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KOMATSU PC200-8 PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00084C0-21 – PDF DOWNLOAD
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Description
KOMATSU PC200-8 PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00084C0-21 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC200-8 PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00084C0-21 – PDF DOWNLOAD
Language : English
Pages : 1467
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC200-8 PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00084C0-21 – PDF DOWNLOAD
COVER.......................................................................................................... 1 00 Index and foreword.......................................................................................... 3 Index...................................................................................................... 3 Composition of shop manual............................................................................. 4 Table of contents...................................................................................... 6 Foreword and general information........................................................................... 15 Safety notice.......................................................................................... 16 How to read the shop manual............................................................................ 21 Explanation of terms for maintenance standard.......................................................... 23 Handling of electric equipment and hydraulic component................................................. 25 Handling of connectors newly used for engines.......................................................... 34 How to read electric wire code......................................................................... 37 Precautions when carrying out operation................................................................ 40 Method of disassembling and connecting push-pull type coupler.......................................... 43 Standard tightening torque table....................................................................... 46 Conversion table....................................................................................... 50 01 Specification............................................................................................... 57 Specification and technical data........................................................................... 57 Specification dimension drawings....................................................................... 58 Working range diagram.................................................................................. 59 Specifications......................................................................................... 60 Weight table........................................................................................... 64 Table of fuel, coolant and lubricants.................................................................. 68 10 Structure, function and maintenance standard................................................................ 71 Engine and cooling system.................................................................................. 71 Engine related parts................................................................................... 72 Radiator, oil cooler, aftercooler and fuel cooler...................................................... 73 Power train............................................................................................ 75 Power train........................................................................................ 76 Final drive........................................................................................ 78 Swing machinery.................................................................................... 82 Swing circle....................................................................................... 86 Hydraulic system, Part 1................................................................................... 103 Hydraulic equipment layout drawing..................................................................... 104 Hydraulic tank and filter.............................................................................. 106 Hydraulic pump......................................................................................... 108 Pilot oil filter....................................................................................... 130 Hydraulic system, Part 2................................................................................... 133 Control valve.......................................................................................... 134 CLSS................................................................................................... 147 Functions and operation by valve....................................................................... 152 Hydraulic system, Part 3................................................................................... 191 Swing motor............................................................................................ 193 Center swivel joint.................................................................................... 202 Travel motor........................................................................................... 204 PPC valve.............................................................................................. 215 Valve control.......................................................................................... 238 Solenoid valve......................................................................................... 240 PPC accumulator........................................................................................ 242 Anti-drop valve for boom............................................................................... 244 Anti-drop valve for arm................................................................................ 250 Return oil filter...................................................................................... 257 Attachment circuit selector valve...................................................................... 258 Hydraulic cylinder..................................................................................... 260 Work equipment......................................................................................... 265 Work equipment..................................................................................... 266 Dimensions of arm.................................................................................. 277 Dimensions of bucket............................................................................... 279 Cab and its attachments.................................................................................... 283 Air conditioner piping................................................................................. 284 Electrical system.......................................................................................... 287 Engine control......................................................................................... 288 Electrical control system.............................................................................. 296 Monitor system......................................................................................... 319 Sensor................................................................................................. 346 KOMTRAX system......................................................................................... 349 20 Standard value table........................................................................................ 353 Standard service value table............................................................................... 353 Standard value table for engine related parts.......................................................... 354 Standard value table for chassis related parts......................................................... 356 30 Testing and adjusting....................................................................................... 375 Testing and adjusting, Part 1.............................................................................. 375 Tools for testing, adjusting, and troubleshooting...................................................... 377 Sketch of special tool................................................................................. 380 Testing engine speed................................................................................... 381 Testing intake air pressure (boost pressure)........................................................... 382 Testing exhaust gas color.............................................................................. 383 Adjusting valve clearance.............................................................................. 384 Testing compression pressure........................................................................... 386 Testing blow-by pressure............................................................................... 387 Testing engine oil pressure............................................................................ 388 Handling fuel system parts............................................................................. 389 Releasing residual pressure from fuel system........................................................... 389 Testing fuel pressure.................................................................................. 390 Testing fuel delivery, return and leak amount.......................................................... 393 Bleeding air from fuel circuit......................................................................... 