Komatsu PC200,LC-6 , PC210,LC-6 , PC220,LC-6, PC230,LC-6 Hydraulic Excavator Shop Manual

This Complete Service Repair Workshop Manual PDF Download for the PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6 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 PC200-6 STD - S/N: 96514 and up
Komatsu PC200LC-6 STD - S/N: 96514 and up
Komatsu PC200-6 HYPER GX - S/N: 96514 and up
Komatsu PC200LC-6 HYPER GX - S/N: 96514 and up
Komatsu PC210-6 STD - S/N: 30980 and up
Komatsu PC210LC-6 STD - S/N: 30980 and up
Komatsu PC220-6 STD - S/N: 52852 and up
Komatsu PC220LC-6 STD - S/N: 52852 and up
Komatsu PC230-6 STD - S/N: 10177 and up
Komatsu PC230LC-6 STD - S/N: 10177 and up

Komatsu PC200-6, PC210-6 mount the S6D102-1 engine.
Komatsu PC220-6, PC230-6 mount the SA6D102-1 engine.
For details of the engine, see the 102 Series Engine Shop Manual.


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM010106
Total Pages : 1278


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
SAFETY
Safety Notice
FOREWORD
General
How to Read the Shop Manual
Hoisting Instructions
Method of Disassembling, Connecting Push-Pull Type Coupler
Coating Materials
Standard Tightening Torque
Electric Wire Code
Conversion Table
Units

01 GENERAL
Specification Dimension Drawings
Specifications
Weight Table
Fuel, Coolant and Lubricants

10 STRUCTURE AND FUNCTION
Engine Related Parts
Radiator, Oil Cooler, Aftercooler
Power Train
Final Drive
Swing Circle
Swing Machinery
Track Frame, Recoil Spring
Track Shoe
Hydraulic Piping Drawing
Hydraulic Circuit Diagram
Hydraulic Tank
Hydraulic Pump
Line Oil Filter
Control Valve
Self-reducing Pressure Valve
CLSS
Swing Motor
Center Swivel Joint
Travel Motor
Valve Control
Work Equipment, Swing PPC Valve
Travel PPC Valve
Service PPC Valve
Safety Lock Valve
PPC Accumulator
Straight-Travel System
Solenoid Valve
Boom Holding Valve
Additional Filter for Breaker
Swivel Joint for Arm Rotation
Arm Rotation Motor
Work Equipment
Air Conditioner
Actual Electric Wiring Diagram
Electrical Circuit Diagram
PC220-6 STD Serial No.: 96514 - 102228
PC210-6 STD Serial No.: 30980 - 31424
PC220-6 STD Serial No.: 52852 - 53561
PC230-6 STD Serial No.: 10177 - 10246
Engine Control System
Electronic Control System for STD
Electronic Control System for Hyper GX
Machine Monitor System
Sensors
Front Window Auto Pull-up System

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TESTING AND ADJUSTING
Tools for Testing, Adjusting, and Troubleshooting
Measuring Engine Speed
Measuring Exhaust Gas Color
Adjusting Valve Clearance
Measuring Compression Pressure
Measuring Blow-by Pressure
Testing and Adjusting Fuel Injection Timing
Measuring Engine Oil Pressure
Testing and Adjusting Alternator Belt Tension
Testing and Adjusting Belt Tension for Air Conditioner Compressor
Measuring Speed Sensor
Testing and Adjusting Governor Motor Lever Stroke
Testing and Adjusting Hydraulic Pressure in Work Equipment, Swing, Travel Circuit
Testing and Adjusting PC Valve Output Pressure (Servo Piston Input Pressure)
Testing and Adjusting LS Valve Output Pressure (Servo Piston Input Pressure) and LS Differential Pressure
Testing and Adjusting Control Circuit Oil Pressure
Testing Solenoid Valve Output Pressure
Measuring PPC Valve Output Pressure
Measuring EPC Solenoid Valve Output Pressure and Checking EPC Shuttle Valve
Adjusting Work Equipment, Swing PPC Valve
Testing Travel Deviation
Testing Locations Causing Hydraulic Drift of Work Equipment
Measuring Oil Leakage
Releasing Remaining Pressure in Hydraulic Circuit
Testing Clearance of Swing Circle Bearing
Testing and Adjusting Track Shoe Tension
Bleeding Air
Input/Output Structure of GX Controller
Basic Operation and GX Function
Special Functions on GX Panel (Background Mode)
Check Procedure when Operation of GX Automatic Function is Defective
Adjusting Swing Back Prevention Function (Swing Teaching Mode)
Bucket Dimension Input Mode when Using Custom Bucket
Procedure for Replacing Sensor
TROUBLESHOOTING
Points to Remember When Troubleshooting
Sequence of Events in Troubleshooting
Precautions When Carrying Out Maintenance
Checks Before Troubleshooting
Connector Types and Mounting Locations
Connection Table for Connector Pin Numbers
