Complete service repair manual with Electrical Wiring Diagrams for Hydraulic Excavator PC200, PC200LC, PC220, PC220LC, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC200-2, PC200-6, PC200LC-2, PC200LC-6, PC200LC-8, PC220-2, PC220LC-2 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.

TEN00205-00 - Hydraulic Excavator PC200-8, PC200LC-8 Operation & Maintenance Manual.pdf
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SEBM0205B04 - Hydraulic Excavator PC200-2, PC200LC-2, PC220-2, PC220LC-2 Shop Manual.pdf
SEAM045200ATH - Hydraulic Excavator GALEO PC200-7, PC200LC-7 Operation & Maintenance Manual.pdf
SEAM023800PT - Hydraulic Excavator PC200-6, PC200LC-6 Operation & Maintenance Manual.pdf
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SEAM016301 - Hydraulic Excavator PC200-6 Operation & Maintenance Manual.pdf
CEBM025500 - Hydraulic Excavator PC200LC-8 Shop Manual.pdf
CEAM025700 - Hydraulic Excavator PC200LC-8 Latin America Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 4,613 pages
File Format: PDF
Language: English

CEAM025700 - Hydraulic Excavator PC200LC-8 Latin America Operation & Maintenance Manual...2
CEBM025500 - Hydraulic Excavator PC200LC-8 Shop Manual...405
  CEBM025500 PC200LC-8 LATIN AMERICA...405
    CONTENTS...406
    GENERAL...409
    HOW TO READ THE SHOP MANUAL...410
      Volumes...410
      Distribution And Updating...410
      Filing Method...410
      Revised Edition Mark...410
      Revisions...410
      Symbols...410
    HOISTING INSTRUCTIONS...411
      Hoisting...411
      Wire Ropes...411
    PUSH PULL COUPLER...412
      Type 1...412
        Disconnection...412
        Connection...412
      Type 2...413
        Disconnection...413
        Connection...413
      Type 3...414
        Disconnection...414
        Connection...414
    COATING MATERIALS...415
    STANDARD TIGHTENING TORQUE...418
      Standard Tightening Torque Of Bolts And Nuts...418
      Tightening Torque Of Hose Nuts...419
      Tightening Torque Of Split Flange Bolts...419
      Tightening Torque For Flared Nuts...419
      Table Of Tightening Torques For O-ring Boss Piping Joints...420
      Table Of Tightening Torques For O-ring Boss Plugs...420
      Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)...420
    ELECTRIC WIRE CODE...421
      Classification By Thickness...421
      Classification By Color And Code...421
    CONVERSION TABLES...422
      Method Of Using The Conversion Table...422
  01 GENERAL...429
    SPECIFICATION AND TECHNICAL DATA...430
      Specification Dimension Drawings...430
      Working Range Diagram...431
      Specifications...432
      Weight Table...434
      Table Of Fuel, Coolant And Lubricants...436
      Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil...437
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...439
    ENGINE AND COOLING SYSTEM...443
      Engine Related Parts...443
      Radiator, Oil Cooler, Aftercooler and Fuel Cooler...444
    POWER TRAIN...445
      Power Train...445
      Final Drive...446
      Swing Machinery...448
      Swing Circle...450
    UNDERCARRIAGE AND FRAME...452
      Track Frame And Recoil Spring...452
        Standard Shoe...453
      Idler...454
      Carrier Roller...456
      Track Roller...458
      Track Shoe...460
        Triple Grouser Shoe...463
    HYDRAULIC SYSTEM...464
      Hydraulic Equipment Layout Drawing...464
      Hydraulic Tank And Filter...466
      Hydraulic Pump...468
        Type: HPV95+95...468
        Operation of pump...473
        Control of delivery...474
        LS Valve...475
        PC Valve...481
        LS (PC)-EPC Valve...488
      Pilot Oil Filter...491
        For breaker...491
      Control Valve...493
        Outline...493
        General View...494
        Sectional View...496
      CLSS...506
        Outline of CLSS...506
        LS Differential Pressure and Pump Swash Plate Angle...507
      Functions and Operation by Valve...510
        Hydraulic Circuit Diagram and the Name of Valves...510
        Unload Valve...512
        Introduction Of LS Pressure...514
        LS Bypass Plug...515
        Pressure Compensation Valve...516
        Integrated Pressure Compensation Valve...517
        Pressure Compensation Valve Inner Shuttle Valve...519
        Boom Regeneration Circuit...521
        Arm Regeneration Circuit...523
        Merge-divider Valve...525
        LS Select Valve...528
        Self Pressure Reducing Valve...529
        Travel Junction Valve...532
        Travel PPC Shuttle Valve...534
        Boom Drift Prevention Valve...537
        Arm Drift Prevention Valve (if equipped)...540
        Quick Return Valve...544
        Lift Check Valve...547
        Main Relief Valve...548
        2-stage Safety-suction Valve...549
      Swing Motor...552
        Torque Values...553
        Specifications...553
        Swing Holding Brake...556
        Relief Valve Portion...557
        Outline...557
        Reverse Prevention Valve...558
        Center Swivel Joint...562
        Travel Motor...564
        Operation Of Motor...568
        Operation of Parking Brake...570
        Brake Valve...572
        Operation When Pressurized Oil is Supplied...572
        Operation of Brake During Traveling Downhill...573
      PPC Valve...576
        Work Equipment and Swing PPC Valve...576
        Travel PPC Valve...582
        Pressure reducing valve function...586
        Travel Signal/steering Function...588
        Service PPC Valve (With EPC Valve)...594
        EPC valve...596
        When Signal Current Is 0...598
        When Signal Current is Very Small...598
        When Signal Current Is Maximum...599
      Service PPC Valve...600
      Valve Control...602
        Lever Positions...603
      Solenoid Valve...604
        When Solenoid is De-energized...605
        When Solenoid is Energized...606
      PPC Accumulator...607
        Specifications...607
      CRN (Canadian certified) PPC Accumulator...607
      Return Oil Filter...608
      Attachment Circuit Selector Valve...609
        When Attachment Other Than Breaker is Installed...610
        When Breaker is Installed...610
      Hydraulic Cylinder...612
        PC200LC-8...612
    WORK EQUIPMENT...614
      Dimensions of Components...614
        PC200LC-8...615
    CAB AND ITS ATTACHMENTS...621
      Air Conditioner Piping...621
    ELECTRICAL SYSTEM...622
      Engine Control...622
        Operation of system...622
      Component...623
        Fuel Control Dial...623
        Engine Controller...624
        Coolant Temperature Sensor...627
        Oil Pressure Switch...627
        Rotation Sensor...628
        Boost Pressure and Temperature Sensor...628
        WIF (Water-in-fuel Detection) Sensor...629
        Engine Oil Level Sensor...629
      Electrical Control System...631
        Machine Control System Diagram...631
    MONITOR SYSTEM...655
      Machine Monitor...656
        Input And Output Signals...657
      Monitor Control, Display Portion...659
        Precautions on the Machine Monitor Display...660
        Monitor Items and Display...661
      Switches...665
        Buzzer Cancel Switch...665
        Auto-deceleration Switch...665
        Guidance Icon And Function Switch...665
        Working Mode Selector Switch...667
        Travel Speed Selector Switch...667
        Window Washer Switch...668
        Wiper Switch...668
        Air Conditioner Control Switch...668
        Camera Screen Display Function...669
        Service Meter/Time Selector Function...670
        Maintenance Function...670
        User Mode...672
        Breaker/Attachment Setting...672
        Changing Breaker Mode Setting...673
        Changing Attachment Mode Setting...675
        Message Display...676
        Screen Adjustment...677
        Clock Adjustment...677
        Language Setting...678
        Economy Mode Adjustment...678
        Idle Stop Guidance Function...679
        Service Meter Check Function...679
        Display LCD Check Function...679
        User Code/Failure Code Display Function...680
    SENSOR...681
      Fuel Level Sensor...681
      Air Cleaner Clogging Sensor...682
      Coolant Level Sensor...682
    KOMTRAX TERMINAL SYSTEM...683
      KOMTRAX Communication ORBCOMM...684
        TH300...684
        Input And Output Signals...684
  20 STANDARD VALUE TABLES...685
    STANDARD SERVICE VALUE TABLE...687
      Standard Service Value Table for Engine...687
      Standard Value Table for Chassis Related Parts...688
      Machine Position for Measurement...695
        Control Valve: Spool Stroke...695
        Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing...695
        Swing 2: Hydraulic Drift Of Swing...695
        Travel 1: Travel Speed (Without Load)...695
        Travel 2: Travel Speed (Actual Run), Travel Deviation...696
        Travel 3: Travel Deviation...696
        Travel 4: Hydraulic Drift Of Travel...696
        Work Equipment 1: Hydraulic Drift Of Work Equipment...696
        Work Equipment 2: Boom Speed...697
        Work Equipment 3: Arm Speed...697
        Work Equipment 4: Bucket Speed...697
        Work Equipment 5: Boom Time Lag...697
        Work Equipment 6: Arm Time Lag...698
        Work Equipment 7: Bucket Time Lag...698
        Work Equipment 8: Characteristics Of PC Flow Control Valve...698
  30 TESTING AND ADJUSTING...699
    SPECIAL TOOL LIST...702
      Sketch Of Special Tool...705
    ENGINE COMPONENTS...706
      Determining A Defective Cylinder...706
        Procedures...706
        Determining Cylinder Group...706
        Isolating the Defective Cylinder...706
      Water Pump Leakage...707
      Engine Speed...712
      Intake Air Pressure (Boost Pressure)...714
      Exhaust Gas Color...715
      Valve Clearance...717
      Compression Pressure...719
      Blow-by Pressure...721
      Engine Oil Pressure...722
      Handling Fuel System Parts...723
        Releasing Residual Pressure From Fuel System...723
      Fuel Pressure...724
      Fuel Return Rate And Leakage...727
      Bleeding Air From Fuel Circuit...732
      Fuel Circuit - Checking For Leakage...733
    AIR CONDITIONER COMPRESSOR BELT TENSION...734
      Checking...734
      Adjusting...734
    FAN BELT...735
    SWING CIRCLE BEARING CLEARANCE...736
    TRACK SHOE TENSION...738
      Checking...738
      Adjusting...738
    OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...740
      Measuring...740
      Adjusting...743
    CONTROL CIRCUIT BASIC PRESSURE...745
    OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...747
      Measuring...747
      Adjusting...749