396 Checking fuel circuit for leakage...................................................................... 397 Checking and adjusting air conditioner compressor belt tension......................................... 398 Replacing fan belt..................................................................................... 399 Testing swing circle bearing clearance................................................................. 400 Checking and adjusting track shoe tension.............................................................. 401 Inspection and adjustment oil pressure in work equipment, swing, and travel circuits................... 403 Testing control circuit source pressure................................................................ 406 Testing and adjusting oil pressure in pump PC control circuit.......................................... 407 Testing and adjusting oil pressure in pump LS control circuit.......................................... 410 Testing solenoid valve output pressure................................................................. 415 Testing PPC valve output pressure...................................................................... 418 Adjusting play of work equipment and swing PPC valves.................................................. 420 Checking parts which cause hydraulic drift of work equipment........................................... 421 Releasing residual pressure from hydraulic circuit..................................................... 423 Testing oil leakage.................................................................................... 424 Bleeding air from each part............................................................................ 427 Checking cab tipping stopper........................................................................... 429 Adjusting mirrors...................................................................................... 430 Angle adjustment of rear view camera................................................................... 437 Testing and adjusting, Part 2.............................................................................. 441 Special functions of machine monitor................................................................... 442 Testing and adjusting, Part 3.............................................................................. 499 Handling voltage circuit of engine controller.......................................................... 500 Preparation work for troubleshooting of electrical system.............................................. 501 Procedure for testing diodes........................................................................... 506 Pm Clinic service...................................................................................... 507 40 Troubleshooting............................................................................................. 517 Failure code table and fuse locations...................................................................... 517 Failure codes table.................................................................................... 518 Fuse locations......................................................................................... 523 General information on troubleshooting..................................................................... 529 Points to remember when troubleshooting................................................................ 530 Sequence of events in troubleshooting.................................................................. 531 Check before troubleshooting........................................................................... 532 Classification and procedures for troubleshooting...................................................... 533 How to read electric wire code......................................................................... 537 Connection table for connector pin numbers............................................................. 540 T- branch box and T- branch adapter table.............................................................. 576 Troubleshooting by failure code (Display of code), Part 1.................................................. 581 Failure code [989L00].................................................................................. 583 Failure code [989M00].................................................................................. 584 Failure code [989N00].................................................................................. 585 Failure code [AA10NX].................................................................................. 586 Failure code [AB00KE].................................................................................. 588 Failure code [B@BAZG].................................................................................. 590 Failure code [B@BAZK].................................................................................. 591 Failure code [B@BCNS].................................................................................. 592 Failure code [B@BCZK].................................................................................. 593 Failure code [B@HANS].................................................................................. 594 Failure code [CA111]................................................................................... 595 Failure code [CA115]................................................................................... 596 Failure code [CA122]................................................................................... 597 Failure code [CA123]................................................................................... 599 Failure code [CA131]................................................................................... 601 Failure code [CA132]................................................................................... 604 Failure code [CA144]................................................................................... 606 Failure code [CA145]................................................................................... 608 Failure code [CA153]................................................................................... 610 Failure code [CA154]................................................................................... 612 Failure code [CA155]................................................................................... 614 Failure code [CA187]................................................................................... 616 Failure code [CA221]................................................................................... 618 Failure code [CA222]................................................................................... 620 Failure code [CA227]................................................................................... 622 Failure code [CA234]................................................................................... 624 Failure code [CA238]................................................................................... 626 Failure code [CA271]................................................................................... 628 Failure code [CA272]................................................................................... 630 Failure code [CA322]................................................................................... 632 Failure code [CA323]................................................................................... 634 Failure code [CA324]................................................................................... 636 Failure code [CA325]................................................................................... 638 Failure code [CA331]................................................................................... 640 Failure code [CA332]................................................................................... 642 Troubleshooting by failure code (Display of code), Part 2.................................................. 645 Failure code [CA342]................................................................................... 647 Failure code [CA351]................................................................................... 648 Failure code [CA352]................................................................................... 652 Failure code [CA386]................................................................................... 654 Failure code [CA428]................................................................................... 656 Failure code [CA429]................................................................................... 658 Failure code [CA435]................................................................................... 660 Failure code [CA441]................................................................................... 662 Failure code [CA442]................................................................................... 666 Failure code [CA449]................................................................................... 668 Failure code [CA451]................................................................................... 670 Failure code [CA452]................................................................................... 672 Failure code [CA488]................................................................................... 674 Failure code [CA553]................................................................................... 675 Failure code [CA559]................................................................................... 676 Failure code [CA689]................................................................................... 678 Failure code [CA731]................................................................................... 