Komatsu Hydraulic Excavator PC200, PC200LC, PC210LC, PC220LC, PC250LC Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 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:
Total Pages: 2,913 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM000102 - Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Shop Manual.pdf
CEBM001001 - Hydraulic Excavator PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Shop Manual.pdf
CEBMX20601 - Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Shop Manual.pdf
CEAM000101 - Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Operation & Maintenance Manual.pdf
CEAM001200 - Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Operation & Maintenance Manual.pdf
CEAMX20601 - Hydraulic Excavator PC200-6, PC200LC-6, PC210LC-6, PC220LC-6, PC250LC-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
01 GENERAL...25
GENERAL ASSEMBLY DRAWING (PC200-6, PC2OOLC-6, PC210LC-6)...26
GENERAL ASSEMBLY DRAWING (PC220LC-6, PC250LC-6)...28
SPECIFICATIONS (PC200-6, PC200LC-6)...31
SPECIFICATIONS (PC210LC-6)...33
SPECIFICATIONS (PC220LC-6)...35
SPECIFICATIONS (PC250LC-6)...37
WEIGHT TABLE (PC200-6, PC200LC-6)...39
WEIGHT TABLE (PC210LC-6)...41
WEIGHT TABLE (PC220LC-6, PC250LC-6)...43
FUEL, COOLANTS AND LUBRICANTS...45
10 STRUCTURE AND FUNCTION...48
ENGINE RELATED PARTS...49
RADIATOR, OIL COOLER, AFTERCOOLER...50
POWER TRAIN...51
FINAL DRIVE...52
SWING CIRCLE...54
SWING MACHINERY...55
TRACK FRAME, RECOIL SPRING...56
TRACK SHOE...57
HYDRAULIC PIPING DRAWING...59
HYDRAULIC CIRCUIT DIAGRAM...60
HYDRAULIC TANK...62
HYDRAULIC PUMP...63
CONTROL VALVE...85
CLSS...94
SWING MOTOR...138
CENTER SWIVEL JOINT...141
TRAVEL MOTOR...142
VALVE CONTROL...153
WORK EQUIPMENT, SWING PPC VALVE...154
TRAVEL PPC VALVE...158
SERVICE PPC VALVE...162
SAFETY LOCK VALVE...165
PPC ACCUMULATOR...165
PPC SHUTTLE, TRAVEL JUNCTION VALVE...166
EPC, SOLENOID VALVE...173
HYDRAULIC CYLINDER...181
ADDITIONAL FILTER FOR BREAKER...182
OVERLOAD WARNING DEVICE...183
HOSE BURST PROTECTION VALVE (BOOM)...187
WORK EQUIPMENT...190
20 TESTING AND ADJUSTING...232
TABLE OF JUDGEMENT STANDARD VALUE...233
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...245
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTNG...254
MEASURING ENGINE SPEED...255
MEASURING INTAKE MANIFOLD PRESSURE...256
MEASURING INTAKE AIR RESTRICTION...257
MEASURING LUBRICATING OIL PRESSURE...258
MEASURING FUEL (FILTER) INLET RESTRICTION...259
MEASURING BLOWBY PRESSURE...260
MEASURING ENGINE BACK PRESSURE...261
MEASURING EXHAUST COLOR...262
MEASURING COOLANT TEMPERATURE...263
MEASURING VALVE CLEARANCE...264
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...265
ADJUSTING ENGINE SPEED SENSOR...266
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...267
TESTING CLEARANCE OF SWING CIRCLE BEARING...268
TESTING AND ADJUSTING TRACK SHOE TENSION...269
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...270
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...273
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...275
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE...278
TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE...280
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...282
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...284
ADJUSTING TRAVEL LEVER...285
TESTING TRAVEL DEVIATION...286
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...287
MEASURING OIL LEAKAGE...289
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...290
TROUBLESHOOTING...293
POINTS TO REMEMBER WHEN TROUBLESHOOTING...294
SEQUENCE OF EVENTS IN TROUBLESHOOTING...295
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...296
CHECKS BEFORE TROUBLESHOOTING...303
CONNECTOR TYPES AND MOUNTING LOCATIONS...304
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...308
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...321
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...322
METHOD OF USING JUDGEMENT TABLE...331
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...335
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)...340
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM...341
ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM...342
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...344
JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS...345
E-1 Abnormality in engine throttle controller power source system (engine speed stays at low idling)...346
E-2 [E3:08] Abnormality in fuel control dial input value is displayed...347
E-3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayed...348
E-4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed...349
E-5 [E3:01] Abnormality in network reception system is displayed...350
E-6 [E3:05] Abnormality in model code is displayed...352
E-7 [E3:06] Abnormality in governor potentiometer system is displayed...353
E-8 [E3:07] Abnormality in pump controller throttle system is displayed...354