Explanation of Control Mechanism for Electrical System
Display Method and Special Functions of Monitor Panel
Method of Using Judgement Table
Method of Using Troubleshooting Charts
Details of Troubleshooting and Troubleshooting Procedure
Troubleshooting of Communication Abnormality System ( N Mode)
N-1 (E218) Communications Abnormality
Troubleshooting of Engine Throttle - Pump Controller (Govenor Control System) (E Mode)
Points to Remember When Carrying Out Troubleshooting of Engine Throttle - Pump Controller System
Action Taken by Controller When Abnormality Occurs and Problems on Machine
Judgement Table for Engine Throttle - Pump Controller (Govenor Control System) and Engine Related Parts
Electrical Circuit Diagram for E Mode System
E-1 Abnormality in Engine Throttle - Pump Controller Power Source (controller LED is OFF)
E-2 (E308) Abnormality in Fuel Control Dial Imput Value is Displayed
E-3 (E317) Abnormality (disconnection) in Motor Drive System is Displayed
E-4 (E318) Abnormality (short circuit) in Motor Drive System is Displayed
E-5 (E306) Abnormality in Feedback Potentionmeter System is Displayed
E-6 (E315) Abnormality (short circuit) in Battery Relay Output System is Displayed
E-7 (E316) Abnormality (step-out) in Motor is Displayed
E-8 Engine Does Not Start
E-9 Engine Speed is Irregular
a) Idling Speed is Irregular
b) There is Hunting
E-10 Lack of Output (engine high idling speed is too low)
E-11 Engine Does Not Stop
E-12 Defective Operation of Battery Relay System (engine does not stop)
Troubleshooting of Engine System (S Mode)
Method of Using Troubleshooting Charts
S-1 Starting Performance is Poor (starting always takes time)
S-2 Engine Does Not Start
(1) Engine Does Not Turn
(2) Engine Turns But no Exhaust Smoke Comes Out (fuel is not being injected)
(3) Exhaust Smoke Comes Out but Engine Does Not Start (fuel is being injected)
S-3 Engine Does Not Pick Up Smoothly (follow-up is poor)
S-4 Engine Stops During Operation
S-5 Engine Does Not Rotate Smoothly (hunting)
S-6 Engine Lacks Output ( no power)
S-7 Exhaust Smoke is Black (incomplete combustion)
S-8 Oil Consumption is Excessive (or exhaust smoke is blue)
S-9 Oil Becomes Contaminated Quickly
S-10 Fuel Consumption is Excessive
S-11 Oil is in Cooling Water, or Water Spurts Back, or Water Level Goes Down
S-12 Oil Pressure Caution Lamp Lights Up (drop in oil pressure)
S-13 Oil Level Rises (water, fuel in oil)
S-14 Water Temperature Becomes Too High (overheating)
S-15 Abnormal Noise is Made
S-16 Vibration is Excessive
Troubleshooting of Engine Throttle - Pump Controller (Pump Control System) (C Mode)
Points to Remember When Troubleshooting Pump Controller System
Action Taken by Controller When Abnormality Occurs and Problems on Machine
Judgement Table for Engine Throttle - Pump Controller (pump control system) and Hydraulic Related Parts
Electrical Circuit Diagram for C Mode
C-1 Abnormality in Controller Power Source System (controller LED is OFF)
C-2 (E232) Short Circuit in PC-EPC Solenoid System is Displayed
C-3 (E233) Disconnection in PC-EPC Solenoid System is Displayed
C-4 (E203) Short Circuit in Swing Brake Solenoid System is Displayed
C-5 (E213) Disconnection in Swing Brake Solenoid System is Displayed
C-6 (E204) Short Circuit in Pump Merge/Divider Solenoid System is Displayed
C-7 (E214) Disconnection in Pump Merge/Divider Solenoid System is Displayed
C-8 (E207) Short Circuit In Active Mode Solenoid System is Displayed
C-9 (E208) Disconnection in Active Mode Solenoid System is Displayed
C-10 (E206) Short Circuit in Travel Speed Solenoid System is Displayed
C-11 (E216) Disconnection in Travel Speed Solenoid System is Displayed
C-12 (E205) Short Circuit in 2-Stage Relief Solenoid System is Displayed
C-13 (E215) Disconnection in 2-State Relief Solenoid System is Displayed
C-14 (E217) Model Selection Input Error is Displayed
C-15 (E222) Short Circuit in LS-EPC Solenoid System is Displayed
C-16 (E223) Disconnection in LS-EPC Solenoid System is Displayed
C-17 (E224) Abnormality in Front Pump Pressure Sensor System is Displayed
C-18 (E225) Abnormality in Rear Pump Pressure Sensor System is Displayed
