Komatsu PC200LC-6LE PC210LC-6LE PC220LC-6LE PC250LC-6LE Excavator Repair & Operation Manual PDF - MKMTSPC200LCLE250LCLE.zip
A full workshop service and repair guide, complete with electrical wiring schematics, covering the Komatsu Hydraulic Excavators PC200LC-6LE, PC210LC-6LE, PC220LC-6LE, and PC250LC-6LE. It contains every technical detail needed to service, troubleshoot, and rebuild these machines to a professional standard.
Inside the Komatsu Hydraulic Excavator PC200LC-6LE, PC210LC-6LE, PC220LC-6LE, PC250LC-6LE workshop service repair manual, you'll find:
* 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: 1,485 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
FOREWORD...15
SAFETY...15
SAFETY NOTICE...15
IMPORTANT SAFETY NOTICE...15
GENERAL PRECAUTIONS...15
PREPARATIONS FOR WORK...15
PRECAUTIONS DURING WORK...15
GENERAL...17
HOW TO READ THE SHOP MANUAL...18
VOLUMES...18
DISTRIBUTION AND UPDATING...18
FILING METHOD...18
REVISED EDITION MARK...18
REVISIONS...18
SYMBOLS...18
HOISTING INSTRUCTIONS...19
HOISTING...19
WIRE ROPES...19
PUSH PULL COUPLER...20
TYPE 1...20
DISCONNECTION...20
CONNECTION...20
TYPE 2...21
DISCONNECTION...21
CONNECTION...21
TYPE 3...22
DISCONNECTION...22
CONNECTION...22
COATING MATERIALS...23
STANDARD TIGHTENING TORQUE...25
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...25
TIGHTENING TORQUE OF HOSE NUTS...26
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...26
TIGHTENING TORQUE FOR FLARED NUTS...26
ELECTRIC WIRE CODE...27
CLASSIFICATION BY THICKNESS...27
CLASSIFICATION BY COLOR AND CODE...27
CONVERSION TABLES...28
METHOD OF USING THE CONVERSION TABLE...28
01 GENERAL...35
GENERAL ASSEMBLY DRAWING...36
PC200LC-6LE, PC210LC-6LE...36
PC220LC-6LE, PC250LC-6LE...38
SPECIFICATIONS...41
PC200LC-6LE...41
PC210LC-6LE...43
PC220LC-6LE...45
PC250LC-6LE...47
WEIGHT TABLE...49
PC200LC-6LE...49
PC210LC-6LE...50
PC220LC-6LE, PC250LC-6LE...51
FUEL COOLANT AND LUBRICANTS...52
10 STRUCTURE AND FUNCTION...53
ENGINE RELATED PARTS...55
RADIATOR - OIL COOLER - AFTERCOLLER...56
PC200LC-6LE, PC210LC-6LE...56
PC220LC-6LE, PC250LC-6LE...57
POWER TRAIN...58
FINAL DRIVE...59
PC200LC-6LE, PC210LC-6LE, PC220LC- 6LE...59
PC250LC-6LE...63
SWING CIRCLE...66
SWING MACHINERY...69
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...69
PC250LC-6LE...73
TRACK FRAME...76
TRACK FRAME - RECOIL SPRING...76
IDLER...78
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...78
PC250LC-6LE...80
CARRIER ROLLER...82
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...82
PC250LC-6LE...83
TRACK ROLLER...84
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...84
PC250LC-6LE...85
TRACK SHOE...87
STANDARD SHOE...87
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...88
PC250LC-6LE...90
TRIPLE GROUSER SHOE...92
SWAMP SHOE...93
HYDRAULIC PIPING DRAWING...94
HYDRAULIC CIRCUIT DIAGRAM...97
HYDRAULIC TANK...99
HYDRAULIC PUMP...100
LS AND PC VALVE...107
LS VALVE...108
PC VALVE...113
IN-LINE OIL FILTER...120
CONTROL VALVE...122
VARIABLE PRESSURE COMPENSATION VALVE...134
SAFETY-SUCTION VALVE FOR SERVICE VALVE...135
SELF-REDUCING PRESSURE VALVE...137
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)...143
OPERATION OF CLSS SYSTEM AS A WHOLE...173
SWING MOTOR...192
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...192
PC250LC-6LE...196
SWING LOCK VALVE...200
RELIEF VALVE PORTION...201
REVERSE PREVENTION VALVE...202
CENTER SWIVEL JOINT...204
4-PORT SWIVEL...204
6-PORT SWIVEL...206
TRAVEL MOTOR...208
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE...208
PC250LC-6LE...212
MOTOR OPERATION...216
PARKING BRAKE OPERATION...218
BRAKE VALVE OPERATION...219
VALVE CONTROL...222
WORK EQUIPMENT - SWING PPC VALVE...223
TRAVEL PPC VALVE...230
SERVICE PPC VALVE...235
SAFETY LOCK VALVE...239
PPC ACCUMULATOR...239
STRUCTURE-TRAVEL SYSTEM...240
EPC SOLENOID VALVE...241
BOOM LOCK VALVE...244
ADDITIONAL FILTER FOR BREAKER...248
WORK EQUIPMENT...249
DIMENSION...250
ARM PORTION...250
BUCKET PORTION...252
CLEARANCE...254
HYDRAULIC CYLINDER...256
PC200LC-6LE, PC210-6LE...256
BOOM CYLINDER...256
ARM CYLINDER...256
BUCKET CYLINDER...256
PC220LC-6LE, PC250LC-6LE...258
BOOM CYLINDER...258
ARM CYLINDER...258
BUCKET CYLINDER...258
AIR CONDITIONER...260
ELECTRICAL CIRCUIT NIPPON DENSO AIR CONDITIONER...262
AIR CONDITIONING (GENERAL)...263
BASIC INFORMATION ON AIR CONDITIONERS...263
CONDENSER...272
COMPRESSOR...275
RECEIVER WITH SIGHT GLASS (LIQUID TANK)...276
AIR CONDITIONER UNIT...278
ELECTRICAL WIRING DIAGRAM...280
ELECTRICAL CIRCUIT DIAGRAM...284
ENGINE CONTROL SYSTEM...285
ELECTRONIC CONTROL SYSTEM...295
TOTAL SYSTEM DIAGRAM...296
COMPONENTS OF SYSTEM...320
MACHINE MONITOR SYSTEM...324
SENSORS...331
20 TESTING, ADJUSTING AND TROUBLESHOOTING...335
STANDARD VALUE TABLE FOR ENGINE...337
FOR ENGINE - PC200/210LC-6LE...337
