Komatsu Galeo PC200LL-7L PC220LL-7L Hydarulic Excavator Shop Manual CEBM014300 – PDF DOWNLOAD

Komatsu Galeo PC200LL-7L PC220LL-7L Hydarulic Excavator Shop Manual CEBM014300 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Galeo PC200LL-7L PC220LL-7L Hydarulic Excavator Shop Manual CEBM014300 – PDF DOWNLOAD

Language : English
Pages : 744
Downloadable : Yes
File Type : PDF
Size: 25.7 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Galeo PC200LL-7L PC220LL-7L Hydarulic Excavator Shop Manual CEBM014300 – PDF DOWNLOAD

SERIAL NUMBERS
PC200LL-7L A86001   and UP
PC220LL-7L A86001    and UP

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1 .Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

•  Always wear safety glasses when hitting parts with a hammer.
•  Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.PREPARATIONS FOR WORK:
1. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
2. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

TABLE OF CONTENTS:

Komatsu Galeo PC200LL-7L PC220LL-7L Hydarulic Excavator Shop Manual CEBM014300 – PDF DOWNLOAD

MAIN MENU……………………………………………………………………… 0
COVER…………………………………………………………………………. 1
CONTENTS………………………………………………………………………. 2
FOREWORD………………………………………………………………………. 5
SAFETY…………………………………………………………………….. 5
SAFETY NOTICE…………………………………………………………… 5
IMPORTANT SAFETY NOTICE………………………………………………. 5
GENERAL PRECAUTIONS………………………………………………….. 5
PREPARATIONS FOR WORK………………………………………………… 5
PRECAUTIONS DURING WORK………………………………………………. 5
GENERAL……………………………………………………………………. 7
HOW TO READ THE SHOP MANUAL………………………………………………….. 8
VOLUMES………………………………………………………………… 8
DISTRIBUTION AND UPDATING………………………………………………… 8
FILING METHOD…………………………………………………………… 8
REVISED EDITION MARK…………………………………………………….. 8
REVISIONS………………………………………………………………. 8
SYMBOLS………………………………………………………………… 8
HOISTING INSTRUCTIONS……………………………………………………….. 9
HOISTING……………………………………………………………….. 9
WIRE ROPES……………………………………………………………… 9
COATING MATERIALS…………………………………………………………… 10
STANDARD TIGHTENING TORQUE…………………………………………………… 12
BOLTS AND NUTS STANDARD TIGHTENING TORQUE………………………………….. 12
HOSE NUTS TIGHTENING TORQUE………………………………………………. 13
SPLIT FLANGE BOLTS TIGHTENING TORQUE………………………………………. 13
FLARED NUTS TIGHTENING TORQUE…………………………………………….. 13
O-RING BOSS PIPING JOINTS TIGHTENING TORQUE………………………………… 14
O-RING BOSS PLUGS TIGHTENING TORQUE……………………………………….. 14
ENGINE SERIES TIGHTENING TORQUE…………………………………………… 15
HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE…………………. 16
ELECTRIC WIRE CODE………………………………………………………….. 17
CLASSIFICATION BY THICKNESS………………………………………………. 17
CLASSIFICATION BY COLOR AND CODE………………………………………….. 17
CONVERSION TABLES…………………………………………………………… 18
METHOD OF USING THE CONVERSION TABLE………………………………………. 18
UNITS………………………………………………………………….. 24
01 GENERAL…………………………………………………………………….. 25
SPECIFICATION DIMENSION DRAWINGS……………………………………………… 26
PC200/220LL-7L………………………………………………………….. 26
DIMENSIONS………………………………………………………….. 26
WORKING RANGE – ROAD BUILDER………………………………………….. 28
SPECIFICATIONS……………………………………………………………… 30
WEIGHT TABLE……………………………………………………………….. 32
FUEL, COOLANT AND LUBRICANTS…………………………………………………. 34
PC200LL-7L……………………………………………………………… 34
PC220LL-7L……………………………………………………………… 35
10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS…………………………………….. 37
ENGINE RELATED PARTS………………………………………………………… 41
RADIATOR, OIL COOLER AND AFTERCOOLER………………………………………….. 42
POWER TRAIN………………………………………………………………… 43
FINAL DRIVE………………………………………………………………… 44
PC200LL-7L……………………………………………………………… 44
PC220LL-7L……………………………………………………………… 46
SWING MACHINERY…………………………………………………………….. 48
PC200LC-7………………………………………………………………. 48
PC220LC-7………………………………………………………………. 50
SWING CIRCLE……………………………………………………………….. 52
PC200LC-7………………………………………………………………. 52
PC220LL-7L……………………………………………………………… 53
UNDERCARRIAGE………………………………………………………………. 54
