Komatsu PC200Z-6LE Hydraulic Excavator Shop Manual CEBM001700 PDF

Description

Komatsu PC200Z-6LE Hydraulic Excavator Shop Manual CEBM001700 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC200Z-6LE Hydraulic Excavator Shop Manual CEBM001700 – PDF DOWNLOAD 

Language : English
Pages : 485
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC200Z-6LE Hydraulic Excavator Shop Manual CEBM001700 – PDF DOWNLOAD 

MACHINE MODEL SERIAL NUMBERS
PC200Z-6LE A83001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu PC200Z-6LE Hydraulic Excavator Shop Manual CEBM001700 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBERS
PC200Z-6LE A83001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
01 GENERAL 20
GENERAL ASSEMBLY DRAWING 21
SPECIFICATIONS 23
WEIGHT TABLE 25
FUEL, COOLANT AND LUBRICANTS 27
ENGINE OIL SPECIFICATION 28
NORMAL OPERATION 28
ARCTIC OPERATION 28
COOLANT 29
10 STRUCTURE AND FUNCTION 30
ENGINE RELATED PARTS 33
SPECIFICATIONS 33
RADIATOR – OIL COOLER 34
SPECIFICATIONS 34
ENGINE CONTROL SYSTEM 35
POWER TRAIN 36
FINAL DRIVE 37
SPECIFICATIONS 37
SWING CIRCLE 38
SPECIFICATIONS 38
SWING MACHINERY 39
SPECIFICATIONS 39
TRACK FRAME – RECOIL SPRING 40
SPECIFICATIONS 40
TRACK SHOE 41
STANDARD SHOE 41
SELECTION OF TRACK SHOE 41
HYDRAULIC PIPING DRAWING 42
HYDRAULIC CIRCUIT DIAGRAM 43
HYDRAULIC TANK 44
HYDRAULIC PUMP 45
BASIC PUMP 45
Outline 45
Function 48
Structure 48
Operation 49
LS and PC valve 51
Function 52
PC valve 52
IN-LINE OIL FILTER 63
Outline 63
CONTROL VALVE 64
Outline 64
6-spool valve (standard) 65
Main structure 66
SAFETY-SUCTION VALVE FOR SERVICE VALVE 70
SELF-REDUCING PRESSURE VALVE 71
Function 73
Operation 73
CLSS 76
Outline of CLSS 76
Features 76
Structure 76
Basic principle 77
Operation for each function and valve 79
Hydraulic circuit diagram for system 79
System diagram 81
Unload valve 82
Introduction of LS pressure 83
LS bypass valve 84
Pressure compensation valve 85
Shuttle valve inside pressure compensation valve 88
Boom regeneration circuit 89
Arm regeneration circuit 91
Pump merge-divider valve (junction valve) 93
LS select valve 95
Spool stroke modulation 96
Timing valve 100
Operation of CLSS system as a whole 101
When all work equipment is at neutral 101
One side actuated, other side neutral 103
Arm OUT, standard mode relief (cut-off control) 105
Boom RAISE 107
Swing operated independently 109
Travel operated independently 111
Compound operation 113
SWING MOTOR 115
BASIC MOTOR 115
Swing lock valve 117
Operation 117
Reverse prevention valve (swing dampening) 118
Operation diagram 118
Explanation of effect 118
Outline 119
Operation 119
CENTER SWIVEL JOINT 120
TRAVEL MOTOR 121
Operation of parking brake 123
Operation of brake valve 124
VALVE CONTROL 127
WORK EQUIPMENT – SWING PPC VALVE 128
Operation 130
TRAVEL PPC VALVE 132
Operation 134
SERVICE PPC VALVE 136
Operation 137
ACCUMULATOR 139
Function 139
Operation 139
STRAIGHT-TRAVEL SYSTEM 140
Function 140
EPC SOLENOID VALVE 141
Operation 142
BOOM LOCK VALVE 143
Operation 144
ADDITIONAL FILTER FOR BREAKER 146
WORK EQUIPMENT 147
AIR CONDITIONER 148
ELECTRICAL WIRING DIAGRAM 149
ELECTRICAL CIRCUIT DIAGRAM 151
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER 153
ELECTRIC CONTROL SYSTEM 154
TOTAL SYSTEM DIAGRAM 154
PUMP CONTROL FUNCTION 155
Function 155
Pump controller 156
SWING LOCK, PPC LOCK FUNCTION 157
Operation 158
MACHINE MONITOR SYSTEM 159
FUNCTION 159
Monitor panel 160
Outline 160
Input/Output signals 160
SENSORS 162
Engine oil pressure sensor 162
Coolant temperature sensor 162
Fuel level sensor 163
20 TESTING, ADJUSTING AND TROUBLESHOOTING 164
TESTING AND ADJUSTING 167
STANDARD VALUE TABLE 168
For engine 168
For chassis 169
For electrical system 177
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 180
MEASURING ENGINE SPEED 181
MEASURING EXHAUST GAS COLOR 182
ADJUSTING VALVE CLEARANCE 183
MEASURING COMPRESSION PRESSURE 184
MEASURING BLOW-BY PRESSURE 184
TESTING AND ADJUSTING FUEL INJECTION TIMING 185
MEASURE ENGINE OIL PRESSURE 186
TESTING AND ADJUSTING FAN BELT TENSION 187
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 187
ADJUSTING SPEED SENSOR 188
ADJUSTING FUEL CONTROL LEVER 189
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT 191
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 194
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE AND LS DIFFERENTIAL PRESSURE) 195