C-19 (E226) Abnormality in Pressure Sensor Power Source System is Displayed
C-20 (E227) Abnormality in Engine Speed Sensor System is Displayed
C-21 (E302) Short Circuit in Swing Stroke Limit Solenoid System is Displayed
C-22 (E303) Disconnection in Swing Stroke Limit Solenoid System is Displayed
Troubleshooting of Engine throttle - Pump Controller (Input Signal System) (F Mode)
Electrical Circuit Diagram for F Mode
F-1 Bit Pattern 20-(1) Swing Oil Pressure Switch Does Not Light Up
F-2 Bit Pattern 20-(2) Travel Oil Pressure Switch Does Not Light Up
F-3 Bit Pattern 20-(3) Boom LOWER Oil Pressure Switch Does Not Light Up
F-4 Bit Pattern 20-(4) Boom RAISE Oil Pressure Switch Does Not Light Up
F-5 Bit Pattern 20-(5) Arm IN Oil Pressure Switch Does Not Light Up
F-6 Bit Pattern 20-(6) Arm OUT Oil Pressure Switch Does Not Light Up
F-7 Bit Pattern 21-(1) Bucket CURL Oil Pressure Switch Does Not Light Up
F-8 Bit Pattern 21-(2) Bucket DUMP Oil Pressure Switch Does Not Light Up
F-9 Bit Pattern 21-(3) Swing Lock Switch Does Not Light Up
F-10 Bit Pattern 22-(5) Kerosene Mode Connection Does Not Light Up
F-11 Bit Pattern 22 (6) L.H. Knob Switch Does Not Light Up
Troubleshooting of Hydraulic and Mechanical system (H Mode)
Table of Failure Modes and Causes for Hydraulic and Mechnaical Systems
Pump Merge/Divider Logic
Solenoid Actuation Table
Troubleshooting Flow Charts for Each Failure Mode
All Work Equipment, Travel, Swing
H-1 Speeds of All Work Equipment, Swing, Travel Are Slow or Lack Power
H-2 There is Excessive Drop in Engine Speed, or Engine Stalls
H-3 No Work Equipment, Travel, Swing Move
H-4 Abnormal Noise Generated (around pump)
H-5 Auto-Deceleration Does Not work (PPC shuttle valve is euqipped only in travel PPC valve)
H-6 Fine Control Ability is Poor or Response is Poor
Work Equipment
H-7 Boom is Slow or Lacks Power
H-8 Arm is Slow or Lacks Power
H-9 Bucket is Slow or Lacks Power
H10- Work Equipment (boom, arm, bucket) Does Not Move (but travel and swing are normal)
H-11 Excessive Hydraulic Drift
H-12 Excessive Time Lag (engine at low idling)
H-13 Other Equipment Moves When Single Circuit is Relieved
H-14 Lack of Power When Pressure Rises
H-15 In L/O, F/O Modes, Work Equipment Speed is Faster Than Specified Speed
Compound Operations
H-16 In Compound Operations, Work Equipment with Larger Load is Slow
H-17 In Swing + Boom RAISE, Boom RAISE is Slow
H-18 In Swing + Travel, Travel Speed Drops Excessively
Travel System
H-19 Travel Deviation
H-20 Travel Speed is Slow
H-21 Steering Does Not Turn Easily or Lacks Power
H-22 Travel Speed Does Not Switch or is Faster than Specified Speed
H-23 Travel Does Not Move (one side only)
Swing System
H-24 Does Not Swing
H-25 Swing Acceleration is Poor or Swing Speed is Slow
H-26 Excessive Overrun When Stopping Swing
H-27 Excessive Shock When Stopping Swing (one direction only)
H-28 Excessive Abnormal Noise When Stopping Swing
H-29 Excessive Hydraulic Drift of Swing
H-30 Swing Speed is Faster than Specified Speed in L/O and F/O Modes
H-31 Operation of Automatic Mode is Defective (HYPER specification)
Troubleshooting of Machine Monitor System (M Mode)
Action Taken by Monitor Panel When Abnormality Occurs and Problems on Machine
Electrical Circuit Diagram for M Mode System
M-1 (E101) Abnormality in Error Data is Displayed
M-1 (E102) Error in Clock Data is Displayed
M-2 (E103) Short Circuit in Buzzer Output or Contact of 24V Wiring Harness with Buzzer Drive Harness is Displayed
M-3 (E104) Air Cleaner Clogging Detected is Displayed
M-4 (E108) Engine Water Temperature 105 degrees C Detected is Displayed
M-5 When Starting Switch is Turned ON, None of Lamps on Monitor Panel Light Up for 3 Seconds
a) None of Lamps on Monitor Panel Light Up
b) Some of Lamps on Monitor Panel Do Not Light Up
M-6 When Starting Switch is Turned ON, Monitor Panel Lamps All Stay Lighted Up and Do Not Go Out
M-7 When Starting Switch is Turned ON, Items Lighted Up on Monitor Palen are Different from Actual Machine (Model)
M-8 When Starting Switch is Turned ON (engine stopped), Basic Check Items Flash
a) Coolant Level Flashes
b) Engine Oil Level Flashes
c) Hydraulic Oil Level Flashes
M-9 Preheating is Not Being Used But Preheating Monitor Lights Up