IDLER……………………………………………………………………… 56
TRACK AND CARRIER ROLLER…………………………………………………….. 58
TRACK CHAIN AND SHOES……………………………………………………….. 61
TRIPLE GROUSER SHOE – PC200LL-7L………………………………………….. 66
TRIPLE GROUSER SHOE – PC220LL-7L………………………………………….. 67
HYDRAULIC EQUIPMENT…………………………………………………………. 68
HYDRAULIC TANK……………………………………………………………… 70
HYDRAULIC PUMP……………………………………………………………… 71
HPV95+95……………………………………………………………….. 71
LS VALVE……………………………………………………………. 75
PC VALVE……………………………………………………………. 76
LS-EPC VALVE……………………………………………………………. 88
MAIN CONTROL VALVE………………………………………………………….. 92
MAIN RELIEF VALVE……………………………………………………………108
VARIABLE PRESSURE COMPENSATION VALVE…………………………………………..109
CLSS……………………………………………………………………….110
OUTLINE OF CLSS………………………………………………………….110
SELF PRESSURE REDUCING VALVE………………………………………………….113
SWING MOTOR…………………………………………………………………116
PC200LL-7L………………………………………………………………116
KMF125ABE-5………………………………………………………….116
PC220LL-7L………………………………………………………………119
KMF230ABE-5………………………………………………………….119
OPERATION OF SWING LOCK…………………………………………………..122
RELIEF VALVE PORTION……………………………………………………..123
REVERSE PREVENTION VALVE……………………………………………………..124
CENTER SWIVEL JOINT………………………………………………………….126
TRAVEL MOTOR………………………………………………………………..127
PC200LL-7L………………………………………………………………127
HMV110-2…………………………………………………………….127
PC220LL-7L………………………………………………………………130
HMV160ADT-2………………………………………………………….130
MOTOR……………………………………………………………….133
PARKING BRAKE………………………………………………………..135
BRAKE VALVE………………………………………………………….135
SAFETY VALVE…………………………………………………………136
TRAVEL JUNCTION VALVE………………………………………………………..138
TRAVEL PPC SHUTTLE VALVE……………………………………………………..140
VALVE CONTROL……………………………………………………………….142
CONNECTIONS……………………………………………………………..142
LEVER POSITIONS………………………………………………………….143
EQUIPMENT PPC VALVE………………………………………………………….144
TRAVEL PPC VALVE…………………………………………………………….148
TRAVEL SIGNAL/STEERING FUNCTION……………………………………………151
SERVICE PPC VALVE……………………………………………………………155
SOLENOID VALVE………………………………………………………………158
ATTACHMENT SOLENOID VALVE…………………………………………………….159
PPC ACCUMULATOR……………………………………………………………..161
BOOM DRIFT PREVENTION VALVE…………………………………………………..162
LIFT CHECK VALVE…………………………………………………………….166
EQUIPMENT CYLINDERS………………………………………………………….168
PC200LL-7……………………………………………………………….168
BOOM CYLINDER………………………………………………………..168
ARM CYLINDER…………………………………………………………168
BUCKET CYLINDER………………………………………………………168
PC220LL-7……………………………………………………………….170
BOOM CYLINDER………………………………………………………..170
ARM CYLINDER…………………………………………………………170
BUCKET CYLINDER………………………………………………………170
WORK EQUIPMENT………………………………………………………………172
PC200LL-7……………………………………………………………….173
100 HOURS……………………………………………………………173
500 HOURS……………………………………………………………173
PC220LL-7……………………………………………………………….174
100 HOURS……………………………………………………………174
500 HOURS……………………………………………………………174
ARM DIMENSION……………………………………………………………176
BUCKET DIMENSIONS………………………………………………………..178
AIR CONDITIONER……………………………………………………………..180
ENGINE CONTROLS……………………………………………………………..181
OPERATION OF SYSTEM………………………………………………………182
STARTING ENGINE………………………………………………………182
ENGINE SPEED CONTROL………………………………………………….182
STOPPING ENGINE………………………………………………………182
COMPONENT……………………………………………………………….183
FUEL CONTROL DIAL…………………………………………………….183
GOVERNOR MOTOR…………………………………………………………..184
ENGINE THROTTLE AND PUMP CONTROLLER………………………………………..185
INPUT AND OUTPUT SIGNALS………………………………………………186
ELECTRONIC CONTROL SYSTEM…………………………………………………….187
MACHINE CONTROL SYSTEM DIAGRAM…………………………………………….188
ENGINE AND PUMP CONTROL FUNCTION……………………………………….190
PUMP VALVE CONTROL……………………………………………………194
ONE TOUCH POWER MAXIMIZING…………………………………………….196
AUTO DECELERATION FUNCTION…………………………………………….197
AUTO WARM UP OVERHEAT PREVENTION……………………………………….199
SWING CONTROL FUNCTION………………………………………………..201
SWING CONTROL FUNCTION WITH SOFT SWING………………………………….203
TRAVEL CONTROL FUNCTION……………………………………………….205