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE 198
TESTING SOLENOID VALVE OUTPUT PRESSURE 199
MEASURING PPC VALVE OUTPUT PRESSURE 201
Plug location diagram 202
ADJUSTING WORK EQUIPMENT – SWING PPC VALVE 203
TESTING TRAVEL DEVIATION 204
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 205
MEASURING OIL LEAKAGE 207
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 209
TESTING CLEARANCE OF SWING CIRCLE BEARING 209
TESTING AND ADJUSTING TRACK SHOE TENSION 210
BLEEDING AIR 211
TROUBLESHOOTING 213
POINTS TO REMEMBER WHEN TROUBLESHOOTING 214
SEQUENCE OF EVENTS IN TROUBLESHOOTING 215
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 216
Points to remember when handling electric equipment 216
Points to remember when troubleshooting electric circuits 221
Points to remember when handling hydraulic equipment 222
CHECKS BEFORE TROUBLESHOOTING 224
CONNECTOR TYPES AND MOUNTING LOCATIONS 225
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 230
METHOD OF USING TROUBLESHOOTING CHARTS 240
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 242
METHOD OF USING TROUBLESHOOTING CHARTS 242
S-1 Starting performance is poor (starting always takes time) 246
S-2 Engine does not start 248
S-3 Engine does not pick up smoothly (follow-up is poor) 251
S-4 Engine stops during operations 252
S-5 Engine does not rotate smoothly (hunting) 253
S-6 Engine lacks output (no power) 254
S-7 Exhaust smoke is black (incomplete combustion) 255
S-8 Oil consumption is excessive (or exhaust smoke is blue) 256
S-9 Oil becomes contaminated quickly 257
S-10 Fuel consumption is excessive 258
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down 259
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 260
S-13 Oil level rises (coolant, fuel in oil) 261
S-14 Coolant temperature becomes too high (overheating) 262
S-15 Abnormal noise is made 263
S-16 Vibration is excessive 264
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 265
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC , AND MECHANICAL SYSTEMS 265
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM 267
E-1 Abnormality in PC-EPC control system 268
E-3 Abnormality in swing holding brake solenoid system 271
E-4 Abnormality in PPC oil pressure lock solenoid system 273
E-5 Abnormality in engine starting system (engine does not start) 275
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 278
TABLE OF FAILURE MODES AND CAUSES 278
H-1 Speeds of all work equipment, travel, swing are slow or lacks power 282
H-2 There is excessive drop in engine speed, or engine stalls 284
H-3 No work equipment, travel, swing move 284
H-4 Abnormal noise generated (around pump) 285
H-5 Fine control ability is poor or response is poor 285
H-6 Boom is slow or lacks power 286
H-7 Arm is slow or lacks power 288
H-8 Bucket is slow or lacks power 290
H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) 290
H-10 Excessive hydraulic drift (boom, arm, bucket) 291
H-11 Excessive time lag (engine at low idle) 292
H-12 Other equipment moves when single circuit is relieved 292
H-13 In compound operations, work equipment with larger load is slow 292
H-14 In swing + boom RAISE, boom RAISE is slow 293
H-15 In swing + travel, travel speed drops excessively 293
H-16 Travel deviation (deviation is excessive in normal travel and when starting) 294
H-17 Travel speed is slow 295
H-18 Steering does not turn easily or lacks power 295
H-19 Travel does not move (one side only) 296
H-21 Does not swing 297
H-22 Swing acceleration is poor or swing speed is slow 298
H-23 Excessive overrun when stopping swing 300
H-24 Excessive shock when stopping swing (one direction only) 300
H-25 Excessive abnormal noise when stopping swing 301
H-26 Excessive hydraulic drift of swing 301
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 303
Monitor system electrical circuit diagram 303
M-1 When the starting switch is turned ON, no display is given (lamps do not light up for 3 seconds) 304
M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out 304
M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds 305
M-4 When power is turned on (before engine is started), charge caution lamp does not light up 306
M-5 When power is turned on (before engine is started), engine oil pressure caution lamp does not light up 307
