEFORE TROUBLESHOOTING...........................................348 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING............................349 CLASSIFICATION OF TROUBLESHOOTING...................................349 STEPS FOR TROUBLESHOOTING...........................................349 FAILURE LOOKING PHENOMENON AND TROUBLESHOOTING NO...................350 ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM....................................353 CONNECTOR TABLE.....................................................353 PC200LC-7L S/N A86001-A87017....................................353 PC220LC-7L S/N A86001-A86659....................................353 PC200LC-7L S/N A87018-UP........................................358 PC220LC-7L S/N A86660-UP........................................358 CONNECTOR LOCATION..................................................364 PC200LC-7L S/N A86001-A87017....................................364 PC220LC-7L S/N A86001-A86659....................................364 PC200LC-7L S/N A87018-UP........................................370 PC220LC-7L S/N A86660-UP........................................370 MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)....................376 PC200LC-7L S/N A86001-A87017....................................376 PC220LC-7L S/N A86001-A86659....................................376 PC200LC-7L S/N A87018-UP........................................378 PC220LC-7L S/N A86660-UP........................................378 GOVERNOR CONTROL SYSTEM CIRCUIT DIAGRAM (G CIRCUIT).................380 PC200LC-7L S/N A86001-A87017....................................380 PC220LC-7L S/N A86001-A86659....................................380 PC200LC-7L S/N A87018-UP........................................382 PC220LC-7L S/N A86660-UP........................................382 PUMP CONTROL SYSTEM CIRCUIT DIAGRAM (P CIRCUIT).....................384 PC200LC-7L S/N A86001-A87017....................................384 PC220LC-7L S/N A86001-A86659....................................384 PC200LC-7L S/N A87018-UP........................................386 PC220LC-7L S/N A86660-UP........................................386 TABLE FOR CONNECTOR PIN NUMBERS.........................................388 T-BRANCH BOX AND T-BRANCH TABLE.........................................410 BEFORE TROUBLESHOOTING FOR DISPLAYED CODE...............................414 TROUBLESHOOTING ELECTRICAL SERVICE CODES AND MECHANICAL FAILURE CODES.......421 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM..........................423 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.......423 USER CODE MEMORY RETENTION FUNCTION.................................423 INFORMATION CONTAINED IN TESTING PROCEDURES.............................424 E101 ERROR IN DATA HISTORY..............................................428 E112 SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM..........................430 E113 SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE.............432 E114 SHORT OR OPEN IN WINDOW WASHER SYSTEM..............................434 E115 ABNORMAL WIPER MOTOR OPERATION.....................................438 E116 ABNORMALITY IN PARKING WIPER ARM...................................440 E201 SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID......................442 E203 SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM..............446 E204 SHORT IN MERGE/DIVIDE SOLENOID.....................................450 E205 SHORT IN 2 STAGE RELIEF SOLENOID...................................454 E206 SHORT IN TRAVEL SPEED SHIFT SOLENOID...............................458 E211 OPEN IN TRAVEL INTERLOCKING SOLENOID...............................462 E213 OPEN IN SWING PARKING BRAKE SOLENOID...............................466 E214 OPEN IN MERGE/DIVIDE SOLENOID......................................474 E215 OPEN IN 2 STAGE RELIEF SOLENOID....................................478 E216 OPEN IN TRAVEL SPEED SOLENOID......................................482 E217 ABNORMAL INPUT FOR MODEL CODE - PC200LC-7L.........................486 E217 ABNORMAL INPUT FOR MODEL CODE - PC220LC-7L.........................488 E218 OPEN IN S-NET SIGNAL...............................................490 E222 SHORT IN LS-EPC SOLENOID...........................................492 E223 OPEN IN LS-EPC SOLENOID SYSTEM.....................................494 E224 ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL.............................496 E225 ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL.............................498 E226 ABNORMAL PRESSURE SENSOR POWER SUPPLY..............................500 E227 ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER.............502 E228 SHORT IN ATTACHMENT RETURN SWITCHING RELAY.........................504 E232 SHORT IN PC-EPC SOLENOID...........................................506 E233 OPEN IN PC-EPC SOLENOID SYSTEM.....................................508 E238 OPEN IN ATTACHMENT RETURN SWITCH RELAY.............................510 E245 SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM.......................512 E246 OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM........................514 E256 INCORRECT NONVOLATILE MEMORY DATA..................................516 E306 ABNORMAL GOVERNOR POTENTIOMETER SIGNALS............................518 E308 ABNORMAL FUEL DIAL SIGNALS.........................................520 E315 SHORT IN BATTERY RELAY SYSTEM......................................522 E316 STEP OUT IN GOVERNOR MOTOR.........................................524 E317 OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"...........................526 E318 SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"..........................528 E501 MODEL SELECTION FUNCTION NOT PROVIDED..............................530 E502 MODEL SELECTING SIGNAL FAULT.......................................531 A000N1 ENGINE SPEED OUT OF RANGE AT HIGH IDLE...........................532 A000N2 ENGINE SPEED OUT OF RANGE AT LOW IDLE............................533 AA10NX AIR CLEANER CLOG INDICATOR FAILURE...............................534 AB00KE LOW CHARGING VOLTAGE INDICATED...................................536 B@BAZG ABNORMAL ENGINE OIL PRESSURE.....................................540 B@BAZK ABNORMAL ENGINE OIL LEVEL........................................542 B@BCNS ENGINE COOLANT INDICATING OVERHEAT CONDITION.....................544 B@BCZK ABNORMAL COOLANT LEVEL INDICATION................................546 B@HANS HYDRAULIC OIL OVERHEAT INDICATION................................548 TROUBLESHOOTING ELECTRICAL SYSTEM E