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION……………………………..207
SYSTEM COMPONENT PARTS……………………………………………………208
ENGINE REVOLUTION SENSOR………………………………………………208
PPC OIL PRESSURE SWITCH……………………………………………….209
PUMP PRESSURE SENSOR………………………………………………….210
MULTI MONITOR SYSTEM…………………………………………………………211
MONITOR PANEL……………………………………………………………212
INPUT AND OUTPUT SIGNALS………………………………………………213
MONITOR CONTROL, DISPLAY PORTION…………………………………………..214
MONITOR PORTION………………………………………………………214
MONITOR ITEMS AND DISPLAY……………………………………………..215
SWITCHES………………………………………………………………..219
SELECT MODE FUNCTION………………………………………………….221
METHOD OF USE………………………………………………………..221
MAINTENANCE FUNCTION………………………………………………….224
METHOD OF CHECKING STATUS MAINTENANCE ITEMS……………………………..225
MAINTENANCE OPERATION…………………………………………………225
BRIGHTNESS CONTRAST ADJUSTMENT FUNCTION…………………………………226
SERVICE METER CHECK FUNCTION…………………………………………..227
DISPLAY LCD CHECK FUNCTION…………………………………………….227
USER CODE DISPLAY FUNCTION…………………………………………….227
SENSORS…………………………………………………………………….229
ENGINE OIL LEVEL SENSOR…………………………………………………..229
COOLANT TEMPERATURE SENSOR………………………………………………..229
HYDRAULIC OIL TEMPERATURE SENSOR…………………………………………..229
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)……………………………….230
FUEL LEVEL SENSOR………………………………………………………..230
AIR CLEANER CLOGGING SENSOR……………………………………………….231
CAB RISER AND RELATED PARTS…………………………………………………..232
POWER CONTROL……………………………………………………………233
CAB RISER HYDRAULIC SYSTEM……………………………………………………234
20 TESTING, ADJUSTING AND TROULBESHOOTING………………………………………….235
STANDARD VALUE TABLES………………………………………………………..236
ENGINE PARTS…………………………………………………………….236
CHASSIS PARTS……………………………………………………………237
FLOW CONTROL CHARACTERISTIC OF PC VALVE…………………………………….246
TESTING AND ADJUSTING………………………………………………………..247
TOOLS FOR TESTING………………………………………………………..250
ENGINE………………………………………………………………….251
AIR BOOST PRESSURE……………………………………………………251
AIR COMPRESSOR BELT TENSION……………………………………………251
BLOW-BY PRESSURE……………………………………………………..251
COMPRESSION PRESSURE………………………………………………….251
ENGINE OIL PRESSURE…………………………………………………..251
ENGINE RPM…………………………………………………………..251
ENGINE SPEED SENSOR…………………………………………………..251
EXHAUST GAS COLOR…………………………………………………….251
FUEL INJECTION TIMING…………………………………………………251
VALVE CLEARANCE………………………………………………………251
AIR CONDITIONER BELT……………………………………………………..252
ENGINE CONTROL FAILURE……………………………………………………253
SWING CIRCLE BEARINGS…………………………………………………….254
TRACK SHOE TENSION……………………………………………………….255
EQUIPMENT, SWING AND TRAVEL PRESSURES………………………………………256
MEASUREMENT………………………………………………………….256
PRE MEASUREMENT WORK………………………………………………256
COMBINATION OF PUMP, ACTUATOR AND VALVE……………………………..256
UNLOAD PRESSURE…………………………………………………..257
WORK EQUIPMENT RELIEF PRESSURE……………………………………..257
SWING RELIEF PRESSURE……………………………………………..257
TRAVEL CIRCUIT RELIEF PRESSURE……………………………………..257
ADJUSTMENT…………………………………………………………..258
MAIN RELIEF PRESSURE………………………………………………258
SWING RELIEF PRESSURE……………………………………………..259
CONTROL CIRCUIT OIL PRESSURE………………………………………………260
PUMP PC CONTROL CIRCUIT PRESSURE…………………………………………..261
TESTING……………………………………………………………..261
PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)………………..261
PC-EPC OUTPUT PRESSURE…………………………………………….262
ADJUSTMENT…………………………………………………………..263
PUMP LS CONTROL CIRCUIT PRESSURE…………………………………………..264
MEASUREMENT………………………………………………………….264
LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)………………..264
LS DIFFERENTIAL PRESSURE…………………………………………..265
LS-EPC VALVE OUTPUT PRESSURE……………………………………….267
ADJUSTMENT…………………………………………………………..268
SOLENOID VALVE OUTPUT PRESSURE…………………………………………….269
TESTING……………………………………………………………..269
ATTACHMENT SOLENOID VALVE OUTPUT……………………………………….270
TABLE FOR FUNCTIONING CONDITIONS……………………………………….271
PPC LOCK SOLENOID VALVE……………………………………………271
SWING AND PARKING BRAKE SOLENOID……………………………………271
