Komatsu PC200-5 Custom, PC220-5 Custom Hydraulic Excavator Shop Manual SEBM0205C503

Description

• Model List:
  • PC200-5 Custom Hydraulic Excavator
  • PC220-5 Custom Hydraulic Excavator

• 1. COVER
• 2. CONTENTS
• 3. STRUCTURE AND FUNCTION
• 3.1. POWER TRAIN
• 3.2. FINAL DRIVE
• 3.3. SWING CIRCLE
• 3.4. SWING MACHINERY
• 3.5. TRACK FRAME AND RECOIL SPRING
• 3.6. IDLER
• 3.7. TRACK ROLLER
• 3.8. CARRIER ROLLER
• 3.9. TRACK SHOE
• 3.10. HYDRAULIC PIPING
• 3.11. HYDRAULIC CIRCUIT DIAGRAM
• 3.12. CENTER SWIVEL JOINT
• 3.13. TRAVEL MOTOR
• 3.14. VALVE CONTROL
• 3.15. PPC VALVE
• 3.16. ACCUMULATOR
• 3.17. SAFETY LOCK VALVE
• 3.18. SWING LOCK SOLENOID VALVE
• 3.19. SHUTTLE VALVE
• 3.20. HYDRAULIC CYLINDER
• 3.21. ELECTRICAL CIRCUIT DIAGRAM
• 3.22. ENGINE CONTROL SYSTEM
• 3.23. EMACC
• 4. TESTING AND ADJUSTING
• 4.1. TABLE OF JUDGEMENT STANDARD VALUE
• 4.2. TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING
• 4.3. ADJUSTING VALVE CLEARANCE
• 4.4. MEASURING COMPRESSION PRESSURE
• 4.5. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.6. TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
• 4.7. ADJUSTING FUEL CONTROL LEVER
• 4.8. INSPECTION OF SWING CIRCLE BEARING CLEARANCE
• 4.9. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
• 4.10. TESTING AND ADJUSTING CHARGING PUMP PRESSURE
• 4.11. TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
• 4.12. MEASURING STROKE OF SERVO PISTON
• 4.13. TESTING AND ADJUSTING TRAVEL DEVIATION
• 4.14. MEASURING OUTPUT PRESSURE OF PPC VALVE
• 4.15. ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
• 4.16. TESTING PPC SHUTTLE VALVE
• 4.17. MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
• 4.18. TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
• 4.19. BLEEDING AIR
• 4.20. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 4.21. TROUBLESHOOTING
• 4.21.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 4.21.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 4.21.3. PRECAUTION WHEN CARRYING OUT MAINTENANCE
• 4.21.4. CHECKS BEFORE TROUBLESHOOTING
• 4.21.5. ELECTRICAL CIRCUIT DIAGRAM
• 4.21.6. POSITION OF CONNECTORS FOR TROUBLESHOOTING
• 4.21.7. CONNECTION TABLE FOR CONNECTOR
• 4.21.8. HANDLING CONNECTORS
• 4.21.9. DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER
• 4.21.10. ACTION OF SELFDIAGNOSTION FUNCTION AND SYMPTOMS ON MACHINE
• 4.21.11. METHOD OF PROCEEDING WITH TROUBLESHOOTING
• 4.21.12. METHOD OF USING JUDGEMENT TABLE
• 4.21.13. METHOD OF USING TROUBLESHOOTING CHARTS
• 4.21.14. TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
• 4.21.15. TROUBLESHOOTING OF ELECTRICAL SYSTEM (C MODE)
• 4.21.16. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
• 4.21.17. TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. METHOD OF USING MANUAL
• 5.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 5.3. SPECIAL TOOL LIST
• 5.4. WEIGHT TABLE
• 5.5. TIGHTENING TORQUES AND STANDARD VALUES TABLE
• 5.6. LUBRICANT AND COOLANT TABLE
• 5.7. STARTING MOTOR
• 5.7.1. REMOVAL AND INSTALLATION
• 5.8. ALTERNATOR
• 5.8.1. REMOVAL AND INSTALLATION
• 5.9. ENGINE OIL COOLER
• 5.9.1. REMOVAL AND INSTALLATION
• 5.10. FUEL INJECTION PUMP
• 5.10.1. REMOVAL AND INSTALLATION
• 5.11. WATER PUMP
• 5.11.1. REMOVAL AND INSTALLATION
• 5.12. NOZZLE HOLDER
• 5.12.1. REMOVAL AND INSTALLATION
• 5.13. TURBOCHARGER
• 5.13.1. REMOVAL AND INSTALLATION
• 5.14. THERMOSTAT
• 5.14.1. REMOVAL AND INSTALLATION
• 5.15. ENGINE FRONT SEAL
• 5.15.1. REMOVAL AND INSTALLATION