MODE....................................551 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM..........................552 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF.......552 USER CODE MEMORY RETENTION FUNCTION.................................552 INFORMATION CONTAINED IN TESTING PROCEDURES.............................553 E-1 ENGINE WILL NOT CRANK...............................................555 E-2 ENGINE STOPS WHILE IN OPERATION.....................................558 E-3 ENGINE SPEED IRREGULAR, OR HUNTING..................................560 E-4 ENGINE DOES NOT STOP................................................564 E-5 AUTO DECELERATOR DOES NOT WORK......................................567 E-6 AUTO ENGINE WARM UP DEVICE DOES NOT WORK............................568 E-7 COLD START PREHEATER DOES NOT WORK..................................570 E-8 ALL WORK EQUIPMENT, SWING AND TRAVEL DOES NOT OPERATE...............572 E-9 ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE.........................574 E-10 NO DISPLAY ON MONITOR PANEL........................................576 E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING........................578 E-12 MONITOR PANEL DISPLAY CONTENTS IRRELEVANT TO THE MODEL.............579 E-13 FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL.........580 E-14 ENGINE COOLANT TEMPERATURE GAUGE NOT INDICATING CORRECTLY..........582 E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........584 E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..............................586 E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY......................588 E-18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS............590 E-19 WINDSHIELD WIPER DOES NOT WORK.....................................592 E-20 ALARM BUZZER CANNOT BE CANCELLED...................................594 E-21 BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR......................596 E-22 BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR......................598 E-23 ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR.....................600 E-24 ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR......................602 E-25 BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR.....................604 E-26 BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR.....................606 E-27 SWING NOT CORRECTLY DISPLAYED ON MONITOR...........................608 E-28 TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR..........................610 E-29 TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR....612 E-30 SERVICE NOT CORRECTLY DISPLAYED ON MONITOR.........................614 E-31 AIR CONDITIONER SYSTEM DOES NOT WORK...............................616 E-31-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR...................621 E-31-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE....................621 E-31-E15 DISCONNECTION IN COOLANT TEMPERATURE SENSOR................622 E-31-E16 SHORT CIRCUIT IN COOLANT TEMPERATURE SENSOR................622 E-31-E18 SHORT IN DAYLIGHT SENSOR...................................623 E-31-E43 ABNORMALITY IN AIR OUTLET DAMPER...........................623 E-31-E44 ABNORMALITY IN AIR MIX DAMPER..............................624 E-31-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER...........624 E-31 - TROUBLESHOOTING BY FAILURE PHENOMENON........................626 E-32 TRAVEL ALARM DOES NOT SOUND........................................630 TROUBLE SHOOTING MECHANICAL SYSTEM H MODE...................................633 SYSTEM CHART............................................................635 HYDRAULIC AND MECHANICAL SYSTEMS....................................635 INFORMATION CONTAINED IN TESTING TABLES.................................637 H-1 WORK EQUIPMENT LACKS POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW.....638 H-2 ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS.........................639 H-3 NO WORK EQUIPMENT, TRAVEL OR SWING OPERATION........................640 H-4 ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP.........................641 H-5 AUTO DECELERATOR DOES NOT WORK......................................642 H-6 FINE CONTROL MODE DOES NOT FUNCTION.................................643 H-7 BOOM MOVES SLOWLY OR LACKS POWER....................................644 H-8 ARM MOVES SLOWLY OR LACKS POWER.....................................645 H-9 BUCKET MOVES SLOWLY OR LACKS POWER..................................646 H-10 WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION.................647 H-11 WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT.......................648 H-12 WORK EQUIPMENT EXCESSIVE LAG TIME..................................649 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT.........650 H-14 ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE........................651 H-15 WORK EQUIPMENT WITH HEAVIER LOADS MOVES SLOWLY.....................652 H-16 SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY..................653 H-17 SWING AND TRAVEL, TRAVEL SPEED DROPS SHARPLY.......................654 H-18 MACHINE TRAVEL DIRECTION VARIES....................................655 H-19 MACHINE TRAVEL IS SLOW.............................................656 H-20 MACHINE CANNOT BE STEERED OR LACKS POWER...........................657 H-21 TRAVEL SPEED IS TOO SLOW OR TOO FAST...............................658 H-22 TRACKS DO NOT TURN (ON ONE SIDE ONLY)..............................659 H-23 MACHINE DOES NOT SWING.............................................660 H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW.................661 H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING..............................662 H-26 SUDDEN SHOCK WHEN STOPPING SWING...................................663 H-27 ABNORMAL NOISE WHEN STOPPING SWING.................................664 H-28 SWING HAS EXCESSIVE DRIFT..........................................665 METHOD OF USING MANUAL..................................................671 30 DISASSEMBLY AND ASSEMBLY.....................................................667 PRECAUTIONS DURING OPERATION................................................672 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..............................672 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.........................673 PRECAUTIONS WHEN COMPLETING THE OPERATIONS..............................674 OTHER PRECAUTIONS.......................................................674 SPECIAL TOOL LIST...........................................................675 SKETCHES OF SPECIAL