M-10 When Starting Switch is Turned ON and Engine is Started, Basic Check Items Flash
a) Alternator System
b) Engine Oil Pressure System
M-11 When Starting Switch is Turned ON (engine stopped), Caution Items, Emergency Items Flash (battery, engine oil pressure l
a) Alternator System
b) Engine Oil Pressure Sensor System
M-12 When Starting Switch is Turned ON and Engine is Started, Caution Items, Emergency Items Flash (when there is no abnormal
a) Engine Oil Pressure Flashes
b) Coolant Level Flashes
c) Battery Charge Flashes
d) Coolant Temperature Flashes
e) Fuel Level Flashes
f) Air Cleaner Clogging Flashes
M-13 When Starting Switch is Turned ON (engine stopped), Buzzer Does Not Sound for 1 Second; Caution Item Flashes but Buzzer
M-14 No Abnormality is Displayed on Monitor but Buzzer Sounds
M-15 Night Lighting on Monitor Panel Does Not Light Up (liquid crystal display is normal)
M-16 Coolant Temperature Gauge Does Not Rise
M-17 Coolant Temperature Gauge Does Not Give Any Display (none of gauge lamps light up during operation)
M-18 Fuel Level Gauge Always Displays FULL
M-19 Fuel Level Gauge Does Not Give Display
M-20 Swing Lock Switch is Turned ON (LOCK) but Swing Lock Monitor Does Not Light Up
M-21 Swing Prolix Switch is Turned ON (prolix), but Swing Lock Monitor Does Not Flash
M-22 Service Meter Does Not Advance While Engine is Running
M-23 When Starting Switch is at OFF and Time Switch is Pressed, Time and Service Meter Are Not Displayed
M-24 Defective Fuel Level Sensor System
M-25 Defective Coolant Temperature Sensor System
M-26 Defective Engine Oil Level Sensor System
M-27 Defective Coolant Level Sensor System
M-28 Defective Hydraulic Oil Level Sensor System
M-29 Wiper Does Not Work, or Switch is Not Being Used but Wiper is Actuated
a) Wiper Does Not Work
b) Wiper Switch is Not Being Operated but Wiper is Actuated
M-30 Washer Motor Does Not Work, or Switch is Not Being Used but Washer Motor is Actuated
a) Washer Motor Does Not Work
b) Switch is Not Being Operated but Washer is Actuated
Troubleshooting of GX Controller System (A Mode)
Points to Remember When Troubleshooting GX Controller System
Procedure for Troubleshooting Hyper GX
Operation of GX Error Code Display Mode and Content of Display
Action Taken by Controller When Abnormality Occurs, and Problems on Machine
Electrical Wiring Diagram for GX Controller
A-1 E6:01, E6:02, E6:03, and E6:04 are Displayed at the Same Time
A-2 E6:01 (GX panel 011, 012) [Abnormality in Boom (RAISE) Pressure Sensor System] is Displayed
A-3 E6:01 (GX panel 013, 014) [Abnormality in Boom (LOWER) Pressure Sensor System] is Displayed
A-4 E6:02 (GX panel 021, 022) [Abnormality in Arm (IN) Pressure Sensor System] is Displayed
A-5 E6:02 (GX panel 023, 024) [Abnormality in Arm (OUT) Pressure Sensor System] is Displayed
A-6 E6:03 (GX panel 031, 032) [Abnormality in Bucket (CURL) Pressure Sensor System] is Displayed
A-7 E6:03 (GX panel 033, 034) [Abnormality in Bucket (DUMP) Pressure Sensor System] is Displayed
A-8 E6:04 (GX panel 041, 042) [Abnormality in Swing (RIGHT) Pressure Sensor System] is Displayed
A-9 E6:04 (GX panel 043, 044) [Abnormality in Swing (LEFT) Pressure Sensor System] is Displayed
A-10 E6:06 (GX panel 061, 063) [Abnormality in Clinometer Input Valve] is Displayed
A-11 E6:07 and E6:08 [Abnormality in Potentiometer Power Source] are Displayed at the Same Time
A-12 E6:07 (GX panel 071, 072) [Abnormality in Boom Potentionmeter System] is Displayed
A-13 E6:08 (GX panel 081, 082) [Abnormality in Arm Potentiometer System] is Displayed
A-14 E6:11 (GX panel 111, 112) [Abnormality in Boom Variable Angle] is Displayed
A-15 E6:12 (GX panel 121, 122) [Abnormality in Arm Variable Angle] is Displayed
A-16 E6:13 (GX panel 131, 132) [Abnormality in Bucket Variable Angle] is Displayed
A-17 E6:14 (GX panel 141) [Abnormality in Comparision of Two Boom Sensor Signals] is Displayed
A-18 E6:15 (GX panel 151) [Abnormality in Comparision of Two Arm Sensor Singals] is Displayed
A-19 E6:16 (GX panel 163) [No Change in Signal When Work Equipment Should Move] is Displayed
A-20 E6:17 (GX panel 171, 172) [Cutting Edge Position Out of Range] is Displayed
A-21 E6:18 (GX panel 181, 182) [Abnormality in Data ROM] is Displayed