TRAVEL INTERCONNECTION SOLENOID VALVE……………………………….271
TRAVEL SPEED SHIFTING SOLENOID VALVE………………………………..272
2 STAGE RELIEF SOLENOID VALVE………………………………………272
MERGE DIVIDE SOLENOID VALVE………………………………………..272
PPC VALVE OUTPUT PRESSURE…………………………………………………273
ATTACHMENT PPC VALVE OUTPUT……………………………………………274
EQUIPMENT AND SWING PPC VALVE……………………………………………..275
WORK EQUIPMENT DRIFT……………………………………………………..276
BOOM AND BUCKET CYLINDERS……………………………………………..276
ARM CYLINDER…………………………………………………………276
BOOM LOCK VALVE………………………………………………………277
PPC VALVE……………………………………………………………277
RELEASE REMAINING OIL PRESSURE…………………………………………….278
OIL LEAKAGE AMOUNT……………………………………………………….279
BOOM CYLINDER………………………………………………………..279
ARM CYLINDER…………………………………………………………279
BUCKET CYLINDER………………………………………………………280
SWING MOTOR………………………………………………………….280
TRAVEL MOTOR…………………………………………………………281
SOFT SWING ADJUSTMENTS……………………………………………………282
BLEEDING AIR…………………………………………………………….283
HYDRAULIC PUMP……………………………………………………….283
HYDRAULIC CYLINDERS…………………………………………………..284
SWING MOTOR………………………………………………………….284
TRAVEL MOTOR…………………………………………………………284
DIODE INSPECTION PROCEDURES……………………………………………….285
USING DIGITAL TYPE CIRCUIT TESTER………………………………………285
USING ANALOG TYPE CIRCUIT TESTER……………………………………….285
CAB DOOR STOP ADJUSTMENT………………………………………………….286
MULTI MONITOR PANEL………………………………………………………287
MONITOR PANEL FUNCTIONS – CONVENTIONAL AND SPECIAL……………………….288
CONVENTIONAL FUNCTION: OPERATOR’S MENU………………………………288
SPECIAL FUNCTION: SERVICE MENU……………………………………..288
OPERATOR’S MENU AND DISPLAY (OUTLINE)…………………………………..289
2. SHOWING KOMATSU LOGO……………………………………………289
3. MACHINE INSPECTION BEFORE STARTING WORK…………………………..289
4. MACHINE MAINTENANCE…………………………………………….289
5. SHOWING PRECAUTION ITEMS………………………………………..289
6. CONFIRMING WORKING MODE AND TRAVEL SPEED………………………….290
7. DISPLAY OF ORDINARY ITEMS……………………………………….290
8. ADJUSTING DISPLAY LUMINANCE AND CONTRAST………………………….290
9. ADJUSTING BREAKER AND ATTACHMENT FLOW RATE………………………..290
10. CONFIRMING MAINTENANCE INFORMATION………………………………291
11. SHOWING SERVICE METER READING…………………………………..291
12. CHECKING DISPLAY LCD…………………………………………..291
13. SHOWING OCCURRENCE OF CAUTION ITEM………………………………291
14. SHOWING USERS CODE NO………………………………………….292
15. SHOWING SERVICE CODE AND FAILURE CODE NO…………………………292
TABLE FOR SERVICE AND FAILURE CODE NOS………………………………….295
OPERATION AND DISPLAY OF SERVICE MENU…………………………………..297
WAY OF SWITCHING TO SERVICE MENU……………………………………297
16. FUNCTION OF MONITORING [01]…………………………………….298
TABLE FOR MONITORING ITEMS…………………………………………….300
17. FUNCTION FOR ABNORMALITY RECORD [02]…………………………….302
18. FUNCTION FOR MAINTENANCE RECORD [03]…………………………….304
19. FUNCTION FOR MAINTENANCE MODE CHANGE [04]………………………..305
20. FUNCTION FOR PHONE NUMBER ENTRY [05]…………………………….306
21. FUNCTION FOR /DEFAULT [06]……………………………………..307
22. FUNCTION FOR ADJUSTMENT [07]……………………………………308
ELECTRICAL SYSTEM PREPARATIONS…………………………………………….311
MONITOR PANEL………………………………………………………..311
GOVERNOR PUMP CONTROLLER………………………………………………311
PC200LL-7L AND PC220LL-7L — PM – TUNE UP SERVICE………………………..313
ENGINE TUNE UP……………………………………………………314
HYDRAULIC SYSTEM………………………………………………….315
TROUBLESHOOTING GENERAL………………………………………………………319
TROUBLESHOOTING POINTS TO REMEMBER…………………………………………320
SEQUENCE OF EVENTS……………………………………………………….322
MAINTENANCE POINTS TO REMEMBER…………………………………………….323
WHEN HANDLING ELECTRIC EQUIPMENT……………………………………….323
WHEN TROUBLESHOOTING ELECTRIC CIRCUITS………………………………….327
WHEN HANDLING HYDRAULIC EQUIPMENT………………………………………328
CHECKS BEFORE TROUBLESHOOTING……………………………………………..330
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING………………………………..331
CLASSIFICATION OF TROUBLESHOOTING………………………………………331
STEPS FOR TROUBLESHOOTING……………………………………………..331
FAILURE LOOKING PHENOMENON AND TROUBLESHOOTING NO………………………..332
ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM……………………………………….335
CONNECTOR TABLE………………………………………………………335
CONNECTOR LOCATION……………………………………………………340
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)…………………………346
GOVERNOR CONTROL SYSTEM CIRCUIT DIAGRAM (G CIRCUIT)………………………348
PUMP CONTROL SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)………………………….350
TABLE FOR CONNECTOR PIN NUMBERS……………………………………………352
CONNECTOR REPAIR PROCEDURES……………………………………………….372
CONTACT TERMINAL REMOVAL (HD30 TYPE)……………………………………372
STRIPPING INSULATION………………………………………………….373
CRIMPING CONTACT TERMINAL (HD30 TYPE)…………………………………..374
INSERTION OF CONTACT TERMINAL (HD30 TYPE)……………………………….375
CONTACT TERMINAL REMOVAL (DT TYPE)……………………………………..376
STRIPPING INSULATION………………………………………………….377
CRIMPING CONTACT TERMINAL (DT TYPE)…………………………………….378
INSERTION OF CONTACT TERMINAL (DT TYPE)…………………………………379
TROUBLESHOOTING ELECTRICAL SERVICE CODES AND MECHANICAL FAILURE CODES……………..381
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM………………………………383
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF……………..383
USER CODE MEMORY RETENTION FUNCTION…………………………………….383
INFORMATION CONTAINED IN TESTING PROCEDURES…………………………………384
E101 – ERROR IN DATA HISTORY………………………………………………386
E112 – SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION…………………388
E112 – SHORT IN GUARD WIPER MOTOR DRIVE FORWARD ROTATION……………………..389
E113 – SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION…………………391
E113 – SHORT IN GUARD WIPER MOTOR DRIVE REVERSE ROTATION……………………..392
E114 – SHORT OR OPEN IN WINDOW WASHER SYSTEM………………………………..394
E114 – SHORT OR OPEN IN GUARD WASHER SYSTEM…………………………………395
E115 – ABNORMAL WINDSHIELD WIPER MOTION…………………………………….397
E115 – ABNORMAL GUARD WIPER MOTION…………………………………………398
E116 – ABNORMALITY IN PARKING WIPER ARM…………………………………….400
E116 – ABNORMALITY IN PARKING WIPER ARM (GUARD)……………………………..401
E201- SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID………………………….404
E203 – SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM………………….406
E203 – SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM (WITH SOFT SWING)….408
E204 – SHORT IN MERGE/DIVIDE SOLENOID………………………………………410
E205 – SHORT IN 2 STAGE RELIEF SOLENOID…………………………………….412
E206 – SHORT IN TRAVEL SPEED SHIFT SOLENOID…………………………………414
E211 – OPEN IN TRAVEL INTERLOCKING SOLENOID…………………………………416
E213 – OPEN IN SWING PARKING BRAKE SOLENOID…………………………………418
E213 – OPEN IN SWING PARKING BRAKE SOLENOID (WITH SOFT SWING)…………………420
NO CODE – SHORT OR OPEN IN SOFT SWING SOLENOID SYSTEM………………………..422
E214 – OPEN IN MERGE/DIVIDE SOLENOID……………………………………….426
E215 – OPEN IN 2 STAGE RELIEF SOLENOID……………………………………..428
E216 – OPEN IN TRAVEL SPEED SOLENOID……………………………………….430
E217 – ABNORMAL INPUT FOR MODEL CODE – PC200LC-7L (PC200LL-7L)………………..432
E217 – ABNORMAL INPUT FOR MODEL CODE – PC220LC-7L (PC220LL-7L)………………..434
E218 – OPEN IN S-NET SIGNAL……………………………………………….436
E222 – SHORT IN LS-EPC SOLENOID……………………………………………438
E223 – OPEN IN LS-EPC SOLENOID SYSTEM………………………………………440
E224 – ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL……………………………….442
E225 – ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL……………………………….444
E226 – ABNORMAL PRESSURE SENSOR POWER SUPPLY………………………………..446
E227 – ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER…………………448
E228 – SHORT IN ATTACHMENT RETURN SWITCHING RELAY……………………………450
NO CODE – SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM………………………..452
NO CODE – OPEN IN CAB TILT SYSTEM………………………………………….456
E232 – SHORT IN PC-EPC SOLENOID……………………………………………458
E233 – OPEN IN PC-EPC SOLENOID SYSTEM………………………………………460
E238 – OPEN IN ATTACHMENT RETURN SWITCH RELAY……………………………….462
E245 – SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM………………………….464
E246 – OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM…………………………..466
