Komatsu Hydraulic Excavator PC200LL, PC220LL Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200LL-8, PC220LL-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200LL-8, PC220LL-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM001505 - Hydraulic Excavator PC200LL-8, PC220LL-8 Shop Manual.pdf
SERIAL NUMBERS PC200LL-8 A87001 and up; PC220LL-8 A87001 and up
ENGINE 6D107E-1
MAIN SECTIONS
COVER PC200LL/220LL-8...0
CONTENTS...2
00 FOREWORD...15
SAFETY...15
Safety Notice...15
Important Safety Notice...15
General Precautions...15
Preparations For Work...15
Precautions During Work...15
GENERAL...18
HOW TO READ THE SHOP MANUAL...19
Volumes...19
Distribution And Updating...19
Filing Method...19
Revised Edition Mark...19
Revisions...19
Symbols...19
HOISTING INSTRUCTIONS...20
Hoisting...20
Wire Ropes...20
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...21
Points To Remember When Handling Electric Equipment...21
Points To Remember When Handling Hydraulic Equipment...27
PUSH PULL COUPLER...29
Type 1...29
Disconnection...29
Connection...29
Type 2...30
Disconnection...30
Connection...30
Type 3...31
Disconnection...31
Connection...31
EXPLANATION OF MAINTENANCE STANDARD TERMS...32
STANDARD TIGHTENING TORQUE...34
Bolts And Nuts...34
Tightening Torque Of Hose Nuts...35
Tightening Torque Of Split Flange Bolts...35
Tightening Torque For Flared Nuts...35
Tightening Torques For O-ring Boss Piping Joints...36
Table Of Tightening Torques For O-ring Boss Plugs...36
Torque Table For Hoses (Taper Seal Type And Face Seal Type)...36
ELECTRIC WIRE CODE...37
Classification By Thickness...37
Classification By Color And Code...37
How To Read Electric Wire Code...38
CONVERSION TABLES...41
Method Of Using The Conversion Table...41
COATING MATERIALS...47
01 GENERAL...49
SPECIFICATIONS...50
Dimensions PC200LL-8...50
Road Builder...50
Log Loader - 36 Ft Komatsu Forest Front...50
Dimensions PC220LL-8...52
Road Builder...52
Log Loader - 38 Ft Komatsu Forest Front...52
Working Ranges...54
Road Builder...54
PC200LL-8 Log Loader - 36 Ft Komatsu Forest Front...55
PC220LL-8 Log Loader - 38 Ft Komatsu Forest Front...55
Specifications PC200LL-8...56
Specifications PC220LL-8...58
WEIGHT TABLE...61
PC200LL-8...61
PC220LL-8...63
FUEL, COOLANT, AND LUBRICANTS...65
Recommended Brands, Recommended Quality for Products Other Than Komatsu Genuine Oil...67
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...69
ENGINE AND COOLING SYSTEM...74
Engine Related Parts...74
Radiator, Oil Cooler, Aftercooler, and Fuel Cooler...75
Specifications...75
POWER TRAIN...76
Power Train...76
FINAL DRIVE...78
PC200LL-8...78
Specifications...79
PC220LL-8...80
Specification...81
SWING MACHINERY...82
PC200LL-8...82
Specifications...83
PC220LL-8...84
Specifications...85
SWING CIRCLE...86
PC200LL-8...86
Specifications...86
PC220LL-8...88
Specifications...88
UNDERCARRIAGE AND FRAME...90
Track Frame and Recoil Spring...90
Standard Shoe...91
PC200LL-8...91
PC220LL-8...91
Idler...92
PC200LL-8...92
PC220LL-8...94
TRACK AND CARRIER ROLLER...96
PC200LL-8...96
PC220LL-8...97
TRACK SHOES...98
PC200LL-8...98
PC220LL-8...102
Double Grouser Shoe...104
PC200LL-8...104
PC220LL-8...104
Triple Grouser Shoe...105
PC200LL-8...105
PC220LL-8...105
HYDRAULIC SYSTEM...106
Hydraulic Equipment Layout...106
Hydraulic Tank and Filter...108
Specifications...108
Hydraulic Pump...110
Type: HPV95+95...110
LS valve...116
PC valve...121
LS (PC)-EPC valve...129
Pilot Oil Filter...132
Control Valve...134
General View...135
Sectional View (1/5)...138
Sectional View (2/5)...140
Sectional View (3/5)...142
Sectional View (4/5)...144
Sectional View (5/5)...146
CLSS...148
Outline Of CLSS...148
Functions and Operation by Valve...152
Hydraulic Circuit Diagram and the Name of Valves...152
Unload Valve...154
Introduction of LS Pressure...156
LS By-pass Plug...157
Pressure Compensation Valve...158
Pressure Compensation Valve Inner Shuttle Valve...161
Boom Regeneration Circuit...163
Arm Regeneration Circuit...165
Merge-Divider Valve...167
LS Select Valve...169
Self Pressure Reducing Valve...170
Travel Junction Valve...174
Travel PPC Shuttle Valve...177
Boom Drift Prevention Valve...179
Arm Drift Prevention Valve...182