        Pump PC Valve...749
    OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...750
      Measuring...750
      Adjusting...754
        LS valve...754
    SOLENOID VALVE OUTPUT PRESSURE...755
    PPC VALVE OUTPUT PRESSURE...758
      Connecting Points Of PPC Piping...758
      Adjusting Play of Work Equipment and Swing PPC Valves...760
    WORK EQUIPMENT HYDRAULIC DRIFT...761
    RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...763
    OIL LEAKAGE...764
    BLEEDING AIR FROM EACH PART...767
    CAB TIPPING STOPPER...769
    MIRRORS...770
    REAR VIEW CAMERA...773
      Angle Adjustment...773
    MACHINE MONITOR SPECIAL FUNCTIONS...775
      Air Conditioner Specification...775
      Upper Section of Machine Monitor...776
        Display Section...776
        Switch Section...776
      Lower Section Of Machine Monitor...776
        Switch Section...776
      Ordinary Functions and Special Functions of Machine Monitor...777
      Operator Mode (Outline)...779
        Display of KOMATSU Logo...780
        Display of Inputting Password...780
        Display of Check of Breaker Mode...780
        Display of Check Before Starting...781
        Display of Warning After Check Before Starting...781
        Display of Ending of Maintenance Interval...781
        Display of Check of Working Mode and Travel Speed...781
        Display of Ordinary Screen...782
        Display of End Screen...782
        Selection of Auto-Deceleration...782
        Selection of Working Mode...782
        Selection of Travel Speed...784
        Operation to Stop Alarm Buzzer...784
        Operation of Windshield Wiper...784
        Operation of Window Washer...784
        Operation of Air Conditioner/heater...784
        Operation to Display Camera Mode (If Camera is Installed)...785
        Operation to Display Clock and Service Meter...786
        Check of Maintenance Information...786
        Setting and Display of User Mode (Including KOMTRAX Messages for User)...787
        KOMTRAX Message...788
        Display of Energy-Saving Guidance...788
        Display of Caution Monitor...788
        Display of Automatic Judgment of Breaker...788
        Display of User Code and Failure Code...789
        Function of Checking Display of LCD (Liquid Crystal Display)...790
        Function of Checking Service Meter...790
        Function of Changing Attachment/Maintenance Password...790
      Service Mode...792
        Monitoring...793
        Monitoring Items Table...796
        Abnormality Record (Mechanical Systems)...799
        Abnormality Record (Electrical Systems)...800
        Failure Codes Table...802
        Abnormality Record (Air-Conditioning System/ Heater System)...806
        Maintenance Record...807
        Maintenance Mode Change...808
        Phone Number Entry...810
        Default (Key-on Mode)...811
        Default (Unit)...812
        Default (With/Without Attachment)...813
        Default (Attachment/Maintenance Password)...814
        Default (Camera)...815
        Default (ECO Display)...816
        Default (Breaker Detect)...818
        Adjustment (Pump Absorption Torque (F))...819
        Adjustment (Pump Absorption Torque (R))...820
        Adjustment (Low Speed)...821
        Adjustment (Attachment Flow Adjustment)...822
        Cylinder Cut-Out...823
        No Injection...824
        Fuel Consumption...826
        KOMTRAX Settings (Terminal Status)...827
        KOMTRAX Settings (GPS & Communication Status)...828
        KOMTRAX Setting (MODEM S/N: TH300)...829
        Display of KOMTRAX message...830
      Long Distance Transport Mode...831
    HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...833
    PREPARING FOR ELECTRICAL SYSTEM TROUBLESHOOTING...833
    PROCEDURE FOR TESTING DIODES...838
    PM CLINIC SERVICE...840
  40 TROUBLESHOOTING...849
    GENERAL INFORMATION...853
      Points To Remember...853
      Sequence Of Events In Troubleshooting...855
      Handling Electric Equipment and Hydraulic Components...856
      New Connectors for Tier 3 Engines...864
      Check Before Troubleshooting...868
      Classification And Troubleshooting Steps...869
        Troubleshooting Classification...869
        Troubleshooting steps...869
        Information In Troubleshooting Table...870
        Related Circuit Diagram...871
      Possible Problems and Troubleshooting No...872
      How To Read Electric Wire Code...875
      Connection Table For Connector Pin Numbers...878
      T-boxes and T-adapters Table...911
    FAILURE CODE (DISPLAY OF CODE)...914
      Failure Codes Table...914
      Before Troubleshooting With Failure Code Displayed...919
        Fuse Box Connection Table...919
        Locations Of Fusible Links...920
        Location Of Fuse Box And Fuse Nos...920
        Trouble That Occurs When Power Supply Of Pump Controller Is Defective...921
      989L00 Engine Controller Lock Caution 1...923
      989M00 Engine Controller Lock Caution 2...923
      989N00 Engine Controller Lock Caution 3...924
      AA10NX Air Cleaner Clogging...924
      AB00KE Charge Voltage Low...926
      B@BAZG Eng Oil Press. Low...928
      B@BAZK Eng Oil Level Low...928
      B@BCNS Eng Water Overheat...929
      B@BCZK Eng Water Level Low...929
      B@HANS Hydr Oil Overheat...930
      CA111 EMC Critical Internal Failure...930
      CA115 Eng Ne and Bkup Speed Sens Error...931
      CA122 Chg Air Press Sensor High Error...932
      CA123 Chg Air Press Sensor Low Error...934
      CA131 Throttle Sensor High Error...936
      CA132 Throttle Sensor Low Error...938
      CA144 Coolant Temp Sens High Error...940
      CA145 Coolant Temp Sens Low Error...942
      CA153 Chg Air Temp Sensor High Error...944
      CA154 Chg Air Temp Sensor Low Error...946
      CA155 Chg Air Temp High Speed Derate...948
      CA187 Sens Supply 2 Volt Low Error...950
      CA221 Ambient Press Sens High Error...952
      CA222 Ambient Press Sens Low Error...954
      CA227 Sens Supply 2 Volt High Error...956
      CA234 Eng Overspeed...957
      CA238 Ne Speed Sens Supply Volt Error...958
      CA271 IMV/PCV1 Short Error...959
      CA272 IMV/PCV1 Open Error...960
      CA322 Inj #1 Open/Short Error...962
      CA323 Inj #5 Open/Short Error...964
      CA324 Inj #3 Open/Short Error...966
      CA325 Inj #6 Open/Short Error...968
      CA331 Inj #2 Open/Short Error...970
      CA332 Inj #4 Open/Short Error...972
      CA342 Calibration Code Incompatibility...974
      CA351 Injectors Drive Circuit Error...976
      CA352 Sens Supply 1 Volt Low Error...978
      CA386 Sens Supply 1 Volt High Error...980
      CA428 Water in Fuel Sensor High Error...982
      CA429 Water in Fuel Sensor Low Error...984
      CA435 Eng Oil Press Sw Error...986
      CA441 Battery Voltage Low Error...987
      CA442 Battery Voltage High Error...990
      CA449 Rail Press Very High Error...992
      CA451 Rail Press Sensor High Error...994
      CA452 Rail Press Sensor Low Error...996
      CA488 Chg Air Temp High Torque Derate...998
      CA553 Rail Press High Error...999
      CA559 Rail Press Low Error...1000
      CA689 Eng Ne Speed Sensor Error...1002
      CA731 Eng Bkup Speed Sens Phase Error...1004
      CA757 All Continuous Data Lost Error...1006
      CA778 Eng Bkup Speed Sensor Error...1008
      CA2185 Throt Sens Sup Volt High Error...1011
      CA2186 Throt Sens Sup Volt Low Error...1012
      CA2249 Rail Press Very Low Error...1013
      CA2311 IMV Solenoid Error...1014
      CA2555 Grid Htr Relay Volt High Error...1016
      CA2556 Grid Htr Relay Volt Low Error...1018
      D19JKZ Personal Code Relay Abnormality...1020
      D862KA GPS Antenna Discon...1022
      DA22KK Pump Solenoid Power Low Error...1024
      DA25KP 5V Sensor 1 Power Abnormality...1026
      DA29KQ Model Selection Abnormality...1032
      DA2RMC CAN Discon (Pump Con Detected)...1034
      DAF8KB Short Circuit In Camera Power Supply...1042
      DAFGMC GPS Module Error...1044
      DAFRMC CAN Discon (Monitor Detected)...1045
      DGH2KB Hyd Oil Sensor Short...1052
      DHPAMA F Pump Press Sensor Abnormality...1054
      DHPBMA R Pump Press Sensor Abnormality...1056
      DHS3MA Arm Curl PPC Press Sensor Abnormality...1058
      DHS4MA Bucket Curl PPC Press Sensor Abnormality...1060
      DHS8MA Boom Raise PPC Press Sensor Abnormality...1062
      DHSAMA Swing RH PPC Press Sensor Abnormality...1064
      DHSBMA Swing LH PPC Press Sensor Abnormality...1066
      DHSDMA Bucket Dump PPC Press Sensor Abnormality...1068
      DHX1MA Overload Sensor Abnormality (Analog)...1070
      DW43KA Travel Speed Sol Discon...1074
      DW43KB Travel Speed Sol Short...1076
      DW45KA Swing Brake Sol Discon...1078
      DW45KB Swing Brake Sol Short...1080
      DW91KA Travel Junction Sol Discon...1082
      DW91KB Travel Junction Sol Short...1084
      DWA2KA Service Sol Discon...1086
      DWA2KB Service Sol Short...1087
      DWK0KA 2-Stage Relief Sol Discon...1088
      DWK0KB 2-Stage Relief Sol Short...1090
      DXA8KA PC-EPC (F) Sol Discon...1092
      DXA8KB PC-EPC (F) Sol Short...1094
      DXA9KA PC-EPC (R) Sol Discon...1096
      DXA9KB PC-EPC (R) Sol Short...1098
      DXE0KA LS-EPC Sol Discon...1100
      DXE0KB LS-EPC Sol Short...1102
      DXE4KA Service Current EPC Discon...1104
      DXE4KB Service Current EPC Short...1106
      DXE5KA Merge-divider Main Sol Discon...1108
      DXE5KB Merge-divider Main Sol Short...1110
      DXE6KA Merge-divider LS Sol Discon...1112
      DXE6KB Merge-divider LS Sol Short...1114
      DY20KA Wiper Working Abnormality...1116
      DY20MA Wiper Parking Abnormality...1118
      DY2CKA Washer Drive Discon...1120
      DY2CKB Washer Drive Short...1122
      DY2DKB Wiper Drive (For) Short...1124
      DY2EKB Wiper Drive (Rev) Short...1126
    ELECTRICAL SYSTEM (E-MODE)...1128
      Troubleshooting Table...1128
      E-1 No Machine Monitor Display When Starting Switch Is Turned On...1130
      E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)...1132
      E-3 Engine Does Not Start...1135
      E-4 Preheater Does Not Operate...1140
      E-5 Automatic Warm-up System Does Not Operate (In Cold Season)...1144
      E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked...1146
      E-7 Precaution Lights Up While Engine Is Running...1148
      E-8 Emergency Stop Item Lights Up While Engine Is Running...1153
      E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally...1154
      E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally...1155
      E-11 Fuel Level Gauge Does Not Indicate Normally...1158