E256 – INCORRECT NONVOLATILE MEMORY DATA……………………………………468
E306 – ABNORMAL GOVERNOR POTENTIOMETER SIGNALS………………………………470
E308 – ABNORMAL FUEL DIAL SIGNALS………………………………………….472
E315 – SHORT IN BATTERY RELAY SYSTEM……………………………………….474
E316 – STEP OUT IN GOVERNOR MOTOR………………………………………….476
E317 – OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”……………………………..478
E318 – SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”…………………………….480
E501 – MODEL SELECTION FUNCTION NOT PROVIDED………………………………..482
E502 – MODEL SELECTING SIGNAL FAULT………………………………………..483
A000N1 – ENGINE SPEED OUT OF RANGE AT HIGH IDLE……………………………..484
A000N2 – ENGINE SPEED OUT OF RANGE AT LOW IDLE………………………………485
AA10NX – AIR CLEANER CLOG INDICATOR FAILURE…………………………………486
AB00KE – LOW CHARGING VOLTAGE INDICATED…………………………………….488
B@BAZG – ABNORMAL ENGINE OIL PRESSURE………………………………………490
B@BAZK – ABNORMAL ENGINE OIL LEVEL…………………………………………492
B@BCNS – ENGINE COOLANT INDICATING OVERHEAT CONDITION………………………..494
B@BCZK – ABNORMAL COOLANT LEVEL INDICATION………………………………….496
B@HANS – HYDRAULIC OIL OVERHEAT INDICATION………………………………….498
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)……………………………………..501
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM………………………………503
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF……………..503
USER CODE MEMORY RETENTION FUNCTION…………………………………….503
INFORMATION CONTAINED IN TESTING PROCEDURES…………………………………504
E-1 – ENGINE WILL NOT CRANK……………………………………………….506
E-2 – ENGINE STOPS WHILE IN OPERATION………………………………………508
E-3 – ENGINE SPEED IRREGULAR, OR HUNTING……………………………………510
E-4 – ENGINE DOES NOT STOP………………………………………………..512
E-5 – AUTO DECELERATOR DOES NOT WORK……………………………………….514
E-6 – AUTO ENGINE WARM UP DEVICE DOES NOT WORK………………………………515
E-7 – COLD START PREHEATER DOES NOT WORK……………………………………516
E-8 – ALL WORK EQUIPMENT, SWING AND TRAVEL DOES NOT OPERATE…………………..518
E-9 – ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE……………………………520
E-10 – NO DISPLAY ON MONITOR PANEL…………………………………………522
E-11 – PART OF DISPLAY ON MONITOR PANEL IS MISSING…………………………..524
E-12 – MONITOR PANEL DISPLAY CONTENTS IRRELEVANT TO THE MODEL…………………525
E-13 – FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL……………..526
E-14 – ENGINE COOLANT TEMPERATURE GAUGE NOT INDICATING CORRECTLY………………528
E-15 – HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY……………..530
E-16 – FUEL GAUGE DOES NOT DISPLAY CORRECTLY………………………………..532
E-17 – SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…………………………534
E-18 – WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS………………..536
E-19 – WINDSHIELD WIPER DOES NOT WORK………………………………………538
E-19 – GUARD WIPER DOES NOT WORK…………………………………………..539
E-20 – ALARM BUZZER CANNOT BE CANCELLED…………………………………….542
E-21 – BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR…………………………544
E-22 – BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR…………………………546
E-23 – ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR…………………………548
E-24 – ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR………………………..550
E-25 – BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR………………………..552
E-26 – BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR………………………..554
E-27 – SWING NOT CORRECTLY DISPLAYED ON MONITOR……………………………..556
E-28 – TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR…………………………….558
E-29 – TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR…………560
E-30 – SERVICE NOT CORRECTLY DISPLAYED ON MONITOR……………………………562
E-31 – AIR CONDITIONER SYSTEM DOES NOT WORK…………………………………564
E-32 – TRAVEL ALARM DOES NOT SOUND…………………………………………568
TROUBLESHOOTING MECHANICAL SYSTEM (H MODE)……………………………………..571
SYSTEM CHART…………………………………………………………….572
HYDRAULIC AND MECHANICAL SYSTEMS……………………………………….572
INFORMATION CONTAINED IN TESTING TABLES…………………………………….574
