Komatsu PC200,LC-5 Mighty , PC220,LC-5 Hydraulic Excavator Service Repair Shop Manual - SEBM02050508

This Complete Service Repair Workshop Manual PDF Download for the PC200-5, PC200LC-5, PC200-5 Mighty, PC200LC-5 Mighty, PC220-5, PC220LC-5 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC200-5 - S/N: 45001 and up
Komatsu PC200LC-5 - S/N: 45001 and up
Komatsu PC200-5 Mighty - S/N: 58019 and up
Komatsu PC200LC-5 Mighty - S/N: 58019 and up
Komatsu PC220-5 - S/N: 35001 and up
Komatsu PC220LC-5 - S/N: 35001 and up

PC200, 200LC-5, MIGHTY mount the S6D95L engine;
PC220, 220LC-5 mount the SA6D95L engine.
For details of the engine, see the 95 Series Engine Shop Manual.


TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM02050508
Total Pages : 662


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
CONTENTS

10 STRUCTURE AND FUNCTION
ENGINE RELATED PARTS AND ENGINE MOUNT
RADIATOR OIL COOLER AND AFTER-COOLER
FUEL TANK AND PIPING
FINAL DRIVE
SWING CIRCLE
SWING MACHINERY
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER, CARRIER ROLLER
TRACK SHOE
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
OLSS (OPEN CENTER LOAD SENSING SYSTEM)
HYDRAULIC PUMP
CONTROL VALVE
CENTER SWIVEL JOINT
TRAVEL MOTOR
VALVE CONTROL
PPC VALVE
ACCUMULATOR
SAFETY LOCK VALVE
SOLENOID VALVE ASSEMBLY
SHUTTLE VALVE
BOOM HOLDING VALVE
HYDRAULIC CYLINDER
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM
GOVERNOR MOTOR LINKAGE
PEMC SYSTEM
EMACC

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
INSPECTION OF SWING CIRCLE BEARING CLEARANCE
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
MEASURING STROKE OF SERVO PISTON
TESTING AND ADJUSTING TRAVEL DEVIATION
MEASURING OUTPUT PRESSURE OF PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
TESTING PPC SHUTTLE VALVE
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
HANDLING CONNECTORS
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED
E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED
E-8 ENGINE DOES NOT START
E-9 ENGINE ROTATION IS IRREGULAR
a) IDLING ROTATION IS IRREGULAR
b) THERE IS HUNTING
E-10 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)
E-11 ENGINE DOES NOT STOP
E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS
C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP
C-2 [01] [SHORT CIRCUIT IN 2-STAGE RELIEF .CO CANCEL SOLENOID VALVE, 2-STAGE RELIEF SYSTEM] IS DISPLAYED
C-3 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED
C-4 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED
C-5 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED
C-6 [07] [SHORT CIRCUIT IN 2-STAGE RELIEF .CO CANCEL SOLENOID VALVE, CO CANCEL SYSTEM] IS DISPLAYED
C-7 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1)] IS DISPLAYED
C-8 [09] [SHORT CIRCUIT IN TVC SOLENOID VALVE SYSTEM (2)] IS DISPLAYED
C-9 [11] [DISCONNECTION IN 2-STAGE RELIEF .CO CANCEL SOLENOID VALVE, 2-STAGE RELIEF SYSTEM] IS DISPLAYED
C-10 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED
C-11 [14] [DISCONNECTION IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED
C-12 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED
C-13 [17] [DISCONNECTION IN 2-STAGE RELIEF .CO CANCEL SOLENOID VALVE, CO CANCEL SYSTEM] IS DISPLAYED
C-14 [18] [DISCONNECTION IN TVC SOLENOID VALVE SYSTEM] IS DISPLAYED
C-15 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED
C-16 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED
C-17 [23] [ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED
C-18 [24] [ABNORMALITY IN REAR PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED
C-19 [25] [ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED
C-20 [26] [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED
C-21 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED
C-22 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED
C-23 [. ] [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1]
F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2]
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6]
F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5]
F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Hi OR Lo]
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad]
F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [UP]
F-8 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [ . ]
F-9 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH
F-10 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL, SWING ARE ALL SLOW
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW
H-4 WORK EQUIPMENT, TRAVEL, SWING LACK POWER
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
H-7 AUTO-DECELERATION DOES NOT WORK
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW
H-10 WHEN BOOM AND ARM ARE OPERATED SIMULTANEOUSLY, BOOM IS SLOW
H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER
H-12 EXCESSIVE HYDRAULIC DRIFT
H-13 EXCESSIVE TIME LAG
H-14 DOES NOT ENTER F.O MODE (HALF FLOW FUNCTIUON)
H-15 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, ARM IS SLOW
H-16 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE
H-17 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS
H-18 EXCESSIVE DEVIATION WHEN STARTING
H-19 TRAVEL LACKS POWER (OR SPEED IS SLOW)
H-20 TRAVEL SPEED DOES NOT SWITCH
H-21 MACHINE DOES NOT MOVE (ONE SIDE ONLY)
H-22 DOES NOT SWING
H-23 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-28 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON
a) NO MONITOR PANEL LAMPS LIGHT UP
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH
a) COOLANT LEVEL FLASHES
b) ENGINE OIL LEVEL FLASHES
c) HYDRAULIC OIL LEVEL FLASHES
P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP
P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH
a) ALTERNATOR SYSTEM
b) ENGINE OIL PRESSURE SYSTEM
P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH
P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH
a) ENGINE OIL PRESSURE FLASHES
b) COOLANT LEVEL FLASHES
c) COOLANT TEMPERATURE FLASHES
d) CHARGE FLASHES
e) FUEL LEVEL FLASHES
P-8
a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND, CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND
b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS
P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY
P-12 FUEL GAUGE ALWAYS DISPLAYS FULL
P-13 FUEL GAUGE GIVES NO DISPLAY
P-14
a) LAMPS DO NOT LIGHT UP
b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED
P-15
a) WIPERS DO NOT WORK
b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED
P-16
a) FAN DOES NOT WORK
b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED
P-17 WORKING MODE DOES NOT SWITCH
P-18 POWER SET DOES NOT SWITCH
P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)
P-20 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO
P-21 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃
P-22 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP
P-23 FUEL LEVEL SENSOR SYSTEM DEFECTIVE
P-24 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE
P-25 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM
P-26 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE
P-27 HYDRAULIC OIL LEVEL SENSOR SYSTEM DEFECTIVE