      E-12 Machine Monitor Content Displays Are Different From Applicable Machine...1160
      E-13 Machine Monitor Does Not Display Some Items...1160
      E-14 Function Switch Does Not Work...1160
      E-15 Auto-decelerator Does Not Operate Normally...1161
      E-16 Working Mode Does Not Change...1162
      E-17 Travel Speed Does Not Change...1163
      E-18 Alarm Buzzer Cannot be Stopped...1164
      E-19 Windshield Wiper and Window Washer Do Not Operate...1166
      E-20 Power Maximizing Function Does Not Operate Normally...1168
      E-21 Swing Holding Brake Does Not Operate Normally...1170
      E-22 Travel Alarm Does Not Sound or Does Not Stop...1172
      E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)...1174
      E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position...1196
      E-25 Machine Monitor Cannot Be Set In Service Mode...1196
      E-26 Monitoring Function Does Not Display Lever Control Signal Normally...1197
      E-27 Komtrax System Does Not Operate Normally...1206
    HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1208
      System Diagram of Hydraulic and Mechanical System...1208
      Information In Troubleshooting Table...1210
      H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow...1211
      H-2 Engine Speed Drops Sharply or Engine Stalls...1213
      H-3 Work Equipment, Swing, and Travel Systems Do Not Work...1214
      H-4 Abnormal Noise Is Heard Around Hydraulic Pump...1214
      H-5 Auto-decelerator Does Not Work...1215
      H-6 Fine Control Mode Does Not Function or Responds Slow...1215
      H-7 Boom Moves Slowly or Lacks Power...1216
      H-8 Arm Moves Slowly or Lacks Power...1217
      H-9 Bucket Moves Slowly or Lacks Power...1218
      H-10 Work Equipment Does Not Move In Its Single Operation...1218
      H-11 Work Equipment Hydraulic Drift Is Too Fast...1219
      H-12 Work Equipment Has Big Time Lag...1221
      H-13 Other Work Equipment Moves When Relieving Single Circuit...1221
      H-14 Power Maximizing Function Does Not Work...1222
      H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly...1222
      H-16 In Swing and Boom Raise Operation, Boom Moves Slowly...1223
      H-17 In Swing and Travel Operation, Travel Speed Drops Sharply...1223
      H-18 Machine Swerves In Travel...1224
      H-19 Machine Travels Slowly...1225
      H-20 Machine Steers With Difficulty or Lacks Power...1226
      H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast...1227
      H-22 Track Shoe Does Not Turn (On One Side Only)...1228
      H-23 Machine Does Not Swing...1229
      H-24 Swing Acceleration Is Poor or Swing Speed Is Slow...1231
      H-25 Excessive Overrun When Stopping Swing...1233
      H-26 There Is a Big Jolt When Stopping Swing...1234
      H-27 Large Sound Is Made When Upper Structure Stops Swinging...1234
      H-28 Swing Hydraulic Drift Is Too Big...1235
      H-29 Attachment Circuit Is Not Changed...1236
      H-30 Oil Flow In Attachment Circuit Cannot Be Controlled...1236
  50 DISASSEMBLY AND ASSEMBLY...1237
    HOW TO READ THIS SECTION...1241
      Removal And Installation Of Assemblies...1241
        Special Tools...1241
        Removal...1241
        Installation...1241
      Disassembly And Assembly Of Assemblies...1242
        Special Tools...1242
        Disassembly...1242
        Assembly...1243
    SPECIAL TOOLS LIST...1244
    SKETCHES OF SPECIAL TOOLS...1249
    CONNECTOR REPAIR PROCEDURES...1254
      Stripping Insulation...1254
      Wire Inspection...1254
      Contact Terminal Removal (HD30 Type)...1255
      Crimping Contact Terminal (HD30 Type)...1256
      Insertion Of Contact Terminal (HD30 Type)...1257
      Contact Terminal Removal (DT Type)...1258
      Crimping Contact Terminal (DT Type)...1259
      Insertion Of Contact Terminal (DT Type)...1260
    ENGINE AND COOLING SYSTEM...1261
      Fuel Supply Pump Assembly...1261
        Special Tools...1261
        Removal...1261
        Installation...1265
      Fuel Injector Assembly...1267
        Special Tools...1267
        Removal...1267
        Installation...1272
      Engine Front Seal...1277
        Special Tools...1277
        Removal...1277
        Installation...1279
      Engine Rear Seal...1281
        Special Tools...1281
        Removal...1281
        Installation...1282
      Cylinder Head...1285
        Special Tools...1285
        Removal...1285
        Installation...1293
      Radiator...1303
        Removal...1303
        Installation...1305
      Hydraulic Oil Cooler...1307
        Removal...1307
        Installation...1309
      Aftercooler Assembly...1310
        Removal...1310
        Installation...1312
      Fuel Cooler...1313
        Removal...1313
        Installation...1313
      Engine And Hydraulic Pump...1314
        Special Tools...1314
        Removal...1314
        Installation...1323
    POWER TRAIN...1326
      Final Drive...1326
        Removal...1326
      PC200LC-8 Final Drive...1328
        Special Tools...1328
        Disassembly...1328
        Assembly...1331
      Swing Motor and Swing Machinery...1338
        Removal...1338
        Installation...1340
      Swing Motor and Swing Machinery...1341
        Special Tools...1341
        Disassembly...1341
        Assembly...1346
      Swing Circle Assembly...1352
        Removal...1352
        Installation...1352
    UNDERCARRIAGE AND FRAME...1353
      Carrier Roller...1353
        Special Tools...1353
        Disassembly...1353
        Assembly...1354
      Track Roller...1357
        Special Tools...1357
        Disassembly...1357
        Assembly...1357
      Idler, Recoil Spring...1359
        Removal...1359
        Installation...1359
      Idler...1360
        Special Tools...1360
        Disassembly...1360
        Assembly...1361
      Recoil Spring...1364
        Special Tools...1364
        Disassembly...1364
        Assembly...1365
      Sprocket...1367
        Removal...1367
        Installation...1367
      Track Shoe...1368
        Special Tools...1368
        Expanding Track Shoe...1368
        Installation of Track Shoe...1370
      Revolving Frame...1371
        Removal...1371
        Installation...1373
      Counterweight...1374
        Special Tools...1374
        Removal...1374
        Installation...1376
    HYDRAULIC SYSTEM...1377
      Center Swivel Joint...1377
        Removal...1377
        Installation...1378
        Special Tools...1379
        Disassembly...1379
        Assembly...1380
      Hydraulic Tank...1381
        Removal...1381
        Installation...1384
      Control Valve...1385
        Removal...1385
        Installation...1390
        Special Tools...1391
        Precautions for Replacing Pressure Compensation Valve Seal...1392
        Precautions for Assembling Control Valve...1394
      Hydraulic Pump...1397
        Special Tools...1397
        Removal...1397
        Installation...1401
      Oil Seal In Hydraulic Pump Input Shaft...1402
        Special Tools...1402
        Removal...1402
        Installation...1402
      Work Equipment PPC Valve...1403
        Disassembly...1403
        Assembly...1403
      Travel PPC Valve...1405
        Special Tools...1405
        Disassembly...1405
        Assembly...1406
      Hydraulic Cylinder...1408
        Special Tools...1408
        Disassembly...1409
        Assembly...1411
    WORK EQUIPMENT...1415
      Work Equipment Assembly...1415
        Special Tools...1415
        Removal...1415
        Installation...1417
    CAB AND ITS ATTACHMENTS...1418
      Operator's Cab...1418
        Removal...1418
        Installation...1421
      Operator Cab Glass (Fixed Glass)...1422
        Special Tools...1423
        Removal...1423
        Installation...1424
      Front Window...1433
        Removal...1433
        Installation...1436
      Floor Frame Assembly...1441
        Special Tools...1441
        Removal...1441
        Installation...1445
    ELECTRICAL SYSTEM...1446
      Air Conditioner Unit Assembly...1446
        Special Tools...1446
        Removal...1446
        Installation...1450
      KOMTRAX Communication Modem...1451
        Removal...1451
        Installation...1451
      Monitor...1452
        Removal...1452
        Installation...1453
      Pump Controller...1454
        Removal...1454
        Installation...1455
      Engine Controller...1457
        Removal...1457
        Installation...1458
  90 DIAGRAMS AND SCHEMATICS...1459
    HYDRAULIC SYSTEM...1461
      Hydraulic Circuit Diagram...1461
    ELECTRICAL SYSTEM...1462
      Electrical Circuit Diagram...1462
      Connector Arrangement Diagram...1463
      Electrical Circuit Diagram for Air Conditioner...1464
SEAM016301 - Hydraulic Excavator PC200-6 Operation & Maintenance Manual...1465
  1. FOREWORD...1466
  2. SAFETY INFORMATION...1467
  3. INTRODUCTION...1468
  4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1469
  5. CONTENTS...1470
  SAFETY ...1474
    6. GENERAL PRECAUTIONS ...1475
    7. PRECAUTIONS DURING OPERATION ...1482
      7.1 BEFORE STARTING ENGINE ...1482
      7.2 AFTER STARTING ENGINE ...1484
      7.3 TRANSPORTATION ...1491
      7.4 BATTERY...1492
      7.5 TOWING ...1494
      7.6 LIFTING OPERATIONS ...1494
    8. PRECAUTIONS FOR MAINTENANCE ...1495
      8.1 BEFORE CARRYING OUT MAINTENANCE ...1495
      8.2 DURING MAINTENANCE...1499
    9. POSITION FOR ATTACHING SAFETY LABELS ...1504
  OPERATION ...1508
    10. GENERAL VIEW ...1509
      10.1 GENERAL VIEW OF MACHINE ...1509
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES...1510
    11. EXPLANATION OF COMPONENTS ...1511
      11.1 MACHINE MONITOR ...1511
      11.2 SWITCHES ...1516
      11.3 CONTROL LEVERS AND PEDALS ...1520
      11.4 CEILING WINDOW ...1525
      11.5 FRONT WINDOW...1526
      11.6 DOOR LOCK ...1528
      11.7 ASHTRAY ...1528
      11.8 CAP, COVER WITH LOCK ...1529
      11.9 COOLER ...1530
      11.10 CASSETTE/RADIO ...1532
      11.11 FUSE...1538
      11.12 FUSIBLE LINK ...1539
      11.13 TOOL BOX ...1539
      11.14 GREASE PUMP HOLDER ...1539
      11.15 HANDLING ACCUMULATOR...1540
    12. OPERATION ...1541
      12.1 CHECK BEFORE STARTING ENGINE ...1541
      12.2 STARTING ENGINE...1550
      12.3 OPERATIONS AND CHECKS AFTER  STARTING ENGINE ...1552
      12.4 MOVING MACHINE OFF...1554
      12.5 STEERING MACHINE ...1557
      12.6 STOPPING MACHINE...1559
      12.7 SWINGING...1560
      12.8 OPERATION OF WORK EQUIPMENT ...1561
      12.9 PROHIBITIONS FOR OPERATION ...1562
      12.10 PRECAUTIONS FOR OPERATION...1564
      12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...1565