H-1 – WORK EQUIPMENT LACKS POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW………….575
H-2 – ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS……………………………576
H-3 – NO WORK EQUIPMENT, TRAVEL OR SWING OPERATION…………………………..577
H-4 – ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP……………………………578
H-5 – AUTO DECELERATOR DOES NOT WORK……………………………………….579
H-6 – FINE CONTROL MODE DOES NOT FUNCTION…………………………………..580
H-7 – BOOM MOVES SLOWLY OR LACKS POWER……………………………………..581
H-8 – ARM MOVES SLOWLY OR LACKS POWER………………………………………582
H-9 – BUCKET MOVES SLOWLY OR LACKS POWER……………………………………583
H-10 – WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION…………………….584
H-11 – WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT………………………….585
H-12 – WORK EQUIPMENT EXCESSIVE LAG TIME……………………………………586
H-13 – OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT……………..587
H-14 – ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE…………………………..588
H-15 – WORK EQUIPMENT WITH HEAVIER LOADS MOVES SLOWLY………………………..589
H-16 – SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY……………………..590
H-17 – SWING AND TRAVEL, TRAVEL SPEED DROPS SHARPLY………………………….591
H-18 – MACHINE TRAVEL DIRECTION VARIES……………………………………..592
H-19 – MACHINE TRAVEL IS SLOW……………………………………………..593
H-20 – MACHINE CANNOT BE STEERED OR LACKS POWER……………………………..594
H-21 – TRAVEL SPEED IS TOO SLOW OR TOO FAST…………………………………595
H-22 – TRACKS DO NOT TURN (ON ONE SIDE ONLY)………………………………..596
H-23 – MACHINE DOES NOT SWING……………………………………………..597
H-24 – SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW…………………….598
H-25 – EXCESSIVE OVERRUN WHEN STOPPING SWING………………………………..599
H-26 – SUDDEN SHOCK WHEN STOPPING SWING…………………………………….600
H-27 – ABNORMAL NOISE WHEN STOPPING SWING…………………………………..601
H-28 – SWING HAS EXCESSIVE DRIFT…………………………………………..602
30 DISASSEMBLY AND ASSEMBLY………………………………………………………603
METHOD OF USING MANUAL……………………………………………………….607
PRECAUTIONS DURING OPERATION………………………………………………….608
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK………………………………….608
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK……………………………..609
PRECAUTIONS WHEN COMPLETING THE OPERATIONS………………………………….610
OTHER PRECAUTIONS………………………………………………………..610
SPECIAL TOOL LIST……………………………………………………………611
SKETCHES OF SPECIAL TOOLS…………………………………………………….615
ENGINE……………………………………………………………………..616
AFTERCOOLER CORE…………………………………………………………616
ALTERNATOR………………………………………………………………616
CYLINDER HEAD……………………………………………………………616
ENGINE FRONT SEAL………………………………………………………..616
ENGINE OIL COOLER………………………………………………………..616
ENGINE REAR SEAL…………………………………………………………616
FUEL INJECTION PUMP………………………………………………………616
NOZZLE HOLDER……………………………………………………………616
STARTING MOTOR…………………………………………………………..616
THERMOSTAT………………………………………………………………616
TURBOCHARGER…………………………………………………………….616
WATER PUMP………………………………………………………………616
RADIATOR……………………………………………………………………617
REMOVAL…………………………………………………………………617
INSTALLATION…………………………………………………………….618
HYDRAULIC OIL COOLER…………………………………………………………619
REMOVAL…………………………………………………………………619
INSTALLATION…………………………………………………………….620
ENGINE AND HYDRAULIC PUMPS……………………………………………………621
REMOVAL…………………………………………………………………621
INSTALLATION…………………………………………………………….625
FINAL DRIVE…………………………………………………………………627
REMOVAL…………………………………………………………………627
INSTALLATION…………………………………………………………….628
DISASSEMBLY – 200LL………………………………………………………629
ASSEMBLY – 200LL…………………………………………………………632
DISASSEMBLY – 220LL………………………………………………………637
ASSEMBLY – 220LL…………………………………………………………641
SWING MOTOR AND SWING MACHINERY……………………………………………….648
REMOVAL – 200LL………………………………………………………….648
REMOVAL – 220LL………………………………………………………….649
INSTALLATION 200LL AND 220LL………………………………………………650
DISASSEMBLY – 200LL AND 220LL……………………………………………..651
ASSEMBLY – 200LL AND 220LL………………………………………………..654
TRACK/CARRIER ROLLER…………………………………………………………660