• 5.16. ENGINE REAR SEAL
• 5.16.1. REMOVAL AND INSTALLATION
• 5.17. GOVERNOR MOTOR
• 5.17.1. REMOVAL AND INSTALLATION
• 5.18. CYLINDER HEAD
• 5.18.1. REMOVAL AND INSTALLATION
• 5.19. AFTERCOOLER
• 5.19.1. REMOVAL AND INSTALLATION
• 5.20. HYDRAULIC COOLER
• 5.20.1. REMOVAL AND INSTALLATION
• 5.21. RADIATOR, HYDRAULIC COOLER
• 5.21.1. REMOVAL AND INSTALLATION
• 5.22. ENGINE, HYDRAULIC PUMP
• 5.22.1. REMOVAL AND INSTALLATION
• 5.23. DAMPER
• 5.23.1. REMOVAL AND INSTALLATION
• 5.24. CENTER SWIVEL JOINT
• 5.24.1. REMOVAL AND INSTALLATION
• 5.24.2. DISASSEMBLY AND ASSEMBLY
• 5.25. TRAVEL MOTOR
• 5.25.1. REMOVAL AND INSTALLATION
• 5.25.2. DISASSEMBLY
• 5.25.3. ASSEMBLY
• 5.26. FINAL DRIVE
• 5.26.1. REMOVAL AND INSTALLATION
• 5.26.2. DISASSEMBLY
• 5.26.3. ASSEMBLY
• 5.27. SPROCKET
• 5.27.1. REMOVAL AND INSTALLATION
• 5.28. SWING MOTOR
• 5.28.1. REMOVAL AND INSTALLATION
• 5.28.2. DISASSEMBLY
• 5.28.3. ASSEMBLY
• 5.29. SWING MACHINERY
• 5.29.1. REMOVAL AND INSTALLATION
• 5.29.2. DISASSEMBLY
• 5.29.3. ASSEMBLY
• 5.30. REVOLVING FRAME
• 5.30.1. REMOVAL AND INSTALLATION
• 5.31. SWING CIRCLE
• 5.31.1. REMOVAL AND INSTALLATION
• 5.32. IDLER, RECOIL SPRING
• 5.32.1. REMOVAL AND INSTALLATION
• 5.32.2. DISASSEMBLY AND ASSEMBLY
• 5.33. TRACK ROLLER
• 5.33.1. REMOVAL AND INSTALLATION
• 5.34. CARRIER ROLLER
• 5.34.1. REMOVAL AND INSTALLATION
• 5.35. TRACK SHOE
• 5.35.1. REMOVAL AND INSTALLATION
• 5.36. CHARGING PUMP
• 5.36.1. REMOVAL AND INSTALLATION
• 5.37. HYDRAULIC PUMP
• 5.37.1. REMOVAL AND INSTALLATION
• 5.37.2. DISASSEMBLY
• 5.37.3. ASSEMBLY
• 5.38. MAIN PUMP INPUT SHAFT OIL SEAL
• 5.38.1. REMOVAL AND INSTALLATION
• 5.39. CONTROL VALVE
• 5.39.1. REMOVAL AND INSTALLATION
• 5.39.2. DISASSEMBLY
• 5.39.3. ASSEMBLY
• 5.40. MAIN RELIEF VALVE
• 5.40.1. REMOVAL AND INSTALLATION
• 5.40.2. DISASSEMBLY AND ASSEMBLY
• 5.41. TVC VALVE
• 5.41.1. REMOVAL AND INSTALLATION
• 5.42. CONC VALVE
• 5.42.1. REMOVAL AND INSTALLATION
• 5.43. SERVO VALVE
• 5.43.1. REMOVAL AND INSTALLATION
• 5.44. WORK EQUIPMENT PPC VALVE
• 5.44.1. REMOVAL AND INSTALLATION
• 5.44.2. DISASSEMBLY AND ASSEMBLY
• 5.45. TRAVEL PPC VALVE
• 5.45.1. REMOVAL AND INSTALLATION
• 5.45.2. DISASSEMBLY AND ASSEMBLY
• 5.46. PPC SHUTTLE VALVE
• 5.46.1. REMOVAL AND INSTALLATION
• 5.47. BOOM CYLINDER
• 5.47.1. REMOVAL AND INSTALLATION
• 5.48. ARM CYLINDER
• 5.48.1. REMOVAL AND INSTALLATION
• 5.49. BUCKET CYLINDER
• 5.49.1. REMOVAL AND INSTALLATION
• 5.50. HYDRAULIC CYLINDER
• 5.50.1. DISASSEMBLY
• 5.50.2. ASSEMBLY
• 5.51. WORK EQUIPMENT
• 5.51.1. REMOVAL AND INSTALLATION
• 5.52. BUCKET
• 5.52.1. REMOVAL AND INSTALLATION
• 5.53.1. REMOVAL AND INSTALLATION
• 5.54. ARM, BUCKET
• 5.54.1. REMOVAL AND INSTALLATION
• 5.55. BOOM
• 5.55.1. REMOVAL AND INSTALLATION
• 5.56.1. REMOVAL AND INSTALLATION
• 5.57. COUNTERWEIGHT
• 5.57.1. REMOVAL AND INSTALLATION
• 5.58. ENGINE THROTTLE CONTROLLER
• 5.58.1. REMOVAL AND INSTALLATION
• 5.59. MONITOR PANEL
• 5.59.1. REMOVAL AND INSTALLATION
• 5.60. PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
• 6. MAINTENANCE STANDARD
• 6.1. FINAL DRIVE
• 6.2. SWING MACHINERY
• 6.3. SWING CIRCLE
• 6.4. TRACK FRAME AND RECOIL SPRING
• 6.5. IDLER
• 6.6. TRACK ROLLER
• 6.7. CARRIER ROLLER
• 6.8. TRACK SHOE
• 6.9. HYDRAULIC PUMP
• 6.10. CHARGING PUMP AND RELIEF VALVE
• 6.11. CONTROL VALVE
• 6.12. TRAVEL SHUTTLE VALVE
• 6.13. SWING MOTOR
• 6.14. CENTER SWIVEL JOINT
• 6.15. TRAVEL MOTOR
• 6.16. PPC VALVE
• 6.17. HYDRAULIC CYLINDER
• 6.18. WORK EQUIPMENT