      12.12 HOW TO ESCAPE FROM MUD ...1567
      12.13 WORK POSSIBLE USING HYDRAULIC  EXCAVATOR...1568
      12.14 REPLACEMENT AND INVERSION  OF BUCKET ...1569
      12.15 PARKING MACHINE ...1571
      12.16 CHECK AFTER FINISHING WORK ...1572
      12.17 STOPPING ENGINE ...1573
      12.18 CHECK AFTER STOPPING ENGINE ...1574
      12.19 LOCKING ...1574
    13. TRANSPORTATION ...1575
      13.1 LOADING, UNLOADING WORK...1575
      13.2 PRECAUTIONS FOR LOADING ...1577
      13.3 PRECAUTIONS FOR TRANSPORTATION ...1578
    14. COLD WEATHER OPERATION ...1579
      14.1 PRECAUTIONS FOR LOW TEMPERATURE ...1579
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK...1581
      14.3 AFTER COLD WEATHER ...1581
    15. LONG-TERM STORAGE ...1582
      15.1 BEFORE STORAGE ...1582
      15.2 DURING STORAGE ...1583
      15.3 AFTER STORAGE ...1583
      15.4 STARTING MACHINE AFTER LONG-TERM  STORAGE ...1583
    16. TROUBLESHOOTING ...1584
      16.1 PHENOMENA THAT ARE NOT FAILURES ...1584
      16.2 METHOD OF TOWING MACHINE ...1584
      16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE ...1584
      16.4 PRECAUTIONS ON PARTICULAR JOBSITES ...1585
      16.5 IF BATTERY IS DISCHARGED ...1585
      16.6 OTHER TROUBLE...1589
  MAINTENANCE ...1593
    17. GUIDES TO MAINTENANCE ...1594
    18. OUTLINES OF SERVICE ...1597
      18.1 OUTLINE OF OIL, FUEL, COOLANT ...1597
      18.2 OUTLINE OF ELECTRIC SYSTEM ...1600
      18.3 OUTLINE OF HYDRAULIC SYSTEM ...1601
    19. WEAR PARTS LIST ...1602
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING  TO  AMBIENT  TEMPERATURE ...1604
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1608
      21.1 INTRODUCTION OF NECESSARY TOOLS ...1608
      21.2 TORQUE LIST ...1609
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1610
    23. MAINTENANCE SCHEDULE CHART ...1614
      23.1 MAINTENANCE SCHEDULE CHART ...1614
      23.2 MAINTENANCE INTERVAL WHEN USING  HYDRAULIC BREAKER ...1616
    24. SERVICE PROCEDURE ...1617
      24.1 INITIAL 250 HOURS SERVICE ...1617
      24.2 WHEN REQUIRED ...1618
      24.3 CHECK BEFORE STARTING ...1636
      24.4 EVERY 100 HOURS SERVICE ...1641
      24.5 EVERY 250 HOURS SERVICE ...1644
      24.6 EVERY 500 HOURS SERVICE ...1650
      24.7 EVERY 1000 HOURS SERVICE ...1655
      24.8 EVERY 2000 HOURS SERVICE ...1658
      24.9 EVERY 4000 HOURS SERVICE ...1661
      24.10 EVERY 5000 HOURS SERVICE ...1662
  SPECIFICATIONS ...1667
    25. SPECIFICATIONS ...1668
  OPTIONS, ATTACHMENTS ...1671
    26. GENERAL PRECAUTIONS ...1672
      26.1 PRECAUTIONS RELATED TO SAFETY ...1672
      26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ...1673
    27. HANDLING BUCKET WITH HOOK ...1674
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH ...1674
      27.2 PROHIBITED OPERATIONS ...1674
      27.3 PRECAUTIONS DURING OPERATIONS ...1674
    28. USING SEAT BELT ...1675
      28.1 SEAT BELT ...1675
    29. MACHINES READY FOR ATTACHMENTS ...1677
      29.1 EXPLANATION OF COMPONENTS...1677
      29.2 HYDRAULIC CIRCUIT ...1679
      29.3 ATTACHMENT MOUNTING/DISMOUNTING  PROCEDURE ...1681
      29.4 OPERATION ...1683
      29.5 LONG-TERM STORAGE ...1684
      29.6 SPECIFICATIONS ...1684
    30. INTRODUCTION OF ATTACHMENTS ...1685
      30.1 SPECIFICATION, USE ...1685
      30.2 ATTACHMENT INSTALLATION COMBINATION TABLE ...1686
      30.3 SELECTION OF TRACK SHOES ...1687
      30.4 SELECTION OF BUCKET TEETH ...1688
      30.5 HANDLING RUBBER PAD SHOE ...1689
      30.6 HANDLING TRAPEZOIDAL BUCKET ...1691
      30.7 HANDLING EXTENSION ARM...1692
      30.8 HANDLING CLAMSHELL BUCKET ...1693
    31. EXTENDING MACHINE SERVICE LIFE ...1694
      31.1 HYDRAULIC BREAKER ...1694
      31.2 POWER RIPPER ...1697
      31.3 FORK GRAB ...1698
      31.4 GRAPPLE BUCKET ...1699
      31.5 SCRAP GRAPPLE ...1700
      31.6 CRUSHER & CUTTER ...1701
      31.7 HYDRAULIC PILE DRIVER ...1702
      31.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE ...1703
SEAM021701 - Hydraulic Excavator PC200-6 avance Series Operation & Maintenance Manual...1705
  COVER...1705
  1. FOREWORD...1708
  2. SAFETY INFORMATION...1709
  3. INTRODUCTION...1710
  4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. DISTRIBUTOR...1711
  5. CONTENTS...1712
  SAFETY...1716
    6. GENERAL PRECAUTIONS...1717
    7. PRECAUTIONS DURING OPERATION...1725
      7.1 BEFORE STARTING ENGINE...1725
      7.2 AFTER STARTING ENGINE...1727
      7.3 SHIPPING...1734
      7.4 BATTERY...1735
      7.5 TOWING...1737
      7.6 LIFTING OPERATIONS...1737
      7.7 BUCKET WITH HOOK...1738
    8. PRECAUTIONS FOR MAINTENANCE...1740
      8.1 BEFORE CARRYING OUT MAINTENANCE...1740
      8.2 DURING MAINTENANCE...1744
    9. POSITION FOR ATTACHING SAFETY LABELS...1750
  OPERATION...1754
    10. GENERAL VIEW...1755
      10.1 GENERAL VIEW OF MACHINE...1755
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES...1756
    11. EXPLANATION OF COMPONENTS...1757
      11.1 MACHINE MONITOR...1757
      11.2 SWITCHES...1762
      11.3 CONTROL LEVERS AND PEDALS...1766
      11.4 CEILING WINDOW...1771
      11.5 FRONT WINDOW...1772
      11.6 DOOR LOCK...1774
      11.7 ASHTRAY...1774
      11.8 CAP, COVER WITH LOCK...1775
      11.9 HANDLING CAR HEATER...1776
      11.10 FUSE...1777
      11.11 FUSIBLE LINK...1778
      11.12 TOOL BOX...1778
      11.13 GREASE PUMP HOLDER...1778
      11.14 HANDLING ACCUMULATOR...1779
    12. OPERATION...1780
      12.1 CHECK BEFORE STARTING ENGINE...1780
      12.2 STARTING ENGINE...1790
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...1792
      12.4 MOVING MACHNE OFF...1794
      12.5 STEERING MACHINE ...1797
      12.6 STOPPING MACHINE...1799
      12.7 SWINGING...1800
      12.8 OPERATION OF WORK EQUIPMENT...1801
      12.9 PROHIBITIONS FOR OPERATION...1802
      12.10 PRECAUTIONS FOR OPERATION...1804
      12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...1805
      12.12 HOW TO ESCAPE FROM MUD...1807
      12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...1808
      12.14 REPLACEMENT AND INVERSION OF BUCKET...1809
      12.15 PARKING MACHINE...1811
      12.16 CHECK AFTER FINISHING WORK...1812
      12.17 STOPPING ENGINE...1813
      12.18 CHECK AFTER STOPPING ENGINE...1814
      12.19 LOCKING...1814
    13. TRANSPORTATION...1815
      13.1 LOADING, UNLOADING WORK...1815
      13.2 PRECAUTIONS...1817
      13.3 PRECAUTIONS FOR TRANSPORATION...1818
    14. COLD WEATHER OPERATION...1819
      14.1 PRECAUTIONS FOR LOW TEMPERATURE...1819
      14.2 PRECAUTIONS FOR LOADING...1821
      14.3 AFTER COLD WEATHER...1821
    15. LONG-TERM STORAGE...1822
      15.1 BEFORE STORAGE...1822
      15.2 DURING STORAGE...1823
      15.3 AFTER STORAGE...1823
      15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...1823
    16. TROUBLESHOOTING...1824
      16.1 PHENOMENA THAT ARE NOT FAILURES...1824
      16.2 METHOD OF TOWING MACHINE...1824
      16.3 USING METHOD FOR LIGHT-WEIGHT TOWING MACHINE...1824
      16.4 PRECAUTIONS ON PARTICULAR JOBSITES...1825
      16.5 IF BATTERY IS DISCHARGED...1825
      16.6 OTHER TROUBLE...1829
  MAINTENANCE...1834
    17. GUIDES TO MAINTENANCE...1835
    18. OUTLINES OF SERVICE...1838
      18.1 OUTLINE OF OIL, FUEL, COOLANT...1838
      18.2 OUTLINE OF ELECTRIC SYSTEM...1841
      18.3 OUTLINE OF HYDRAULIC SYSTEM...1713
    19. WEAR PARTS LIST...1843
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...1844
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1849
      21.1 INTRODUCTION OF NECESSARY TOOLS...1849
      21.2 TORQUE LIST...1850
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1851
    23. MAINTENANCE SCHEDULE CHART...1855
      23.1 MAINTENANCE SCHEDULE CHART...1855
      23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...1857
    24. SERVICE PROCEDURE...1858
      24.1 INITIAL 250 HOURS SERVICE...1858
      24.2 WHEN EQUIRED...1859
      24.3 CHECK BEFORE STARTING...1878
      24.4 EVERY 100 HOURS SERVICE...1883
      24.5 EVERY 250 HOURS SERVICE...1886
      24.6 EVERY 500 HOURS SERVICE...1892
      24.7 EVERY 1000 HOURS SERVICE...1897
      24.8 EVERY 2000 HOURS SERVICE...1900
      24.9 EVERY 4000 HOURS SERVICE...1903
      24.10 EVERY 5000 HOURS SERVICE...1904
  SPECIFICATIONS...1910
    25. SPECIFICATIONS...1911
  OPTIONS AND ATTACHMENTS...1916
    26. GENERAL PRECAUTIONS...1917
      26.1 PRECAUTIONS RELATED TO SAFETY...1917
      26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...1918
    27. HANDLING BUCKET WITH HOOK...1919
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...1919
      27.2 PROHIBITED OPERATIONS...1919
      27.3 PRECAUTIONS DURING OPERATIONS...1919
    28. AIR CONDITIONER (MACHINES EQUIPPED WITH AIR CONDITIONER)...1920
      28.1 AIR CONDITIONER...1920
    29. MACHINES READY FOR ATTACHMENTS...1923
      29.1 EXPLANATION OF COMPONENTS...1923
      29.2 HYDRAULIC CIRCUIT...1925
      29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...1927
      29.4 OPERATION...1929
      29.5 LONG-TERM STORAGE...1930
      29.6 SPECIFICATIONS...1930
    30. INTRODUCTION OF ATTACHMENTS...1931
      30.1 BUCKET SELECTION...1931
      30.2 BUCKET INSTALLATION COMINATIONS...1931
      30.3 BACKHOE CONTROL PATTERN CONVERSION...1933
      30.4 SELECTION OF TRACK SHOES...1934
      30.5 HANDLING RUBBER PAD SHOE...1935
      30.6 HANDLING TRAPEZODIAL BUCKET...1937
      30.7 HANDLING EXTENSION ARM...1938
      30.8 HANDLING CLAMSHELL BUCKET...1939
    31. EXTENDING MACHINE SERVICE LIFE...1940
      31.1 HYDRAULIC BREAKER...1940
      31.2 POWER RIPPER...1943
      31.3 FORK GRAB...1944
      31.4 GRAPPLE BUCKET...1945
      31.5 SCRAP GRAPPLE...1946
      31.6 CRUSHER & CUTTER...1947
      31.7 HYDRAULIC PILE DRIVER...1948
      31.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE...1949
SEAM023800PT - Hydraulic Excavator PC200-6, PC200LC-6 Operation & Maintenance Manual...1953
  COVER...1954
  CONTENTS...1961
  1. FOREWORD...1957
  2. SAFETY INFORMATION...1958
  3. INTRODUCTION...1959
  4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1960
  SAFETY...1965
    6. GENERAL PRECAUTIONS...1966
    7. PRECAUTIONS DURING OPERATION...1973
      7.1 BEFORE STARTING ENGINE...1973
      7.2 AFTER STARTING ENGINE...1975
      7-3 TRANSPORTATION...1982
      7-4 BATTERY...1983
      7.5 TOWING...1985
      7.6 LIFTING OPERATIONS...1985
    8. PRECAUTIONS FOR MAINTENANCE...1986
      8.1 BEFORE CARRYING OUT MAINTENANCE...1986
      8.2 DURING MAINTENANCE...1990
    9. POSITION FOR ATTACHING SAFETY LABELS...1996
  OPERATION...2003
    10. GENERAL VIEW...2004