M-6 During preheating, preheating pilot does not light up 307
M-7 When switch is operated, swing lock lamp does not light up 308
M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil pressure is normal) 309
M-9 Charge caution lamp lights up when engine is running 310
M-10 Abnormality in coolant temperature gauge 310
M-11 Abnormality in fuel gauge 312
M-12 Defective operation of alarm buzzer 314
M-13 Engine is running, but service meter does not move 315
M-14 Night lighting does not light up 316
M-15 Wiper does not move, or does not stop moving 317
M-16 Heater does not work 319
30 DISASSEMBLY AND ASSEMBLY 321
METHOD OF USING MANUAL 325
When removing or installing unit assemblies 325
General precautions 325
Listing of special tools 325
PRECAUTIONS WHEN CARRYING OUT OPERATION 326
Precautions when carrying out removal work 326
Precautions when carrying out installation work 327
Precautions when completing the operations 327
SPECIAL TOOL LIST 328
SKETCHES OF SPECIAL TOOLS 332
STARTING MOTOR 333
Removal 333
Installation 333
ALTERNATOR 334
Removal 334
Installation 334
AIR CONDITIONER COMPRESSOR 335
Removal 335
Installation 335
CONDENSER 336
Removal 336
Installation 336
FUEL INJECTION PUMP 337
Removal 337
Installation 339
WATER PUMP 340
Removal 340
Installation 341
NOZZLE HOLDER 342
Removal 342
Installation 342
TURBOCHARGER 343
Removal 343
Installation 343
THERMOSTAT 344
Removal 344
Installation 345
CYLINDER HEAD ASSEMBLY 346
Removal 346
Installation 349
RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY 350
Removal 350
Installation 352
ENGINE, MAIN PUMP 353
Removal 353
Installation 356
DAMPER 357
Removal 357
Installation 357
FUEL TANK 358
Removal 358
Installation 358
CENTER SWIVEL JOINT 359
Removal 359
Installation 360
Disassembly 361
Assembly 361
FINAL DRIVE 362
Removal 362
Installation 362
Disassembly 363
Assembly 366
SPROCKET 371
Removal 371
Installation 371
SWING MOTOR 372
Removal 372
Installation 372
SWING MACHINERY 373
Removal 373
Installation 373
Disassembly 374
Assembly 377
REVOLVING FRAME 381
Removal 381
Installation 382
SWING CIRCLE 383
Removal 383
Installation 383
IDLER – RECOIL SPRING 384
Removal 384
Installation 384
RECOIL SPRING 385
Disassembly 385
Assembly 386
IDLER 387
Disassembly 387
Assembly 388
TRACK ROLLER 390
Removal 390
Installation 390
Disassembly 391
Assembly 392
CARRIER ROLLER 394
Removal 394
Installation 394
Disassembly 395
Assembly 396
TRACK SHOE 398
Removal 398
Installation 398
HYDRAULIC TANK 399
Removal 399
Installation 400
MAIN PUMP 401
Removal 401
Installation 403
MAIN PUMP INPUT SHAFT OIL SEAL 404
Removal 404
Installation 404
CONTROL VALVE 405
Removal 405
Installation 406
Disassembly 407
Assembly 411
PUMP MERGE-DIVIDER VALVE 413
Disassembly 413
Assembly 413
MAIN RELIEF VALVE 414
Disassembly 414
Assembly 414
PC VALVE 415
Removal 415
Installation 415
LS VALVE 416
Removal 416
Installation 416
PC-EPC VALVE 417
Removal 417
Installation 417
SOLENOID VALVE 418
Removal 418
Installation 418
WORK EQUIPMENT – SWING PPC VALVE 419
Removal 419
Installation 419
Disassembly 420
Assembly 421
TRAVEL PPC VALVE 422
Removal 422
Installation 422
Disassembly 423
Installation 423
BOOM LOCK VALVE 424
Removal 424
Installation 424
BOOM CYLINDER 425
Removal 425
Installation 426
ARM CYLINDER 427
Removal 427
Installation 428
BUCKET CYLINDER 429
Removal 429
Installation 430
HYDRAULIC CYLINDER 431
Disassembly 431
Assembly 433
WORK EQUIPMENT 437
Removal 437
Installation 438
BUCKET 439
Removal 439
Installation 440
ARM 441
Removal 441
Installation 442
BUCKET – ARM 443
Removal 443
Installation 444
BOOM 445
Removal 445
Installation 446
OPERATOR’S CAB 447
Removal 447
Installation 447
COUNTERWEIGHT 448
Removal 448
Installation 448
MONITOR 449
Removal 449
Installation 449
40 MAINTENANCE STANDARD 450
SWING MACHINERY 451
SWING CIRCLE 453
FINAL DRIVE 454
TRACK FRAME – RECOIL SPRING 456
IDLER 457
CARRIER ROLLER 459
TRACK ROLLER 460
TRACK SHOE 461
CONTROL VALVE 463
SAFETY-SUCTION VALVE FOR SERVICE VALVE 469
SELF-REDUCING PRESSURE VALVE 470
SWING MOTOR 471
TRAVEL MOTOR 472
WORK EQUIPMENT – SWING PPC VALVE 473
TRAVEL PPC VALVE 474
SERVICE PPC VALVE 475
CENTER SWIVEL JOINT 476
BOOM LOCK VALVE 477
HYDRAULIC CYLINDER 478
Boom cylinder 478
Arm cylinder 478
Bucket cylinder 478
WORK EQUIPMENT 480
DIMENSION OF WORK EQUIPMENT 482
Arm portion 482
Bucket portion 484

S.V 14/12/24