A-22 E6:21 (GX panel 211, 212, 213, 214) [Abnromality in Engine Pick-up] is Displayed
A-23 E6:22 (GX panel 221) [Change in Wiring Harness After Engine Picks up] is Displayed
A-23 E6:22 (GX panel 222) [Automatic Operation Disconnection Switch Signal Does Not Match in Valve Controller and GX Control
A-23 E6:22 (GX panel 223) [Abnormality in Controller Power Source] is Displayed
A-24 E6:23 (GX panel 231) [Abnormality in Remote Singal] is Displayed
A-24 E6:23 (GX panel 235) [Abnormality in 12V Power Source (overcurrent detection)] is Displayed
A-24 E6:23 (GX panel 236) [Abnormality in 24V Power Source (overcurrent detection)] is Displayed
A-25 E6:24 (GX panel 241) [Abnormality in Buzzer Drive System] is Diaplayed
A-26 E6:25 (GX panel 251, 252) [Impossible to Receive Network (S-NET) Signal] is Displayed
A-26 E6:25 (GX panel 253) [Impossible to Receive Network (HS-NET) Signal] is Displayed
A-27 E6:26 (GX panel 261, 262, 263, 264) [Abnormality in Non-Volatile Memory Data Range] is Displayed
A-28 E6:27 [Non-Volatile Read Error] is Displayed
A-29 E6:28 [Non-Volatile Write Error] is Displayed
A-30 Buzzer Does Not Sound (when there is no abnormal display)
A-31 Automatic Mode is Not Actuated When Knob Switch is Pressed (when there is no abnormal display
Troubleshooting of Valve Controller System (K Mode)
Points to Remember When Troubleshooting Valve Controller System
Action Taken by Controller When Abnormality Occurs and Problems on Machine
Judgement Table for Valve Controller System
Electrical Circuit Diagram of Valve Controller System
K-1 [LED OFF] Controller Power Source System
K-2 [E4:02] L.H. Knob Switch OFF System is Displayed
K-3 [E4:07] Abnormality in Model Code Input is Displayed
K-4 [E4:51] Abnormality in S-NET Communication is Displayed
1. Disconnection Related
2. Short Circuit Related
K-5 [E4:56] Abnormality in Teaching, Playback RAM Data is Displayed
K-6 [E4:57] Abnormality in Knob Switch is Displayed
K-7 [E4:01] Abnormality in Control Lever Neutral System is Displayed
K-8 [E4:04] Abnormality in Control Lever Potentiometer Power Source System is Displayed
K-9 [E4:11) Short Circuit in EPC Relay 1 Drive Power Source System is Displayed
K-10 [E4:12] Contact Between Chassis Power Source and EPC Relay 1 Drive Power Source System is Displayed
K-11 [E4:13] Short Circuit in EPC Relay 2 Drive Power Source System is Displayed
K-12 [E4:14] Contact Between Chassis Power Source and EPC Relay 2 Drive Power Source System is Displayed
K-13 [E4:15] Disconnection in EPC Relay 1,2 Solenoid Power Source System is Displayed
K-14 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed
K-14 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed
1) When E4:16 is Displayed Independently
2) When E4:16, E4:17 are Displayed Simultaneously
K-15 [E4:17] EPC Relay 2 Points Melted or Short Circuit in Solenoid Power Source System is Displayed
K-15 [E4:16] EPC Relay 1 Points Melted or Short Circuit in Solenoid Power Source System is Displayed
1) When E4:17 is Displayed Independently
2) When E4:16, E4:17 are Displayed Simultaneously
K-16 [E4:18] Abnormality in Lever Signal Input Delay Circuit System is Displayed
K-17 [E4:21] Abnormality 1 in Drive Circuit System for Boom LOWER EPC Valve is Displayed
K-17 [E4:25] Abnormality 1 in Drive Circuit System for Boom RAISE EPC Valve is Displayed
K-17 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed
K-17 [E4:25] [E4:35] Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed
K-18 [E4:31 Abnormality 2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed
K-18 [E4:35] Abnormality 2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed
K-18 [E4:21] [E4:31] Abnormality 1,2 in Drive Circuit System for Boom LOWER EPC Valve is Displayed
K-18 [E4:25] [E4:35} Abnormality 1,2 in Drive Circuit System for Boom RAISE EPC Valve is Displayed
K-19 [E4:32} Abnormality 2 in Drive Circuit System for Arm IN EPC Valve is Displayed
K-19 [E4:33] Abnormality 2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed
K-19 [E4:34] Abnormality 2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed
K-19 [E4:36] Abnormality 2 in Drive Circuit System for Arm OUT LEFT EPC Valve is Displayed