      10.1 GENERAL VIEW OF MACHINE...2004
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES...2005
    11. EXPLANATION OF COMPONENTS ...2006
      11.1 MACHINE MONITOR...2006
      11.2 SWITCHES...2017
      11.3 CONTROL LEVERS, PEDALS...2021
      11.4 CEILING WINDOW...2026
      11.5 FRONT WINDOW...2027
      11.6 DOOR LOCK...2029
      11.7 CAP, COVER WITH LOCK...2030
      11.8 HOT/COOL BOX...2031
      11.9 LUGGAGE BOX...2031
      11.10 ASHTRAY...2031
      11.11 AIR CONDITIONER...2032
      11.12 CAR RADIO...2035
      11.13 FUSE...2040
      11.14 FUSIBLE LINK...2041
      11.15 CONTROLLERS...2041
      11.16 TOOL BOX...2041
      11.17 GREASE PUMP HOLDER...2041
      11.18 HANDLING ACCUMULATOR...2042
    12. OPERATION...2044
      12.1 CHECK BEFORE STARTING ENGINE...2044
      12.2 STARTING ENGINE...2054
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...2057
      12.4 MOVING MACHINE OFF...2063
      12.5 STEERING MACHINE...2066
      12.6 STOPPING MACHINE...2068
      12.7 SWINGING...2069
      12.8 OPERATION OF WORK EQUIPMENT...2070
      12.9 HANDLING ACTIVE MODE...2071
      12.10 WORKING MODE SELECTION...2073
      12.11PROHIBITIONS FOR OPERATION...2075
      12.12 PRECAUTIONS FOR OPERATION...2077
      12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILL...2078
      12.14 HOW TO EXCAOR FRON...2080
      12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...2081
      12.16 REPLACEMENT AND INVERSION OF BUCKET...2082
      12.17 PARKING MACHINE...2084
      12.18 CHECK AFTER FINISHING WORK...2085
      12.19 STOPPING ENGINE...2086
      12.20 CHECK AFTER STOPPING ENGINE...2087
      12.21 LOCKING...2087
    13. TRANSPORTATION...2088
      13.1 LOADING, UNLOADING WORK...2088
      13.2 PRECAUTION...2090
      13.3 PRECAUTIONS FOR TRANSPORTATION...2091
    14. COLD WEATHER...2092
      14.1 PRECAUTIONS FOR LOADING...2092
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK...2094
      14.3 AFTER COLD WEATHER...2094
    15. LONG-TERM STORAGE...2095
      15.1 BEFORE STORAGE...2095
      15.2 DURING STORAGE...2096
      15.3 AFTER STORAGE...2096
      15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...2096
    16. TROUBLESHOOTING...2097
      16.1 PHENOMENA THAT ARE NOT FAILURES...2097
      16.2 METHOD OF TOWING MACHINE...2097
      16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...2097
      16.4 PRECAUTIONS ON PARTICULAR JOBSITES...2098
      16.5 IF BATTERY IS DISCHARGED...2098
      16.6 OTHER TROUBLE...2102
  MAINTENANCE...2107
    17. GUIDES TO MAINTENANCE...2108
    18. OUTLINES OF SERVICE...2111
      18.1 OUTLINE OF OIL, FUEL, COOLANT...2111
      18.2 OUTLINE OF ELECTRIC SYSTEM...2114
      18.3 OUTLINE OF HYDRAULIC SYSTEM...2115
    19. WEAR PARTS  LIST...2116
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2118
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...2122
      21.1 INTRODUCTION OF NECESSARY TOOLS...2122
      21.2 TORQUE LIST...2123
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2124
    23. MAINTENANCE SCHEDULE CHART...2128
      23.1 MAINTENANCE SCHEDULE CHART...2128
      23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...2130
    24. SERVICE PROCEDURE...2131
      24.1 INITIAL 250 HOURS SERVICE...2131
        REPLACE FUEL CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION)...2131
        CHECK ENGINE VALVE CLEARANCE, ADJUST...2131
      24.2 WHEN REQUIRED ...2132
        CHECK, CLEAN AND REPLACE AIR CLEANER  ELEMENT...2132
        CLEAN INSIDE OF COOLING SYSTEM...2134
        CHECK AND TIGHTEN TRACK SHOE BOLTS...2138
        CHECK AND TIGHTEN TRACK TENSION...2139
        CHECK ELECTRICAL INTAKE AIR HEATER...2141
        REPLACE BUCKET TEETH  (VERTICAL PIN TYPE)...2142
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...2145
        ADJUST BUCKET CLEARANCE...2146
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...2147
        CHECK AND ADJUST AIR CONDITIONER...2148
        REPLACE ADDITIONAL BREAKET FILTER ELEMENT...2149
      24.3 CHECK BEFORE STARTING...2150
        CHECK COOLANT LEVEL, ADD WATER...2150
        CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...2150
        CHECK FUEL LEVEL IN HYDRAULIC TANK, ADD OIL...2151
        CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...2152
        CHECK AIR CLEANER FOR CLOGGING...2153
        CHECK ELECTRIC WIRINGS...2153
        LUBRICATE CLAMSHELL BUCKET (12 POINTS)...2154
        CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER (OPTION)...2154
      24.4 EVERY 100 HOURS SERVICE...2155
        BOOM CYLINDER FOOT PIN (2 POINTS)...2155
        BOOM FOOT PIN (2 POINTS)...2155
        BOOM CYLINDER ROD END (2 POINTS)...2155
        ARM CYLINDER FOOT PIN (1 POINT)...2155
        BOOM-ARM COUPLING PIN (1 POINT)...2156
        ARM CYLINDER ROD END (1 POINT)...2156
        BUCKET CYLINDER FOOT PIN (1 POINT)...2156
        ARM-LINK COUPLING PIN (1 POINT)...2156
        ARM-BUCKET COUPLING PIN (1 POINT)...2156
        LINK COUPLING PIN (2 POINT)...2156
        BUCKET CYLINDER ROD END (1 POINT)...2156
        BUCKET-LINK COUPLING PIN (1 POINT)...2156
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...2156
        DRAIN WATER AND SEDIMENT FROM FUEL TANK...2157
      24.5 EVERY 250 HOURS SERVICE...2158
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...2158
        CHECK LEVEL OF BATTERY ELECTROLYTE...2159
        CHANGE OIL ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...2160
        LUBRICATE SWING CIRCLE (2 POINTS)...2161
        CHECK FAN TENSION, ADJUST...2162
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...2163
      24.6 EVERY 500 HOURS SERVICE...2164
        REPLACE FUEL FILTER CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION)...2164
        CHECK SWING PINION GREASE LEVEL, ADD GREASE...2165
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)...2166
        CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)...2167
        REPLACE HYDRAULIC TANK BREAHER ELEMENT...2167
        REPLACE HYDRAULIC FILTER ELEMENT...2168
      24.7 EVERY 1000 HOURS SERVICE...2169
        CHANGE OIL IN SWING MACHINERY CASE...2169
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...2170
        CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...2170
        CHECK PLAY OF TURBOCHARGER ROTOR...2170
        CHECK ALTERNATOR BELT TENSION AND REPLACE ALTERNATOR BELT...2171
        REPLACE CORROSION RESISTOR CARTRIDGE...2171
      24.8 EVERY 2000 HOURS SERVICE...2172
        CHANGE OIL IN FINAL DRIVE CASE...2172
        CLEAN HYDRAULIC TANK STRAINER...2173
        CLEAN, CHECK TURBOCHARGER...2173
        CHECK ALTERNATOR, STARTING MOTOR...2173
        CHECK ENGINE VALVE CLEARANCE, ADJUST...2173
        CHECK VIBRATION DAMPER...2174
      24.9  EVERY 4000 HOURS SERVICE...2175
        CHECK WATER PUMP...2175
      24.10 EVERY 5000 HOURS SERVICE...2176
        CHANGE OIL IN HYDRAULIC TANK...2176
  SPECIFICATIONS...2181
    25. SPECIFICATIONS...2182
  OPTIONS, ATTACHMENTS...2186
    26. GENERAL PRECAUTIONS...2187
      26.1 PRECAUTIONS RELATED TO SAFETY...2187
      26.2 PRECAUTIONS RELATED TO SAFETY...2188
    27. HANDLING BUCKET WITH HOOK...2189
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2189
      27.2 PROHIBITED OPERATIONS...2189
      27.3 PRECAUTIONS DURING OPERATIONS...2189
    28. USING SEAT BELT...2190
      28.1 SEAT BELT...2190
    29. HANDLING CAR HEATER...2192
      29.1 EXPLANATION OF COMPONENTS...2192
      29.2 PREPARING CAR HEATER...2193
    30. MACHINE READY FOR ATTACHMENTS...2194
      30.1 EXPLANATION OF COMPONENTS...2194
      30.2 HYDRAULIC CIRCUIT...2196
      30.3 ATTACHMENT MOUNTING/D IMOUNTING...2198
      30.4  OPERATION...2200
      30.5 LONG-TERM STORAGE...2201
      30.6 SPECIFICATIONS...2201
    31. INTRODUCTION OF ATTACHMENTS...2202
      31.1 SPECIFICATION, USE...2202
      31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...2203
      31.3 SELECTION OF TRACK SHOES...2204
      31.4 SELECTION OF BUCKET TEETH...2205
      31.5 HANDLING RUBBER PAD SHOE...2206
      31.6 HANDLING TAPEZOID ...2208
      31.7 HANDING EXTENSION ARM...2209
      31.8 HANDLING CLAMSHELL BUCKET...2210
      31.9 HANDLING VARIABLE 2-PIECE BOOM, ROTATING ARM...2211
    32. EXTENDING MACHINE SERVICE LIFE...2220
      32.1 HYDRAULIC BREAKER...2220
      32.2 POWER RIPPER...2224
      32.3 FORK GRAB...2225
      32.4 GRAPPLE BUCKET...2226
      32.5 SCRAP BUCKET...2227
      32.6 CRUSHER & CUTTER...2228
      32.7 HYDRAULIC PILE DRIVER...2229
      32.8 HYDRAULIC EXCAVTOR WITH MULTI-PURPOSE CRANE ...2230
SEAM045200ATH - Hydraulic Excavator GALEO PC200-7, PC200LC-7 Operation & Maintenance Manual...2232
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SEBM010201 - Hydraulic Excavator PC200-6 Shop Manual...2606
  COVER...2606
  CONTENTS...2607
  SAFETY ...2608
    SAFETY NOTICE ...2608
  FOREWORD ...2610
    GENERAL...2610
    HOW TO READ THE SHOP MANUAL...2611
    HOISTING INSTRUCTIONS...2612
    COATING MATERIALS...2613
    STANDARD TIGHTENING TORQUE...2615
    ELECTRIC WIRE CODE...2618
    CONVERSION TABLE...2619
  01 GENERAL...2625
    SPECIFICATION DIMENSION DRAWINGS...2626
    SPECIFICATIONS ...2627
    WEIGHT TABLE ...2629
    FUEL, COOLANT AND LUBRICANTS...2631
  10 STRUCTURE AND FUNCTION...2633
    ENGINE RELATED PARTS ...2634
    RADIATOR, OIL COOLER, AFTERCOOLER ...2635
    ENGINE CONTROL ...2636
    POWER TRAIN ...2637
    FINAL DRIVE ...2638
    SWING CIRCLE ...2639
    SWING MACHINERY ...2640
    TRACK FRAME, RECOIL SPRING ...2641
    TRACK SHOE ...2642
    HYDRAULIC PIPING DRAWING...2643
    HYDRAULIC CIRCUIT DIAGRAM ...2644
    HYDRAULIC TANK ...2645
    HYDRAULIC PUMP ...2646
    CONTROL VALVE ...2665
    SELF-REDUCING PRESSURE VALVE ...2673
    CLSS ...2678
    SWING MOTOR...2712
    CENTER SWIVEL JOINT...2716
    TRAVEL MOTOR...2718
    VALVE CONTROL...2726
    WORK EQUIPMENT, SWING PPC VALVE...2727
    TRAVEL PPC VALVE...2731
    SERVICE PPC VALVE...2735
    ACCUMULATOR...2738
    STRAIGHT-TRAVEL SYSTEM...2739
    EPC SOLENOID VALVE...2740
    BOOM HOLDING VALVE...2742
    ADDITIONAL FILTER FOR BREAKER...2745
    WORK EQUIPMENT...2746
    ACTUAL ELECTRICAL WIRING DIAGRAM...2747
    ELECTRICAL CIRCUIT DIAGRAM...2749
    ELECTRIC CONTROL SYSTEM...2751
    MACHINE MONITOR SYSTEM...2758
    SENSORS...2761
  20 TESTING AND ADJUSTING...2763
    STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ...2764
    STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ...2765
    STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ...2773
    TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ...2776
