Komatsu PC200LC-7L PC220LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005806 PDF

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Komatsu PC200LC-7L PC220LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005806  – PDF DOWNL0AD

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Komatsu PC200LC-7L PC220LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005806  – PDF DOWNL0AD

Language : English
Pages : 852
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200LC-7L PC220LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005806  – PDF DOWNL0AD

• SERIAL NUMBERS
  PC200LC-7L    A86001 and up
  PC220LC-7L    A86001 and up

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

DESCRIPTION:

Komatsu PC200LC-7L PC220LC-7L HYDRAULIC EXCAVATOR Shop Manual CEBM005806  – PDF DOWNL0AD

• SERIAL NUMBERS
  PC200LC-7L    A86001 and up
  PC220LC-7L    A86001 and up

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

G.B  21/12/24