Quick Return Valve...186
Lift Check Valve...188
Main Relief Valve...189
Swing Motor...191
PC200LL-8 Type: KMF125ABE-6...191
PC220LL-8 Type: KMF230ABE-5...195
Swing Holding Brake...198
Relief Valve Portion...199
Reverse Prevention Valve...200
Center Swivel Joint...204
Travel Motor PC200LL-8 Type: HMV110ADT-3...206
Operation of motor...210
Operation of Parking Brake...212
Brake Valve...214
Travel Motor PC220LL-8 Type: HMV160ADT-3...217
Operation of Motor...220
Operation of Parking Brake...222
Brake Valve...224
PPC Valve...229
Work Equipment and Swing PPC Valve...229
Travel PPC Valve...235
Service PPC Valve (with EPC Valve)...244
Service Valve (Straight Travel Option)...250
Valve Control...252
Solenoid Valve...254
Attachment Solenoid Valve...256
PPC Accumulator...258
CRN (Canadian certified) PPC Accumulator...258
Return Oil Filter...259
Hydraulic Cylinder - Road Builder PC200LL-8...260
Boom Cylinder...260
Arm Cylinder...260
Bucket Cylinder...260
Hydraulic Cylinders - Log Loader PC200LL-8...262
Boom Cylinder...262
Arm Cylinder...262
Heel Cylinder...262
Hydraulic Cylinder - Road Builder PC220LL-8...264
Boom Cylinder...264
Arm Cylinder...264
Bucket Cylinder...264
Hydraulic Cylinders - Log Loader PC220LL-8...266
Boom Cylinder...266
Arm Cylinder...266
Heel Cylinder...266
WORK EQUIPMENT...268
Dimensions of Components...268
PC200LL-8...269
PC220LL-8...270
Arm...272
Bucket...274
CAB AND ITS ATTACHMENTS...276
Air Conditioner Piping...276
ELECTRICAL SYSTEM...277
Engine Control...277
Fuel Control Dial...278
Engine Controller...279
CN-CE01...280
CN-CE02...281
CN-CE03...282
Coolant Temperature Sensor...283
Oil Pressure Switch...283
Rotation Sensor...284
Boost Pressure and Temperature Sensor...284
WIF (Water-In-Fuel Detection) Sensor...285
Engine Oil Level Sensor...285
ELECTRICAL CONTROL SYSTEM...286
Machine Control System Diagram...286
Engine and Pump Composite Control Function...288
Pump and Valve Control Function...292
Power Maximizing Function...294
Auto-deceleration Function...295
Auto-warm-up and Overheat Prevention Function...296
Swing Control Function...299
Swing Control Function with Soft Swing (Option)...301
Travel Control Function...303
System Component Parts...305
MONITOR SYSTEM...311
Machine Monitor...312
Input And Output Signals...313
Monitor Control, Display Portion...317
Monitor Items and Display...319
Switches...323
Buzzer Cancel Switch...323
Auto-deceleration Switch...323
Guidance Icon and Function Switch...324
Working Mode Selector Switch...325
Travel Speed Selector Switch...326
Window Washer Switch...326
Wiper Switch...326
Air Conditioner Control Switch...327
Camera Screen Display Function...328
Service Meter/Time Selector Function...329
Maintenance Function...330
User Mode...332
Breaker/Attachment Setting...332
Changing Breaker Mode Setting...333
Changing Attachment Mode Setting...335
Message Display...337
Screen Adjustment...337
Clock Adjustment...338
Language Setting...339
Economy Mode Adjustment...339
Idle Stop Guidance Function...340
Service Meter Check Function...340
Display LCD Check Function...341
User Code/Failure Code Display Function...342
SENSORS...343
Fuel Level Sensor...343
Air Cleaner Clogging Sensor...344
Coolant Level Sensor...344
KOMTRAX TERMINAL SYSTEM...345
Komtrax Communication Orbcomm...346
20 STANDARD VALUE TABLES...349
STANDARD SERVICE VALUE TABLE...350
Engine Related Parts...350
PC200LL-8...350
PC220LL-8...351
Chassis Related Parts...352
PC200LL-8...352
PC220LL-8...359
MACHINE POSTURE...367
Measuring Performance And Measurement Procedure...367
Control Valve: Spool Stroke...367
Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing...367
Swing 2: Hydraulic Drift Of Swing...367
Travel 1: Travel Speed (Without Load)...367
Travel 2: Travel Speed (Actual Run), Travel Deviation...368
Travel 3: Travel Deviation...368
Travel 4: Hydraulic Drift Of Travel...368
Work Equipment 1: Hydraulic Drift Of Work Equipment...368
Work Equipment 2: Boom Speed...369
Work Equipment 3: Arm Speed...369
Work Equipment 4: Bucket Speed...369
Work Equipment 5: Boom Time Lag...369
Work Equipment 6: Arm Time Lag...370
Work Equipment 7: Bucket Time Lag...370
30 TESTING AND ADJUSTING...371