K-19 [E4:37] Abnormality 2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed
K-19 [E4:38] Abnormality 2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed
K-19 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed
K-19 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed
K-19 [E4: 24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed
K-19 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed
K-19 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed
K-19 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed
K-20 [E4:41] [E4:42] [E4:43] [E4:44} Over-range in Control Lever Potentiometer Signal System is Displayed
K-21 [E4:45] [E4:46] [E4:47] [E4:48] Excessive Error in Signal SIG and Switch SIG of Control Lever Potentiometer is Displayed
K-22 [E4:55] Abnormality in ROM, RAM of CPU is Displayed
K-23 [E4:58] Abnormality in Interlock PLD is Displayed
K-24 [E4:22] Abnormality 1 in Drive Circuit System for Arm IN EPC Valve is Displayed
K-24 [E4:23] Abnormality 1 in Drive Circuit System for Bucket CURL EPC Valve is Displayed
K-24 [E4:24] Abnormality 1 in Drive Circuit System for Swing LEFT EPC Valve is Displayed
K-24 [E4:26] Abnormality 1 in Drive Circuit System for Arm OUT EPC Valve is Displayed
K-24 [E4:27] Abnormality 1 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed
K-24 [E4:28] Abnormality 1 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed
K-24 [E4:22] [E4:32] Abnormality 1,2 in Drive Circuit System for Arm IN EPC Valve is Displayed
K-24 [E4:23] [E4:33] Abnormality 1,2 in Drive Circuit System for Bucket CURL EPC Valve is Displayed
K-24 [E4:24] [E4:34] Abnormality 1,2 in Drive Circuit System for Swing LEFT EPC Valve is Displayed
K-24 [E4:26] [E4:36] Abnormality 1,2 in Drive Circuit System for Arm OUT EPC Valve is Displayed
K-24 [E4:27] [E4:37] Abnormality 1,2 in Drive Circuit System for Bucket DUMP EPC Valve is Displayed
K-24 [E4:28] [E4:38] Abnormality 1,2 in Drive Circuit System for Swing RIGHT EPC Valve is Displayed

30 DISASSEMBLY AND ASSEMBLY
Method of Using Manual
Precautions When Carrying Out Operation
Special Tool List
Sketches of Special Tools
Starting Motor
Removal of Starting Motor Assembly
Installation of Starting Motor Assembly
Alternator
Removal of Alternator Assembly
Installation of Alternator Assembly
Air Conditioner Compressor
Removal of Air Conditioner Compressor Assembly
Installation of Air Conditioner Compressor Assembly
Condenser
Removal of Condenser Assembly
Installation of Condenser Assembly
Air Conditioner Condenser
Removal of Air Conditioner Condenser Assembly
Installation of Air Conditioner Condenser Assembly
Dry Receiver
Removal of Dry Receiver Assembly
Installation of Dry Receiver Assembly
Engine Oil Cooler Core
Removal of Engine Oil Cooler Core Assembly
Installation of Engine Oil Cooler Core Assembly
Fuel Injection Pump
Removal of Fuel Injection Pump Assembly
Installation of Fuel Injection Pump Assembly
Water Pump
Removal of Water Pump Assembly
Installation of Water Pump Assembly
Nozzle Holder
Removal of Nozzle Holder Assembly
Installation of Nozzle Holder Assembly
Turbocharger
Removal of Turbocharger Assembly
Installation of Turbocharger Assembly
Thermostat
Removal of Thermostat Assembly
Installation of Thermostat Assembly
Govenor Motor
Removal of Govenor Motor Assembly
Installation of Governor Motor Assembly
Cylinder Head
Removal of Cylinder Head Assembly
Installation of Cylinder Head Assembly
Hydraulic Oil Cooler
Removal of Hydraulic Oil Cooler Assembly
Installation of Hydraulic Oil Cooler Assembly
Radiator - Hydraulic Oil Cooler
Removal of Radiator, Hydraulic Oil Cooler Assembly
Installation of Radiator, Hydraulic Oil Cooler Assembly
Engine - Main Pump
Removal of Engine, Main Pump Assembly
Installation of Engine, Main Pump Assembly
Damper
Removal of Damper Assembly
Installation of Damper Assembly
Fuel Tank
Removal of Fuel Tank Assembly
Installation of Fuel Tank Assembly
Center Swivel Joint
Removal of Center Swivel Joint Assembly
Installation of Center Swivel Joint Assembly
Disassembly of Center Swivel Joint Assembly
Assembly of Center Swivel Joint Assembly
Final Drive
Removal of Final Drive Assembly
Installation of Final Drive Assembly
Disassembly of Final Drive Assembly