    MEASURING ENGINE SPEED...2777
    MEASURING EXHAUST GAS COLOR ...2778
    ADJUSTING VALVE CLEARANCE ...2779
    MEASURING COMPRESSION PRESSURE ...2780
    MEASURING BLOW-BY PRESSURE ...2780
    TESTING AND ADJUSTING FUEL INJECTION TIMING ...2781
    MEASURING ENGINE OIL PRESSURE ...2782
    TESTING AND ADJUSTING FAN BELT TENSION ...2783
    TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR ...2783
    MEASURING SPEED SENSOR ...2784
    ADJUSTING FUEL CONTROL LEVER ...2785
    TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT ...2787
    TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) ...2790
    TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE ...2792
    TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE ...2795
    TESTING SOLENOID VALVE OUTPUT PRESSURE ...2796
    MEASURING PPC VALVE OUTPUT PRESSURE ...2797
    ADJUSTING WORK EQUIPMENT, SWING PPC VALVE ...2799
    TESTING TRAVEL DEVIATION ...2800
    TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ...2801
    MEASURING OIL LEAKAGE ...2803
    RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...2805
    TESTING CLEARANCE OF SWING CIRCLE BEARING...2806
    TESTING AND ADJUSTING TRACK SHOE TENSION...2807
    BLEEDING AIR...2808
    TROUBLESHOOTING...2810
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...2811
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...2812
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...2813
      CHECKS BEFORE TROUBLESHOOTING...2821
      CONNECTOR TYPES AND MOUNTING LOCATIONS...2822
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2827
      METHOD OF USING TROUBLESHOOTING CHARTS...2837
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...2839
        METHOD OF USING TROUBLESHOOTING CHARTS...2840
        S-1 Starting performance is poor (starting always takes time)...2844
        S-2 Engine does not start...2845
          (1) Engine does not turn...2845
          (2) Engine turns but no exhaust smoke comes out (fuel is not being injected)...2846
          (3) Exhaust smoke comes out but engine does not start (fuel is being injected)...2847
        S-3 Engine does not pick up smoothly (follow-up is poor)...2848
        S-4 Engine stops during operations...2849
        S-5 Engine does not rotate smoothly (hunting)...2850
        S-6 Engine lacks output (no power)...2851
        S-7 Exhaust smoke is black (incomplete combustion)...2852
        S-8 Oil consumption is excessive (or exhaust smoke is blue)...2853
        S-9 Oil becomes contaminated quickly...2854
        S-10 Fuel consumption is excessive...2855
        S-11 Oil is in cooling water, or water spurts back, or water level goes down...2856
        S-12 Oil pressure caution lamp lights up (drop in oil pressure)...2857
        S-13 Oil level rises (water, fuel in oil)...2858
        S-14 Water temperature becomes too high (overheating)...2859
        S-15 Abnormal noise is made...2860
        S-16 Vibration is excessive...2861
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...2862
        JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS...2863
        ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...2865
        FAILURE CODES...2866
          E-1 Abnormality in PC-EPC control system...2866
            a) Engine stops even when throttle lever is not returned to STOP position. When sudden load is applied, engine stalls...2866
            b) Lacks power when throttle lever is at FULL, work equipment speed is slow...2867
          E-2 Abnormality in travel speed selector system (travel speed does not switch)...2869
          E-3 Abnormality in swing holding brake solenoid system...2870
            a) Swing holding brake solenoid is not actuated (cannot swing)...2870
            b) Remains actuated (swing cannot be locked)...2871
          E-4 Abnormality in PPC oil pressure lock solenoid system...2872
            a) Solenoid is not actuated (safety lock is not canceled)...2872
            b) Remains actuated (safety lock is not actuated)...2873
          E-5 Abnormality in engine starting system (engine does not start)...2874
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...2877
        TABLE OF FAILURE MODES AND CAUSES (1/2)...2878
        TABLE OF FAILURE MODES AND CAUSES (2/2)...2880
          H-1 Speeds of all work equipments, travel, swing are slow or lacks power...2882
          H-2 There is excessive drop in engine speed, or engine stalls...2884
          H-3 No work equipment, travel, swing move...2885
          H-4 Abnormal noise generated (around pump)...2885
          H-5 Fine control ability is poor or response is poor...2886
          H-6 Boom is slow or lacks power...2887
          H-7 Arm is slow or lacks power...2889
          H-8 Bucket is slow or lacks power...2891
          H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)...2891
          H-10 Excessive hydraulic drift (boom, arm, bucket)...2892
          H-11 Excessive time lag (engine at low idling)...2893
          H-12 Other equipment moves when single circuit is relieved...2893
          H-13 In compound operations, work equipment with larger load is slow...2893
          H-14 In swing + boom RAISE, boom RAISE is slow...2894
          H-15 In swing + travel, travel speed drops excessively...2894
          H-16 Travel deviation (deviation is excessive in normal travel and when starting)...2895
            a) Deviation is excessive in normal travel...2895
            b) Deviation is excessive when starting...2895
          H-17 Travel speed is slow...2896
          H-18 Steering does not turn easily or lacks power...2897
          H-19 Travel does not move (one side only)...2898
          H-20 Travel speed does not switch...2898
          H-21 Does not swing...2899
            a) Does not swing to either left or right...2899
            b) Does not swing in one direction...2899
          H-22 Swing acceleration is poor or swing speed is slow...2900
          H-23 Excessive overrun when stopping swing...2902
            a) One direction only...2902
            b) Both directions...2902
          H-24 Excessive shock when stopping swing (one direction only)...2903
          H-25 Excessive abnormal noise when stopping swing...2903
          H-26 Excessive hydraulic drift of swing...2904
            a) When swing lock is ON...2904
            b) When swing lock is OFF...2904
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...2905
        MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM...2906
          M-1 When the starting switch is turned ON, no display is given (lamps does not light up for 3 seconds)...2907
          M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out...2907
          M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds...2908
            a) No gauge lamps light up (caution lamps light up)...2908
            b) Swing lock, preheating lamps do not light up...2908
            c) Charge caution lamp does not light up...2908
            d) Engine oil pressure caution lamp does not light up...2908
          M-4 When power is turned on (before engine is started), charge caution lamp does not light up...2909
          M-5 When Dower is turned on (before engine is started), engine oil pressure caution lamp does not light up...2909
          M-6 During preheating, preheating pilot lamp does not light up...2910
          M-7 When switch is operated, swing lock lamp does not light up...2910
          M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil pressure is normal)...2911
          M-9 Charge caution lamp lights up when engine is running...2911
          M-10 Abnormality in coolant temperature gauge...2912
            a) After engine is started, level stays at bottom (white range) and does not move...2912
            b) After engine is started, level immediately rises. Engine is not overheating but indicator enters red range...2912
            c) Coolant temperature gauge goes out...2912
          M-11 Abnormality in fuel gauge...2913
            a) All fuel gauge segments go out...2913
            b) Even when fuel level goes down, fuel gauge continues to show FULL...2913
            c) Even when tank is filled, fuel gauge does not show FULL...2913
          M-12 Defective operation of alarm buzzer...2915
            a) Buzzer does not sound...2915
            b) Buzzer continues to sound and does not stop...2915
          M-13 Engine is running, but service meter does not move...2916
            a) Charge caution lamp lights up...2916
            b) Charge caution lamp does not light up...2916
          M-14 Night lighting does not light up...2917
            a) Gauge lighting does not light up...2917
            b) Service meter lighting does not light up (service meter is working normally)...2917
          M-15 Wiper does not move, or does not stop moving...2918
            a) Wiper does not move when wiper switch is turned to ON...2918
            b) Wiper moves even when wiper switch is not turned to ON...2918
          M-16 Heater does not work...2920
            a) Does not work at either Hi or Lo...2920
            b) Does not work at Lo only...2920
            c) Does not work at Hi only...2920
  30 DISASSEMBLY AND ASSEMBLY...2921
    METHOD OF USING MANUAL...2923
    PRECAUTIONS WHEN CARRYING OUT OPERATION...2924
    SPECIAL TOOL LIST...2926
    SKETCHES OF SPECIAL TOOLS...2930
    STARTING MOTOR ASSEMBLY...2931
      REMOVAL AND INSTALLATION...2931
    ALTERNATOR ASSEMBLY...2932
      REMOVAL AND INSTALLATION...2932
    AIR CONDITIONER COMPRESSOR ASSEMBLY...2933
      REMOVAL AND INSTALLATION...2933
    CONDENSER ASSEMBLY...2934
      REMOVAL AND INSTALLATION...2934
    ENGINE OIL COOLER CORE ASSEMBLY...2935
      REMOVAL AND INSTALLATION...2935
    FUEL INJECTION PUMP ASSEMBLY...2936
      REMOVAL...2936
      INSTALLATION...2939
    WATER PUMP ASSEMBLY...2941
      REMOVAL...2941
      INSTALLATION...2942
    NOZZLE HOLDER ASSEMBLY...2943
      REMOVAL AND INSTALLATION...2943
    TURBOCHARGER ASSEMBLY...2944
      REMOVAL AND INSTALLATION...2944
    THERMOSTAT ASSEMBLY...2945
      REMOVAL...2945
      INSTALLATION...2946
    CYLINDER HEAD ASSEMBLY...2947
      REMOVAL...2947
      INSTALLATION...2951
    RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY...2954
      REMOVAL...2954
      INSTALLATION...2956
    ENGINE, MAIN PUMP ASSEMBLY...2957
      REMOVAL...2957
      INSTALLATION...2961
    DAMPER ASSEMBLY...2962
      REMOVAL AND INSTALLATION...2962
    FUEL TANK ASSEMBLY...2963