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
WEIGHT TABLE
TIGHTENING TORQUES AND STANDARD VALUES TABLE
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
GOVERNOR MOTOR
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL AND INSTALLATION
AFTER-COOLER
REMOVAL AND INSTALLATION
HYDRAULIC COOLER
REMOVAL AND INSTALLATION
RADIATOR, HYDRAULIC COOLER
REMOVAL AND INSTALLATION
ENGINE, HYDRAULIC PUMP
REMOVAL AND INSTALLATION
DAMPER
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SPROCKET
REMOVAL AND INSTALLATION
TRAVEL MOTOR
DISASSEMBLY
ASSEMBLY
SWING MOTOR
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING MACHINERY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL AND INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
IDLER, RECOIL SPRING
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION
CARRIER ROLLER
REMOVAL AND INSTALLATION
TRACK SHOE
REMOVAL AND INSTALLATION
CHARGING PUMP
REMOVAL AND INSTALLATION
HYDRAULIC PUMP
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION
CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TVC VALVE
REMOVAL AND INSTALLATION
CO・NC VALVE
REMOVAL AND INSTALLATION
SERVO VALVE
REMOVAL AND INSTALLATION
WORK EQUIPMENT PPC VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
BOOM HOLDING VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
PPC SHUTTLE VALVE
REMOVAL AND INSTALLATION
BOOM CYLINDER
REMOVAL AND INSTALLATION
ARM CYLINDER
REMOVAL AND INSTALLATION
BUCKET CYLINDER
REMOVAL AND INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION
BUCKET
REMOVAL AND INSTALLATION
ARM
REMOVAL AND INSTALLATION
ARM, BUCKET
REMOVAL AND INSTALLATION
BOOM
REMOVAL AND INSTALLATION
OPERATOR'S CAB
REMOVAL AND INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
ENGINE THROTTLE CONTROLLER
REMOVAL AND INSTALLATION
PUMP CONTROLLER
REMOVAL AND INSTALLATION
MONITOR PANEL
REMOVAL AND INSTALLATION
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT

40 MAINTENANCE STANDARD
FINAL DRIVE
SWING MACHINERY
SWING CIRCLE
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
HYDRAULIC PUMP
CHARGING PUMP AND RELIEF VALVE
CONTROL VALVE
TRAVEL SHUTTLE VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
PPC VALVE
BOOM HOLDING VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT

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