Assembly of Final Drive Assembly
Travel Motor
Disassembly of Travel Motor Assembly
Assembly of Travel Motor Assembly
Sprocket
Removal of Sproket
Installation of Sprocket
Swing Motor and Swing Machinery
Removal of Swing Motor, Swing Machinery Assembly
Installation of Swing Motor, Swing Machinery Assembly
Disassembly of Swing Machinery Assembly
Assembly of Swing Machinery Assembly
Swing Motor
Disassembly of Swing Motor Assembly
Assembly of Swing Motor Assembly
Revolving Frame
Removal of Revolving Frame Assembly
Installation of Revolving Frame Assembly
Swing Circle
Removal of Swing Circle Assembly
Installation of Swing Circle Assembly
Idler - Recoil Spring
Removal of Idler - Recoil Spring Assembly
Installation of Idler - Recoil Spring Assembly
Recoil Spring
Disassembly of Recoil Spring Assembly
Assembly of Recoil Spring Assembly
Idler
Disassembly of Idler Assembly
Assembly of Idler Assembly
Track Roller
Removal of Track Roller Assembly
Installation of Track Roller Assembly
Disassembly of Track Roller Assembly
Assembly of Track Roller Assembly
Carrier Roller
Removal of Carrier Roller Assembly
Installation of Carrier Roller Assembly
Disassembly of Carrier Roller Assembly
Assembly of Carrier Roller Assembly
Track Shoe
Removal of Track Shoe Assembly
Installation of Track Shoe Assembly
Hydraulic Tank
Removal of Hydraulic Tank Assembly
Installation of Hydraulic Tank Assembly
Main Pump
Removal of Main Pump Assembly
Installation of Main Pump Assembly
Disassembly of Main Pump Assembly
Assembly of Main Pump Assembly
Main Pump Input Shaft Oil Seal
Removal of Main Pump Input Shaft Oil Seal
Installation of Main Pump Input Shaft Oil Seal
Control Valve
Removal of Control Valve Assembly
Installation of Control Valve Assembly
Disassembly of Control Valve Assembly
Assembly of Control Valve Assembly
Pump Merge-Divider Valve
Disassembly of Pump Merge-Divider Valve Assembly
Assembly of Pump Merge-Divider Valve Assembly
Main Relief Valve
Disassembly of Main Relief Valve Assembly
Assmebly of Main Relief Valve Assembly
Work Equipment EPC Valve
Removal of Work Equipment EPC Valve Assembly
Installation of work Equipment EPC Valve Assembly
PC Valve
Removal of PC Valve Assembly
Installation of PC Valve Assembly
LS Valve
Removal of LS Valve Assembly
Installation of LS Valve Assembly
PC, LS-EPC Valve
Removal of PC, LS-EPC Valve Assembly
Installation of PC, LS-EPC Valve Assembly
Solenoid Valve
Removal of Solenoid Valve Assembly
Installation of Solenoid Valve Assembly
Work Equipment - Swing PPC Valve
Removal of Work Equipment - Swing PPC Valve Assembly
Installation of Work Equipment - Swing PPC Valve Assembly
Disassembly of Work Equipment - Swing PPC Valve Assembly
Assembly of Work Equipment - Swing PPC Valve Assembly
Travel PPC Valve
Removal of Travel PPC Valve Assembly
Installation of Travel PPC Valve Assembly
Disassembly of Travel PPC Valve Assembly
Assembly of Travel PPC Valve Assembly
Boom Lock Valve
Removal of Boom Lock Valve Assembly
Installation of Boom Lock Valve Assembly
Boom Cylinder
Removal of Boom Cylinder Assembly
Installation of Boom Cylinder Assembly
Arm Cylinder
Removal of Arm Cylinder Assembly
Installation of Arm Cylinder Assembly
Bucket Cylinder
Removal of Bucket Cylinder Assembly
Installation of Bucket Cylinder Assembly
Hydraulic Cylinder
Disassembly of Hydraulic Cylinder Assembly
Assembly of Hydraulic Cylinder Assembly
Work Equipment
Removal of Work Equipment Assembly
Installation of Work Equipment Assembly
Bucket
Removal of Bucket Assembly
Installation of Bucket Assembly
Arm
Removal of Arm Assembly
Installation of Arm Assembly
Bucket - Arm
Removal of Bucket - Arm Assembly
Installation of Bucket - Arm Assmebly
Boom
Removal of Boom Assembly
Installation of Boom Assembly
Opeator's Cab
Removal of Operator's Cab Assembly
Installation of Operator's Cab Assembly
Counterweight
Removal of Counterweight Assembly
Installation of Counterweight Assembly
Work Equipment Electric Lever Unit
Removal of Work Equipment Electric Lever Unit Assembly
Installation of Work Equipment Electric Lever Unit Assembly
Engine Throttle - Pump Controller
Removal of Engine Throttle - Pump Controller Assembly
Installation of Engine Throttle - Pump Controller Assembly