      REMOVAL AND INSTALLATION...2963
    CENTER SWIVEL JOINT ASSEMBLY...2964
      REMOVAL...2964
      INSTALLATION...2965
      DISASSEMBLY AND ASSEMBLY...2966
    FINAL DRIVE ASSEMBLY...2967
      REMOVAL AND INSTALLATION...2967
      DISASSEMBLY...2968
      ASSEMBLY...2971
    SPROCKET...2976
      REMOVAL AND INSTALLATION...2976
    SWING MOTOR, SWING MACHINERY ASSEMBLY...2977
      REMOVAL...2977
      INSTALLATION...2978
      DISASSEMBLY...2979
      ASSEMBLY...2983
    REVOLVING FRAME ASSEMBLY...2988
      REMOVAL...2988
      INSTALLATION...2989
    SWING CIRCLE ASSEMBLY...2990
      REMOVAL...2990
      INSTALLATION...2991
    IDLER, RECOIL SPRING ASSEMBLY...2992
      REMOVAL AND INSTALLATION...2992
    RECOIL SPRING ASSEMBLY...2993
      DISASSEMBLY...2993
      ASSEMBLY...2994
    IDLER ASSEMBLY...2995
      DISASSEMBLY...2995
      ASSEMBLY...2996
    TRACK ROLLER ASSEMBLY...2998
      REMOVAL AND INSTALLATION...2998
      DISASSEMBLY...2999
      ASSEMBLY...3001
    CARRIER ROLLER ASSEMBLY...3003
      REMOVAL AND INSTALLATION...3003
      DISASSEMBLY...3004
      ASSEMBLY...3006
    TRACK SHOE ASSEMBLY...3008
      REMOVAL AND INSTALLATION...3008
    HYDRAULIC TANK ASSEMBLY...3009
      REMOVAL...3009
      INSTALLATION...3010
    MAIN PUMP ASSEMBLY...3011
      REMOVAL...3011
      INSTALLATION...3013
    MAIN PUMP INPUT SHAFT OIL SEAL...3014
      REMOVAL AND INSTALLATION...3014
    CONTROL VALVE ASSEMBLY...3015
      REMOVAL...3015
      INSTALLATION...3017
      DISASSEMBLY...3018
      ASSEMBLY...3023
    MAIN RELIEF VALVE ASSEMBLY...3029
      DISASSEMBLY AND ASSEMBLY...3029
    PC VALVE ASSEMBLY...3030
      REMOVAL...3030
      INSTALLATION...3031
    LS VALVE ASSEMBLY...3032
      REMOVAL AND INSTALLATION...3032
    PC-EPC VALVE ASSEMBLY...3033
      REMOVAL AND INSTALLATION...3033
    SOLENOID VALVE ASSEMBLY...3034
      REMOVAL AND INSTALLATION...3034
    WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY...3035
      REMOVAL AND INSTALLATION...3035
      DISASSEMBLY...3036
      ASSEMBLY...3037
    TRAVEL PPC VALVE ASSEMBLY...3038
      REMOVAL AND INSTALLATION...3038
      DISASSEMBLY...3039
      ASSEMBLY...3040
    BOOM LOCK VALVE ASSEMBLY...3041
      REMOVAL AND INSTALLATION...3041
    BOOM CYLINDER ASSEMBLY...3042
      REMOVAL...3042
      INSTALLATION...3043
    ARM CYLINDER ASSEMBLY...3044
      REMOVAL...3044
      INSTALLATION...3045
    BUCKET CYLINDER ASSEMBLY...3046
      REMOVAL...3046
      INSTALLATION...3047
    HYDRAULIC CYLINDER ASSEMBLY...3048
      DISASSEMBLY...3048
      ASSEMBLY...3051
    WORK EQUIPMENT ASSEMBLY...3055
      REMOVAL...3055
      INSTALLATION...3056
    BUCKET ASSEMBLY...3057
      REMOVAL...3057
      INSTALLATION...3058
    ARM ASSEMBLY...3059
      REMOVAL...3059
      INSTALLATION...3060
    BUCKET, ARM ASSEMBLY...3061
      REMOVAL...3061
      INSTALLATION...3062
    BOOM ASSEMBLY...3063
      REMOVAL...3063
      INSTALLATION...3064
    OPERATOR’S CAB ASSEMBLY...3065
      REMOVAL AND INSTALLATION...3065
    COUNTERWEIGHT ASSEMBLY...3066
      REMOVAL AND INSTALLATION...3066
    MONITOR ASSEMBLY...3067
      REMOVAL AND INSTALLATION...3067
  40 MAINTENANCE STANDARD...3068
    SWING MACHINERY ...3069
    SWING CIRCLE ...3071
    FINAL DRIVE ...3072
    TRACK FRAME, RECOIL SPRING ...3074
    IDLER ...3075
    CARRIER ROLLER...3077
    TRACK ROLLER ...3078
    TRACK SHOE ...3079
    HYDRAULIC PUMP ...3084
    CONTROL VALVE ...3085
    SELF-REDUCING PRESSURE VALVE ...3092
    SWING MOTOR...3093
    TRAVEL MOTOR ...3094
    WORK EQUIPMENT, SWING PPC VALVE ...3095
    TRAVEL PPC VALVE ...3096
    SERVICE PPC VALVE ...3097
    CENTER SWIVEL JOINT ...3098
    BOOM HOLDING VALVE ...3100
    HYDRAULIC CYLINDER ...3101
    WORK EQUIPMENT ...3103
    DIMENSION OF WORK EQUIPMENT ...3105
  90 OTHERS...3109
    HYDRAULIC PIPING DRAWING...3110
    HYDRAULIC CIRCUIT DIAGRAM...3111
    ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)...3116
    ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)...3117
    ELECTRICAL CIRCUIT DIAGRAM (1/2)...3118
    ELECTRICAL CIRCUIT DIAGRAM (2/2)...3123
    OPERATION OF CLSS SYSTEM AS A WHOLE...3128
      1. When all work equipment is at neutral...3128
      2. One side actuated, other side neutral...3129
      3. Arm OUT, standard mode relief (cut-off control)...3130
      4. Bucket DUMP, power max. relief...3131
      5. Boom RAISE...3132
      6. Swing operated independently...3133
      7. Travel operated independently...3134
      8. Compound operation...3135
SEBM010202 - Hydraulic Excavator PC200LC-6 Shop Manual...3137
  COVER...3137
  CONTENTS...3138
  01 GENERAL...3139
    SPECIFICATION DIMENSION DRAWINGS...3140
    SPECIFICATIONS...3141
    WEIGHT TABLE...3143
    FUEL, COOLANT AND LUBRICANTS...3145
  10 STRUCTURE AND FUNCTION...3146
    ENGINE RELATED PARTS...3147
    RADIATOR OIL COOLER AFTERCOOLER...3148
    ENGINE CONTROL...3149
    POWER TRAIN...3150
    FINAL DRIVE...3151
    SWING CIRCLE...3152
    SWING MACHINERY...3153
    TRACK FRAME  RECOIL SPRING...3154
    TRACK SHOE...3155
    HYDRAULIC PIPING DRAWING...3156
    HYDRAULIC CIRCUIT DIAGRAM...3157
    HYDRAULIC TANK...3158
    HYDRAULIC PUMP...3159
    IN-LINE FILTER...3178
    CONTROL VALVE...3179
    SELF-REDUCING PRESSURE VALVE...3187
    CLSS...3192
    SWING MOTOR...3226
    CENTER SWIVEL JOINT...3230
    TRAVEL MOTOR...3232
    VALVE CONTROL...3240
    WORK EQUIPMENT SWING PPC VALVE...3241
    TRAVEL PPC VALVE...3245
    SERVICE PPC VALVE...3249
    ACCUMULATOR...3252
    STRAIGHT-TRAVEL SYSTEM...3253
    EPC SOLENOID VALVE...3254
    BOOM HOLDING VALVE...3256
    ADDITIONAL FILTER FOR BREAKER...3259
    WORK EQUIPMENT...3260
    ACTUAL ELECTRICAL WIRING DIAGRAM...3261
    ELECTRIC CIRCUIT SYSTEM...3263
    ELECTRIC CONTROL SYSTEM...3265
    MACHINE MONITOR SYSTEM...3271
    SENSORS...3274
  20 TESTING AND ADJUSTING...3276
    STANDARD VALVE TABLE FOR ENGINE RELATED PARTS...3277
    STANDARD VALVE TABLE FOR ENGINE CHASSIS RELATED PARTS...3278
    STANDARD VALVE TABLE FOR ENGINE ELECTRICAL SYSTEM...3286
    TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...3289
    MEASURING ENGINE SPEED...3290
    MEASURING EXHAUST COLOR...3291
    ADJUSTING VALVE CLEARANCE...3292
    MEASURING COMPRESSION PRESSURE...3293
    MEASURING BLOW BY PRESSURE...3293
    TESTING AND ADJUSTING FUEL INJECTION TIMING...3294
    MEASURING ENGINE OIL PRESSURE...3295
    TESTING AND ADJUSTING FAN BELT TENSION...3296
    TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...3296
    ADJUSTING ENGINE SPEED SENSOR...3297
    ADJUSTING FUEL CONTROL LEVER...3298
    TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...3300
    TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE  (SERVO PISTON INPUT PRESSURE)...3303
    TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE  (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE ...3304
    TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE...3307
    TESTING SOLENOID VALVE OUTPUT PRESSURE...3308
    MEASURING PPC VALVE PUTPUT PRESSURE...3309
    ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...3311
    TESTING TRAVEL DEVIATION...3312
    TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...3313
    MEASURING OIL LEAKAGE...3315
    RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...3317
    TESTING CLEARANCE OF SWING CIRCLE BEARING...3318
    TESTING AND ADJUSTING TRACK SHOE TENSION...3319
    BLEEDING AIR...3320
    TROUBLESHOOTING...3322
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...3323
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...3324
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...3325
      CHECKS BEFORE TROUBLESHOOTING...3333
      CONNECTOR TYPES AND MOUNTING LOCATIONS...3334
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...3339
      METHOD OF USING TROUBLESHOOTING CHARTS...3349
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...3351
        METHOD OF USING TROUBLESHOOTING CHARTS...3352
        S-1 STARTING PERFORMANCE IS POOR (ALWAYS TAKES TIME)...3356
        S-2 ENGINE DOES NOT START...3357
          (1) ENGINE DOES NOT RUN...3357
          (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...3358
          (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES START (FUEL IS BEING INJECTED)...3359
        S-3 ENGINE DOES NOT PICK SMOOTHY (FOLLOW-UP IS POOR)...3360
        S-4 ENGINE STOPS DURING OPERATIONS...3361
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...3362
        S-6 ENGINE LACKS OUTPUT (NO POWER)...3363
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION...3364
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...3365
        S-9 OIL BECOMES CONTAMINATED QUICKLY...3366
        S-10 FUEL CONSUMPTION IS EXCESSIVE...3367
        S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...3368
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...3369
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...3370
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...3371
        S-15 ABNORMAL NOISE IS MADE...3372
        S-16 VIBRATION IS EXCESSIVE...3373
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...3374
        JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS...3375
        ELECTRICAL CIRCUIT DIAGRAM FOR SYSTEM...3377
        FAILURE CODES...3378
          E-1 ABNORMALITY IN PC-EPC CONTROL SYSTEM...3378
            A) ENGINE STOPS EVEN WHEN THROTTLE LEVER IS NOT RETURNED TO STOP POSITION. WHEN SUDDEN LOAD IS APPLIED, ENGINE STALLS...3378
            B) LACKS POWER WHEN THROTTLT LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW ...3379
          E-2 ABNORMALITY IN TRAVEL SPEED SELECTOR SYSTEM (TRAVEL SPEED DOES NOT SWITCH)...3381
          E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM...3382
            A) SWING HOLDING BRAKE SOLENOID IS NOT ACTUATED (CANNOT SWING)...3382
            B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)...3383
          E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM...3384
            A) SOLENOID IS NOT ACTUATED (SAFETY LOCK IS NOT CANCELED)...3384
            B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)...3385
          E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)...3386
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...3389
        TABLE OF FAILURE MODES AND CAUSES...3390
        H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACKS POWER...3394
        H-2 THERE IS NOT EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...3396
        H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...3397