FOR ENGINE - PC220/250LC-6LE...338
STANDARD VALUE TABLE FOR CHASSIS...339
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...348
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...356
ENGINE...357
FUEL...357
BLEEDING AIR FROM FUEL CIRCUIT...357
FUEL PRESSURE...357
HANDLING FUEL SYSTEM DEVICES...357
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE...357
RELEASING RESIDUAL FUEL SYSTEM PRESSURE...357
ADJUSTING ENGINE SPEED SENSOR...357
ADJUSTING VALVE CLEARANCE...357
BLOW-BY PRESSURE...357
COMPRESSION PRESSURE...357
ENGINE OIL PRESSURE...357
ENGINE SPEED SENSOR...357
EXHAUST GAS COLOR...357
EXHAUST TEMPERATURE...357
INTAKE AIR PRESSURE (BOOST PRESSURE)...357
FAN BELT TENSION...358
BELT TENSION FOR AIR CONDITIONER COMPRESSOR...358
SPEED SENSOR...359
GOVERNOR MOTOR LEVER STROKE...360
HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT...361
PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...364
LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE AND LS DIFFERENTIAL PRESSURE)...365
CONTROL CIRCUIT OIL PRESSURE...367
SOLENOID VALVE OUTPUT PRESSURE...368
PPC VALVE OUTPUT PRESSURE...370
WORK EQUIPMENT l SWING PPC VALVE...372
TRAVEL DEVIATION...373
WORK EQUIPMENT - HYDRAULIC DRIFT...374
OIL LEAKAGE...376
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...378
SWING CIRCLE BEARING CLEARANCE...378
TRACK SHOE TENSION...379
BLEEDING AIR...380
TROUBLESHOOTING GENERAL...383
POINTS TO REMEMBER WHEN TROUBLESHOOTING...385
SEQUENCE OF EVENTS IN TROUBLESHOOTING...387
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...388
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...388
HANDLING WIRING HARNESSES AND CONNECTORS...388
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES...390
HANDLING CONTROL BOX...393
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS...394
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...394
CHECKS BEFORE TROUBLESHOOTING...396
CONNECTOR TYPES AND MOUNTING LOCATIONS...398
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...402
T-BRANCH BOX AND T-BRANCH TABLE...424
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...428
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...429
METHOD OF USING JUDGEMENT TABLE...437
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...439
CLASSIFICATION OF TROUBLESHOOTING...439
STEPS FOR TROUBLESHOOTING...439
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...439
SERVICE CODE TABLE...444
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM N-MODE...445
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...447
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...447
USER CODE MEMORY RETENTION FUNCTION...447
INFORMATION CONTAINED IN TESTING PROCEDURES...448
N-1 [E218] COMMUNICATION ABNORMALITY...450
TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE THROTTLE-PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM]...453
TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...454
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER SYSTEM...454
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...455
USER CODE MEMORY RETENTION FUNCTION...455
INFORMATION CONTAINED IN TESTING PROCEDURES...456
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...458
JUDGEMENT TABLE FOR ENGINE THROTTLE-PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATEDPARTS...462
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...464
E-1 ABNORMALITY IN ENGINE THROTTLE-PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...467
E-2 [E308] ABNORMAL FUEL DIAL SIGNALS...468
E-3 [E317] OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"...470
E-4 [E318] SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"...472
E-5 [E306] ABNORMAL GOVERNOR POTENTIOMETER SIGNALS...474
E-6 [E315] SHORT IN BATTERY RELAY SYSTEM...476
E-7 [E316] STEP OUT IN GOVERNOR MOTOR...478
E-8 ENGINE WILL NOT CRANK...480
E-9 ENGINE SPEED IRREGULAR, OR HUNTING...482
IDLING SPEED IS IRREGULAR...482
HUNTING...483
E-10 ENGINE HIGH IDLING SPEED IS TOO LOW (LACK OF OUTPUT)...484
E-11 ENGINE DOES NOT STOPENGINE DOES NOT STOP...486
E-12 BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...488
TROUBLESHOOTING OF ENGINE THROTTLE-PUMP CONTROLLER C-MODE-...491
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...493
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...494
JUDGEMENT TABLE FOR ENGINE THROTTLE-PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...502
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...504
PC200LC-6LE, PC210LC-6LE, PC220LC-6LE, PC250LC-6LE S/N A83001 and UP...504
PC200LC-6LE, PC220LC-6LE S/N A85001 and UP...506
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...508
C-2 [E232] SHORT IN PC-EPC SOLENOID...510
C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID...512
C-4 [E213] OPEN IN SWING PARKING BRAKE SOLENOID...514