E-9 [E3:15] Abnormality (short circuit) in battery relay output system is displayed...354
E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed...355
E-11 Engine does not start...356
E-12 Engine speed is irregular...358
a) Idling speed is irregular...358
b) There is hunting...360
E-13 Lack of output (engine high idling speed is too low)...362
E-14 Engine does not stop...364
E-15 Defective operation of battery relay system (engine does not stop)...366
TROUBLESHOOTING OF ENGINE (S MODE)...367
METHOD OF USING TROUBLESHOOTING CHART...368
S-1 Starting performance is poor (Starting always takes time)...372
S-2 Engine does not start...373
1) Engine does not turn...373
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)...374
3) Exhaust gas comes out but engine does not start (Fuel is being injected)...375
S-3 Engine does not pick up smoothly (Follow-up is poor)...376
S-4 Engine stops during operations...377
S-5 Engine does not rotate smoothly...378
S-6 Engine lacks output (no power)...379
S-7 Exhaust gas is black (incomplete combustion)...380
S-8 Oil consumption is excessive (or exhaust gas is blue)...381
S-9 Oil becomes contaminated quickly...382
S-10 Fuel consumption is excessive...383
S-11 Oil is in cooling water, or water spurts back, or water level goes down...384
S-12 Oil pressure lamp lights up (drop in oil pressure)...385
S-13 Oil level rises...386
S-14 Water temperature becomes too high (overheating)...387
S-15 Abnormal noise is made...388
S-16 Vibration is excessive...389
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)...390
POINTS TO REMEMNBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...391
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...392
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS...396
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM...397
C-1 Abnormality in pump controller power source system (swing brake is not canceled, ect.)...398
C-2 [E2:32] Short circuit in front pump TVC solenoid system is displayed...399
[E2:36] Short circuit in rear pump TVC solenoid system is displayed...399
C-3 [E2:33] Disconnection in front pump TVC solenoid system is displayed...401
[E2:37] Disconnection in rear pump TVC solenoid system is displayed...401
C-4 [E2:03] Short circuit in swing brake solenoid system is displayed...403
C-5 [E2:13] Disconnection in swing brake solenoid system is displayed...405
C-6 [E2:02] Short circuit in LS select solenoid system is displayed...407
[E2:04] Short circuit in pump merge-divider solenoid system is displayed...407
[E2:05] Short circuit in 2-stage relief solenoid system is displayed...407
[E2:06] Short circuit in travel speed solenoid system is displayed...407
C-7 [E2:12] Disconnection in LS select solenoid system is displayed...409
[E2:14] Disconnection in pump merge-divider solenoid system is displayed...409
[E2:15] Disconnection in 2-stage relief solenoid system is displayed...409
[E2:16] Disconnection in travel speed solenoid system is displayed...409
C-8 [E2:17] Model selection input error is displayed...411
C-9 [E2:18] Network response overtime error is displayed...412
C-10 [E2:22] Short circuit in LS control EPC solenoid system is displayed...414
C-11 [E2:23] Disconnection in LS control EPC solenoid system is displayed...415
C-12 [E2:24] Abnormality in front pump pressure sensor system is displayed...416
[E2:25] Abnormality in rear pump pressure sensor system is displayed...416
C-13 [E2:26] Abnormality in pump pressure sensor power source system is displayed...418
C-14 [E2:27] Abnormality in engine speed sensor system is displayed...419
C-15 [E2:28] Abnormality in auto-deceleration output system is displayed...420
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)...421
F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up...422
F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up...423
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up...424
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up...425
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up...426
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up...427
F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up...428
F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up...429
F-9 Bit pattern 21-(3) Swing lock switch does not light up...430
F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system)...431
F-12 Bit pattern 22-(6) L.H. knob switch does not light up...432
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...433
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM...434
PUMP MERGE-DIVIDER LOGIC...436
All work equipment, travel, swing...437
H-1 Speeds of all work equipment, swing, travel are slow or lack power...437
H-2 There is excessive drop in engine speed, or engine stalls...439
H-3 No work equipment, travel, swing move...440
H-4 Abnormal noise generated...440