        H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...3397
        H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...3398
        H-6 BOOM IS SLOW OR LACKS POWER...3399
        H-7 ARM IS SLOW OR LACKS POWER...3401
        H-8 BUCKET IS SLOW OR LACKS POWER...3403
        H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL...3403
        H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...3404
        H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...3405
        H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...3405
        H-13 IN COMPUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS LOW...3405
        H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...3406
        H-15 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...3406
        H-16 TRAVEL DEVIATION...3407
          A) DEVIATION IS EXCESSIVE IN NORMAL TRAVEL...3407
          B) DEVIATION IS EXCESSIVE WHEN STARTING...3407
        H-17 TRAVEL SPEED IS SLOW...3408
        H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER...3409
        H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...3410
        H-20 TRAVEL SPEED DOES NOT SWITCH...3410
        H-21 DOES NOT SWING...3411
          A) DOES NOT SWING TO EITHER LEFT OR RIGHT...3411
          B) DOES NOT SWING IN ONE DIRECTION...3411
        H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS LOW...3412
        H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...3414
          A) ONE DIRECTION ONLY...3414
          B) BOTH DIRECTIONS...3414
        H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...3415
        H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...3415
        H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING...3416
          A) WHEN SWING LOCK IS ON...3416
          B) WHEN SWING LOCK IS OFF...3416
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...3417
        MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM...3418
          M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)...3419
          M-2 WHEN THE STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT...3419
          M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS...3420
            A) NO GAUGE LAMP LIGHTS UP (CAUTION LAMPS LIGHT UP...3420
            B) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP)...3420
            C) CHARGE CAUTION LAMP DOES NOT LIGHT UP ...3420
            D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...3420
          M-4 WHEN POWER IS ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP ...3421
          M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...3421
          M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP...3422
          M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP...3422
          M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...3423
          M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING...3423
          M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE...3424
            A) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE...3424
            B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE...3424
            C) COOLANT TEMPERATURE GAUGE GOES OUT...3424
          M-11 ABNORMALITY IN FUEL GAUGE...3425
            A) ALL FUEL GAUGE SEGMENTS GO OUT...3425
            B) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL...3425
            C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL...3425
          M-12 DEFECTIVE OPERATION OF ALARM BUZZER...3427
            A) BUZZER DOES NOT SOUND...3427
            B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP...3427
          M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE...3428
            A) CHARGE CAUTION  LAMP LIGHTS UP...3428
            B) CHARGE CAUTION LAMP DOES NOT LIGHT UP...3428
          M-14 NIGHT LIGHTING DOES NOT LIGHT UP...3429
            A) GAUGE LIGHTING DOES NOT LIGHT UP...3429
            B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)...3429
          M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING...3430
            A) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED ON...3430
            B) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED ON...3430
          M-16 HEATER DOES NOT WORK AT EITHER HI OR LO...3432
            A) DOES NOT WORK AT EITHER HI OR LO...3432
            B) DOES NOT WORK AT LO ONLY ...3432
            C) DOES NOT WORK AT HI ONLY ...3432
  30 DISASSEMBLY AND ASSEMBLY...3433
    METHOD OF USING MANUAL...3435
    PRECAUTIONS WHEN CARRYING OUT OPERATION...3436
    SPECIAL TOOL LIST...3438
    SKETCHES OF SPECIAL TOOLS...3442
    STARTING MOTOR ASSEMBLY...3443
      REMOVAL AND INSTALLATION...3443
    ALTERNATIVE ASSEMBLY...3444
      REMOVAL AND INSTALLATION...3444
    AIR CONDITIONER COMPRESSOR ASSEMBLY...3445
      REMOVAL AND INSTALLATION...3445
    CONDENSER ASSEMBLY...3446
      REMOVAL AND INSTALLATION...3446
    ENGINE OIL COOLER CORE ASSEMBLY...3447
      REMOVAL AND INSTALLATION...3447
    FUEL INJECTION PUMP ASSEMBLY...3448
      REMOVAL...3448
      INSTALLATION...3451
    WATER PUMP ASSEMBLY...3453
      REMOVAL AND INSTALLATION...3454
    NOZZLE HOLDER ASSEMBLY...3455
      REMOVAL AND INSTALLATION...3455
    TURBOCHARGER ASSEMBLY...3456
      REMOVAL AND INSTALLATION...3456
    THERMOSTAT ASSEMBLY...3457
      REMOVAL AND INSTALLATION...3458
    CYLINDER HEAD ASSEMBLY...3459
      REMOVAL...3459
      INSTALLATION...3463
    RADIATOR - HYDRAULIC COOLER ASSEMBLY...3466
      REMOVAL...3466
      INSTALLATION...3468
    ENGINE - MAIN PUMP ASSEMBLY...3469
      REMOVAL...3469
      INSTALLATION...3473
    DAMPER ASSEMBLY...3474
      REMOVAL AND INSTALLATION...3474
    FUEL TANK ASSEMBLY...3475
      REMOVAL AND INSTALLATION...3475
    CENTER SWIVEL JOINT ASSEMBLY...3476
      REMOVAL AND INSTALLATION...3477
      DISASSEMBLY AND ASSEMBLY...3478
    FINAL DRIVE ASSEMBLY...3479
      REMOVAL AND INSTALLATION...3479
      DISASSEMBLY...3480
      ASSEMBLY...3483
    SPROCKET ...3488
      REMOVAL AND INSTALLATION...3488
    SWIMG MOTOR, SWING MACHINERY...3489
      REMOVAL AND INSTALLATION...3490
      DISASSEMBLY...3491
      ASSEMBLY...3495
    REVOLVING FRAME ASSEMBLY ...3500
      REMOVAL...3500
      INSTALLATION...3501
    SWING CIRCLE ASSEMBLY...3502
      REMOVAL...3502
      INSTALLATION...3503
    IDLER - RECOIL SPRING ASSEMBLY...3504
      REMOVAL AND INSTALLATION...3504
    RECOIL SPRING ASSEMBLY...3505
      DISASSEMBLY...3505
      ASSEMBLY...3506
    IDLER ASSEMBLY...3507
      DISASSEMBLY...3507
      ASSEMBLY...3508
    TRACK ROLLER ASSEMBLY...3510
      REMOVAL AND INSTALLATION...3510
      DISASSEMBLY...3511
      ASSEMBLY...3513
    CARRIER ROLLER ASSEMBLY...3515
      REMOVAL AND INSTALLATION...3515
      DISASSEMBLY...3516
      ASSEMBLY...3518
    TRACK SHOE ASSEMBLY...3520
      REMOVAL AND INSTALLATION...3520
    HYDRAULAIC TANK ASSEMBLY...3521
      REMOVAL...3521
      INSTALLATION...3522
    MAIN PUMP ASSEMBLY...3523
      REMOVAL...3523
      INSTALLATION...3525
    MAIN PUMP INPUT SHAFT OIL SEAL...3526
      REMOVAL AND INSTALLATION...3526
    CONTROL VALVE ASSEMBLY...3527
      REMOVAL...3527
      INSTALLATION...3529
      DISASSEMBLY...3530
      ASSEMBLY...3535
    MAIN RELIEF VALVE ASSEMBLY...3541
      DISASSEMBLY AND ASSEMBLY...3541
    PC VALVE ASSEMBLY...3542
      REMOVAL AND INSTALLATION...3543
    LS VALVE ASSEMBLY...3544
      REMOVAL AND INSTALLATION...3544
    PC-EPC VALVE ASSEMBLY...3545
      REMOVAL AND INSTALLATION...3545
    SOLENOID VALVE ASSEMBLY...3546
      REMOVAL AND INSTALLATION...3546
    WORK EQUIPMENT - SWING PPC VALVE ASSEMBLY...3547
      REMOVAL AND INSTALLATION...3547
      DISASSEMBLY...3548
      ASSEMBLY...3549
    TRAVEL PPC VALVE ASSEMBLY...3550
      REMOVAL AND INSTALLATION...3550
      DISASSEMBLY AND ASSEMBLY...3551
      ASSEMBLY...3552
    BOOM LOCK VALVE ASSEMBLY...3553
      REMOVAL AND INSTALLATION...3553
    BOOM CYLINDER ASSEMBLY...3554
      REMOVAL...3554
      INSTALLATION...3555
    ARM CYLINDER ASSEMBLY ...3556
      REMOVAL...3556
      INSTALLATION...3557
    BUCKET CYLINDER ASSEMBLY...3558
      REMOVAL...3558
      INSTALLATION...3559
    HYDRAULIC CYLINDER ASSEMBLY...3560
      DISASSEMBLY...3560
      ASSEMBLY...3563
    WORK EQUIPMENT ASSEMBLY...3567
      REMOVAL...3567
      INSTALLATION...3568
    BUCKET ASSEMBLY...3569
      REMOVAL...3569
      INSTALLATION...3570
    ARM ASSEMBLY...3571
      REMOVAL...3571
      INSTALLATION...3572
    BUCKET - ARM ASSEMBLY...3573
      REMOVAL...3573
      INSTALLATION...3574
    BOOM ASSEMBLY...3434
      REMOVAL...3434
      INSTALLATION...3434
    OPERATOR'S CAB ASSEMBLY...3575
      REMOVAL AND INSTALLATION...3575
    COUNTERWEIGHT ASSEMBLY...3576
      REMOVAL AND INSTALLATION...3576
    MONITOR ASSEMBLY...3577
      REMOVAL AND INSTALLATION...3577
  40 MAINTENANCE STANDARD...3578
    SWING MACHINERY...3579
    SWING CIRCLE...3581
    FINAL DRIVE...3582
    TRACK FRAME - RECOIL SPRING...3584
    IDLER...3585
    CARRIER ROLLER...3587
    TRACK ROLLER...3588
    TRACK SHOE...3589
    HYDRAULIC PUMP...3594
    CONTROL VALVE...3595
    SELF-REDUCING PRESSURE VALVE...3602
    SWING MOTOR...3603
    TRAVEL MOTOR...3604
    WORK EQUIPMENT - SWING PPC VALVE...3605
    TRAVEL PPC VALVE...3606
    SERVICE PPC VALVE...3607
    CENTER SWIVEL JOINT...3608
    BOOM HOLDING VALVE...3610
    HYDRAULIC CYLINDER...3611
    WORK EQUIPMENT...3613
    DIMENSION OF WORK EQUIPMENT...3615
  90 OTHERS...3619
    HYDRAULIC PIPING DRAWING...3620
    HYDRAULIC CIRCUIT DIAGRAM...3626
    ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)...3628
    ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)...3632
    ELECTRICAL CIRCUIT DIAGRAM (1/2)...3636
    ELECTRICAL CIRCUIT DIAGRAM (2/2)...3640
    OPERATION OF CLSS SYSTEM AS A WHOLE...3644
      1. WHEN ALL WORK EQUIPMENT IS NEUTRAL...3644
      2. ONE SIDE ACTUATED, OTHER SIDE NEUTRAL...3648
      3. ARM  OUT, STANDARD MODE RELIEF (CUT-OFF CONTROL)...3652
      4. BUCKET DUMP, POWER MAX RELIEF...3656
      5. BOOM RAISE...3660
      6. SWING OPERATED INDEPENDENTLY...3664
      7. TRAVEL OPERATED INDEPENDENTLY...3668
      8. COMPOUND OPERATION...3672
SEBM0205B04 - Hydraulic Excavator PC200-2, PC200LC-2, PC220-2, PC220LC-2 Shop Manual...3677
TEN00205-00 - Hydraulic Excavator PC200-8, PC200LC-8 Operation & Maintenance Manual...4229
  TEN00205-00...4231

Komatsu Hydraulic Excavator PC200, PC200LC, PC220, PC220LC Repair Service Manuals