PC200LL-7L………………………………………………………………660
ASSEMBLY…………………………………………………………….660
PC220LL-7L………………………………………………………………661
ASSEMBLY…………………………………………………………….661
IDLER………………………………………………………………………662
DISASSEMBLY……………………………………………………………..662
ASSEMBLY………………………………………………………………..663
RECOIL SPRING……………………………………………………………….665
DISASSEMBLY……………………………………………………………..665
ASSEMBLY………………………………………………………………..666
SPROCKET……………………………………………………………………667
REMOVAL…………………………………………………………………667
INSTALLATION…………………………………………………………….667
TRACK SHOE………………………………………………………………….668
REMOVAL AND EXPANSION TRACK SHOE…………………………………………..668
INSTALLATION TRACK SHOE…………………………………………………..669
SWING CIRCLE………………………………………………………………..670
REMOVAL…………………………………………………………………670
INSTALLATION…………………………………………………………….671
REVOLVING FRAME……………………………………………………………..672
REMOVAL…………………………………………………………………672
INSTALLATION…………………………………………………………….674
CENTER SWIVEL JOINT………………………………………………………….675
REMOVAL…………………………………………………………………675
INSTALLATION…………………………………………………………….676
DISASSEMBLY……………………………………………………………..677
ASSEMBLY………………………………………………………………..677
HYDRAULIC TANK………………………………………………………………678
REMOVAL…………………………………………………………………678
INSTALLATION…………………………………………………………….680
CONTROL VALVE……………………………………………………………….681
REMOVAL…………………………………………………………………681
INSTALLATION…………………………………………………………….684
PROCEDURES FOR REPLACING PRESSURE COMPENSATION VALVE SEAL…………………….685
ASSEMBLY………………………………………………………………..686
HYDRAULIC PUMP………………………………………………………………687
REMOVAL…………………………………………………………………687
INSTALLATION…………………………………………………………….689
INPUT SHAFT – OIL SEAL……………………………………………………690
REMOVAL……………………………………………………………..690
INSTALLATION…………………………………………………………690
WORK EQUIPMENT PPC VALVE……………………………………………………..691
ASSEMBLY………………………………………………………………..691
TRAVEL PPC VALVE…………………………………………………………….692
ASSEMBLY………………………………………………………………..692
HYDRAULIC CYLINDER…………………………………………………………..693
DISASSEMBLY……………………………………………………………..693
ASSEMBLY………………………………………………………………..696
WORK EQUIPMENT………………………………………………………………700
REMOVAL…………………………………………………………………700
INSTALLATION…………………………………………………………….702
AIR CONDITIONER UNIT…………………………………………………………703
REMOVAL…………………………………………………………………703
INSTALLATION…………………………………………………………….706
COUNTERWEIGHT……………………………………………………………….707
REMOVAL…………………………………………………………………707
INSTALLATION…………………………………………………………….707
OPERATOR’S CAB………………………………………………………………708
REMOVAL…………………………………………………………………708
INSTALLATION…………………………………………………………….710
MONITOR…………………………………………………………………….711
REMOVAL…………………………………………………………………711
INSTALLATION…………………………………………………………….711
GOVERNOR PUMP CONTROLLER……………………………………………………..712
REMOVAL…………………………………………………………………712
INSTALLATION…………………………………………………………….712
90 OTHERS………………………………………………………………………713
ELECTRICAL………………………………………………………………….715
CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3) – FOLDOUT 1……………………………715
CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3) – FOLDOUT 2……………………………717
CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3) – FOLDOUT 3……………………………719
CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1) – FOLDOUT 4……………………………721
CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2) – FOLDOUT 5……………………………723
CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2) – FOLDOUT 6……………………………725
CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2) – FOLDOUT 7……………………………727
CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2) – FOLDOUT 8……………………………729
CIRCUIT DIAGRAM SHEET 5 – FOLDOUT 9………………………………………..731
CIRCUIT DIAGRAM SOFT SWING (OPTION) – FOLDOUT 10…………………………….733
HYDRAULIC…………………………………………………………………..735
HYDRAULIC DIAGRAM (SHEET 1 OF 4) – FOLDOUT 11……………………………….735
HYDRAULIC DIAGRAM (SHEET 2 OF 4) – FOLDOUT 12……………………………….737
HYDRAULIC DIAGRAM (SHEET 3 OF 4) – FOLDOUT 13……………………………….739
HYDRAULIC DIAGRAM (SHEET 4 OF 4) – FOLDOUT 14……………………………….741