TOOLS...................................................679 ENGINE......................................................................680 AFTERCOOLER CORE........................................................680 ALTERNATOR..............................................................680 CYLINDER HEAD...........................................................680 ENGINE FRONT SEAL.......................................................680 ENGINE OIL COOLER.......................................................680 ENGINE REAR SEAL........................................................680 FUEL INJECTION PUMP.....................................................680 NOZZLE HOLDER...........................................................680 STARTING MOTOR..........................................................680 THERMOSTAT..............................................................680 TURBOCHARGER............................................................680 WATER PUMP..............................................................680 CONNECTOR REPAIR PROCEDURES.................................................681 CONTACT TERMINAL REMOVAL (HD30 TYPE)....................................681 STRIPING INSULATION.....................................................682 CRIMPING CONTACT TERMINAL (HD30 TYPE)...................................683 INSERTION OF CONTACT TERMINAL (HD30 TYPE)...............................684 CONTACT TERMINAL REMOVAL (DT TYPE)......................................685 STRIPING INSULATION.....................................................686 CRIMPING CONTACT TERMINAL (DT TYPE).....................................687 INSERTION OF CONTACT TERMINAL (DT TYPE).................................688 RADIATOR....................................................................689 REMOVAL.................................................................689 INSTALLATION............................................................690 HYDRAULIC OIL COOLER........................................................691 REMOVAL.................................................................691 INSTALLATION............................................................692 ENGINE AND HYDRAULIC PUMPS..................................................693 REMOVAL.................................................................693 INSTALLATION............................................................697 FINAL DRIVE.................................................................699 REMOVAL.................................................................699 INSTALLATION............................................................700 DISASSEMBLY.............................................................701 ASSEMBLY................................................................704 SWING MOTOR AND SWING MACHINERY.............................................709 REMOVAL.................................................................709 INSTALLATION............................................................709 DISASSEMBLY.............................................................710 PC200LC-7L S/N A86001-A87017........................................710 PC220LC-7L S/N A86001-A86659........................................710 ASSEMBLY................................................................713 PC200LC-7L S/N A86001-A87017........................................713 PC220LC-7L S/N A86001-A86659........................................713 DISASSEMBLY.............................................................719 PC200LC-7L S/N A87018-UP............................................719 PC220LC-7L S/N A86660-UP............................................719 ASSEMBLY................................................................722 PC200LC-7L S/N A87018-UP............................................722 PC220LC-7L S/N A86660-UP............................................722 CARRIER ROLLER..............................................................728 ASSEMBLY................................................................728 TRACK ROLLER................................................................729 ASSEMBLY................................................................729 IDLER.......................................................................730 DISASSEMBLY.............................................................730 ASSEMBLY................................................................731 RECOIL SPRING...............................................................733 DISASSEMBLY.............................................................733 ASSEMBLY................................................................734 SPROCKET....................................................................736 REMOVAL.................................................................736 INSTALLATION............................................................736 TRACK SHOE..................................................................737 REMOVAL AND EXPANSION TRACK SHOE........................................737 INSTALLATION TRACK SHOE.................................................738 ROAD LINERS.................................................................739 REMOVAL AND EXPANSION...................................................739 INSTALLATION............................................................740 SWING CIRCLE................................................................741 REMOVAL.................................................................741 INSTALLATION............................................................742 REVOLVING FRAME.............................................................743 REMOVAL.................................................................743 INSTALLATION............................................................745 CENTER SWIVEL JOINT.........................................................746 REMOVAL.................................................................746 INSTALLATION............................................................747 DISASSEMBLY.............................................................748 ASSEMBLY................................................................748 HYDRAULIC TANK..............................................................749 REMOVAL.................................................................749 INSTALLATION............................................................751 CONTROL VALVE...............................................................752 REMOVAL.................................................................752 INSTALLATION............................................................754 PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL...............755 ASSEMBLY................................................................756 HYDRAULIC PUMP..............................................................757 REMOVAL.................................................................757 INSTALLATION............................................................759 INPUT SHAFT - OIL SEAL..................................................760 REMOVAL.............................................................760 INSTALLATION........................................................760 WORK EQUIPMENT PPC VALVE....................................................761 ASSEMBLY................................................................761 PC200LC-7L S/N A86001-A87017........................................761 PC220LC-7L S/N A86001-A86659........................................761 ASSEMBLY................................................................762 PC200LC-7L S/N A87018- UP...........................................762 PC220LC-7L S/N -A86660-UP...........................................762 TRAVEL PPC VALVE............................................................763 ASSEMBLY................................................................763 HYDRAULIC CYLINDER..........................................................764 DISASSEMBLY.............................................................764 ASSEMBLY................................................................767 WORK EQUIPMENT..............................................................771 REMOVAL.................................................................771 INSTALLATION............................................................773 AIR CONDITIONER UNIT........................................................774 REMOVAL.................................................................774 PC200LC-7L S/N A86001-A87017........................................774 PC220LC-7L S/N A86001-A86659........................................774 INSTALLATION............................................................777 REMOVAL.................................................................778 PC200LC-7L S/N A87018-UP............................................778 PC220LC-7L S/N A86660-UP............................................778 INSTALLATION............................................................780 COUNTERWEIGHT...............................................................781 REMOVAL.................................................................781 INSTALLATION............................................................781 OPERATOR’S CAB..............................................................782 PC200LC-7L S/N A86001-A87017............................................782 PC220LC-7L S/N A86001-A86659............................................782 INSTALLATION............................................................784 REMOVAL.................................................................785 PC200LC-7L S/N A87018-UP............................................785 PC220LC-7L S/N A86660-UP............................................785 INSTALLATION............................................................787 OPERATOR’S CAB GLASS........................................................788 REMOVAL.................................................................789 INSTALLATION............................................................790 FRONT WINDOW................................................................799 REMOVAL.................................................................799 INSTALLATION............................................................802 MONITOR.....................................................................807 REMOVAL.................................................................807 INSTALLATION............................................................807 GOVERNOR PUMP CONTROLLER....................................................808 REMOVAL.................................................................808 PC200LC-7L S/N A86001-A87017........................................808 PC220LC-7L S/N A86001-A86659........................................808 INSTALLATION............................................................808 REMOVAL.................................................................809 PC200LC-7L S/N A87018-UP............................................809 PC220LC-7L S/N A86660-UP............................................809 INSTALLATION............................................................809 90 OTHERS.......................................................................811 ELECTRICAL - PC200LC-7 S/N A86001-A87017, PC220LC-7 S/N A86001-A86659.......813 CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3)...................................813 CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3)...................................815 CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3)...................................817 CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1)...................................819 CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2)...................................821 CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2)...................................823 CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2)...................................825 CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2)...................................827 ELECTRICAL - PC200LC-7 S/N A87018-UP, PC220LC-7 S/N A86660-UP...............829 CIRCUIT DIAGRAM SHEET 1 OF 9............................................829 CIRCUIT DIAGRAM SHEET 2 OF 9............................................831 CIRCUIT DIAGRAM SHEET 3 OF 9............................................833 CIRCUIT DIAGRAM SHEET 4 OF 9............................................835 CIRCUIT DIAGRAM SHEET 5 OF 9............................................837 CIRCUIT DIAGRAM SHEET 6 OF 9............................................839 CIRCUIT DIAGRAM SHEET 7 OF 9............................................841 CIRCUIT DIAGRAM SHEET 8 OF 9............................................843 CIRCUIT DIAGRAM SHEET 9 OF 9............................................845 HYDRAULIC...................................................................847 HYDRAULIC DIAGRAM (SHEET 1 OF 3)........................................847 HYDRAULIC DIAGRAM (SHEET 2 OF 3)........................................849 HYDRAULIC DIAGRAM (SHEET 3 OF 3)........................................851
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