Control Stand Case
Removal of Control Stand Case
Installation of Control Stand Case
Valve Controller
Removal of Valve Controller Assembly
Installation of Valve Controller Assembly
Monitor
Removal of Monitor Assembly
Installation of Monitor Assembly
ITERMS FOR HYPER GX
Swing Motor
Removal of Swing Motor Assembly
Installation of Swing Motor Assembly
Control Valve
Removal of Control Valve Assembly
Installation of Control Valve Assembly
Work Equipment EPC Valve
Removal of Work Equipment EPC Valve Assembly
Installation of Work Equipment EPC Valve Asembly
Boom Cylinder
Removal of Boom Cylinder Assembly
Installation of Boom Cylinder Assembly
Arm Cylinder
Removal of Arm Cylinder Assembly
Installation of Arm Cylinder Assembly
Bucket Cylinder
Removal of Bucket Cylinder Assembly
Installation of Bucket Cylinder Assembly
Disassembly of Bucket Cylinder Assembly
Assembly of Bucket Cylinder Assembly
Work Equipment
Removal of Work Equipment Assembly
Installation of Work Equipment Assembly
Bucket
Removal of Bucket Assembly
Installation of Bucket Assembly
Arm
Removal of Arm Assembly
Installation of Arm Assembly
Bucket - Arm
Removal of Bucket - Arm Assembly
Installation of Bucket - Arm Assembly
Boom
Removal of Boom Assembly
Installation of Boom Assembly
Valve Controller
Removal of Valve Controller Assembly
Installation of Valve Controller Assembly
GX Controller
Removal of GX Controller Assembly
Installation of GX Controller Assembly
GX Panel
Removal of GX Panel Assembly
Installation of GX Panel Assembly

40 MAINTENANCE STANDARD
Swing Machinery
Swing Circle
Final Drive
Track Frame - Recoil Spring
Idler
Carrier Roller
Track Roller
Track Shoe
Hydraulic Pump
Control Valve
Safety-Suction Valve (for Service Valve)
Self-Reducing Pressure Valve
Swing Motor
Travel Motor
Work Equipment - Swing PPC Valve
Work Equipment - Swing EPC Valve
Tavel PPC Valve
Service PPC Valve
EPC Solenoid Valve
Center Swivel Joint
Boom Holding Valve
Hydraulic Cylinder
Work Equipment
Dimension of Work Equipment

90 OTHER
Hydraulic Circuit Diagram (pg. 90-3)
PC200-6 STD Serial No.: 96514 - 102228
PC210-6 STD Serial No.: 30980 - 31424
PC220-6 STD Serial No.: 52852 - 53561
PC230-6 STD Serial No.: 10177 - 10246
Hydraulic Circuit Diagram (pg. 90-5)
PC200-6 STD Serial No.: 102229 and UP
PC210-6 STD Serial NO.: 31425 and UP
PC220-6 STD Serial No.: 53562 and UP
PC230-6 STD Serial NO.: 10247 and UP
Hydraulic Circuit Diagram (pg. 90-7)
PC200-6 HYPER GX Serial No.: 96514 - 102228
Hydraulic Circuit Diagram (pg. 90-9)
PC200-6 HYPER GX Serial No.: 102229 and UP
Hydraulic Circuit Diagram (pg. 90-10-1)
For Rotary Arm = PC200, 200LC-6
Electrical Circuit Diagram [ 1/2 ] (pg. 90-11)
PC200-6 STD Serial No.: 96514 - 102228
PC210-6 STD Serial No.: 30980 - 31424
PC220-6 STD Serial No.: 52852 - 53561
PC230-6 STD Serial No.: 10177 - 10246
Electrical Circuit Diagram [ 2/2 ] (pg. 90-13)
PC200-6 STD Serial No.: 96514 - 102228
PC210-6 STD Serial No.: 30980 - 31424
PC220-6 STD Serial NO.: 52852 - 53561
PC230-6 STD Serial No.: 10177 - 10246
Electrical Circuit Diagram [1/2 ] (pg. 90-15)
PC200-6 STD Serial No.: 102229 and UP
PC210-6 STD Serial No.: 31425 and UP
PC220-6 STD Serial No.: 53562 and UP
PC230-6 STD Serial No.: 10247 and UP
Electrical Circuit Diagram [ 2/2 ] (pg. 90-17)
PC200-6 STD Serial No.: 102229 and UP
PC210-6 STD Serial No.: 31425 and UP
PC220-6 STD Serial No.: 53562 and UP
PC230-6 STD Serial No.: 10247 and UP
Electrical Circuit Diagram [ 1/3 ] (pg. 90-19)
PC200-6 HYPER GX Serial No.: 94999 - 102228
Electrical Circuit Diagram [ 2/3 ] (pg. 90-21)
PC200-6 HYPER GX Serial No.: 94999 - 102228
Electrical Circuit Diagram [ 3/3 ] (pg. 90-23)
PC200-6 HYPER GX Serial No.: 94999 - 102228
Electrical Circuit Diagram (pg. 90-25)
PC200-6 HYPER GX Serial No.: 94999 - 102228
Electrical Circuit Diagram [ 1/3 ] (pg. 90-27)
PC200-6 HYPER GX Serial No.: 102229 and UP
Electrical Circuit Diagram [ 2/3 ] (pg. 90-29)
PC200-6 HYPER GX Serial No.: 102229 and UP
Electrical Circuit Diagram [ 3/3 ] (pg. 90-31)
PC200-6 HYPER GX Serial No.: 102229 and UP
Electrical Circuit Diagram (pg 90-33)
PC200-6 HYPER GX Serial No.: 102229 and UP

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