681 Failure code [CA757]................................................................................... 683 Failure code [CA778]................................................................................... 686 Failure code [CA1633].................................................................................. 689 Failure code [CA2185].................................................................................. 690 Failure code [CA2186].................................................................................. 692 Failure code [CA2249].................................................................................. 694 Failure code [CA2311].................................................................................. 695 Failure code [CA2555].................................................................................. 697 Failure code [CA2556].................................................................................. 700 Failure code [D19JKZ].................................................................................. 703 Failure code [D862KA].................................................................................. 706 Failure code [DA22KK].................................................................................. 707 Failure code [DA25KP].................................................................................. 710 Failure code [DA25KP].................................................................................. 714 Failure code [DA29KQ].................................................................................. 718 Failure code [DA29KQ].................................................................................. 721 Troubleshooting by failure code (Display of code), Part 3.................................................. 725 Failure code [DA2RMC].................................................................................. 727 Failure code [DAF8KB].................................................................................. 736 Failure code [DAFGMC].................................................................................. 738 Failure code [DAFRMC].................................................................................. 739 Failure code [DGH2KB].................................................................................. 746 Failure code [DHPAMA].................................................................................. 748 Failure code [DHPBMA].................................................................................. 751 Failure code [DHS3MA].................................................................................. 754 Failure code [DHS4MA].................................................................................. 757 Failure code [DHS8MA].................................................................................. 760 Failure code [DHSAMA].................................................................................. 763 Failure code [DHSBMA].................................................................................. 766 Failure code [DHSDMA].................................................................................. 769 Failure code [DHX1MA].................................................................................. 772 Failure code [DW43KA].................................................................................. 776 Failure code [DW43KB].................................................................................. 778 Failure code [DW45KA].................................................................................. 780 Failure code [DW45KB].................................................................................. 784 Failure code [DW91KA].................................................................................. 786 Failure code [DW91KB].................................................................................. 788 Failure code [DWA2KA].................................................................................. 790 Failure code [DWA2KB].................................................................................. 792 Failure code [DWK0KA].................................................................................. 794 Failure code [DWK0KB].................................................................................. 796 Troubleshooting by failure code (Display of code), Part 4.................................................. 799 Failure code [DXA8KA].................................................................................. 801 Failure code [DXA8KB].................................................................................. 804 Failure code [DXA9KA].................................................................................. 806 Failure code [DXA9KB].................................................................................. 809 Failure code [DXE0KA].................................................................................. 811 Failure code [DXE0KB].................................................................................. 813 Failure code [DXE4KA].................................................................................. 815 Failure code [DXE4KB].................................................................................. 817 Failure code [DXE5KA].................................................................................. 819 Failure code [DXE5KB].................................................................................. 821 Failure code [DXE6KA].................................................................................. 823 Failure code [DXE6KB].................................................................................. 825 Failure code [DY20KA].................................................................................. 827 Failure code [DY20MA].................................................................................. 829 Failure code [DY2CKA].................................................................................. 831 Failure code [DY2CKB].................................................................................. 834 Failure code [DY2DKB].................................................................................. 836 Failure code [DY2EKB].................................................................................. 838 Troubleshooting of electrical system (E-mode).............................................................. 841 Before troubleshooting for electrical system........................................................... 843 Information described in troubleshooting table......................................................... 845 E-1 When starting switch is turned to ON position, machine monitor displays nothing.................... 847 E-2 When starting switch is turned to ON position (with engine stopped), basic check items light up.... 850 E-3 Engine does not start (engine does not crank)...................................................... 853 E-4 Preheating system does not work.................................................................... 860 E-5 Automatic warm-up system does not work (in cold weather)........................................... 865 E-6 For all work equipment, swing, travel, or lock are not available................................... 866 E-7 Caution item lights up while the engine is running................................................. 869 E-8 Emergency stop item lights up while the engine is running.......................................... 876 E-9 Engine coolant temperature gauge does not indicate correct temperature............................. 878 E-10 Hydraulic oil temperature gauge does not indicate correct temperature............................. 880 E-11 Fuel gauge does not indicate correct level........................................................ 883 E-12 Contents of display on machine monitor are different from actual machine condition................ 886 E-13 Some areas of machine monitor screen are not displayed............................................ 887 E-14 Function switch does not work..................................................................... 888 E-15 Auto-deceleration function does not work properly................................................. 889 E-16 Working mode does not change...................................................................... 891 E-17 Speed range does not change....................................................................... 892 E-18 Alarm buzzer does not stop sounding............................................................... 894 E-19 Wiper or window washer does not operate........................................................... 895 E-20 One-touch power maximizing function does not work properly........................................ 899 E-21 Swing parking brake does not work properly........................................................ 903 E-22 Travel alarm does not sound or does not stop sounding............................................. 907 E-23 Air conditioner does not work properly (including air conditioner abnormality record)............. 911 E-24 Service meter is not displayed while the starting switch is turned off............................ 930 E-25 Service mode cannot be selected................................................................... 931 E-26 Lever operation signal is not displayed correctly with monitoring function........................ 932 E-27 KOMTRAX system does not operate normally.......................................................... 944 Troubleshooting of hydraulic and mechanical system (H-mode)................................................ 947 Hydraulic and mechanical system diagram................................................................ 950 Information described in troubleshooting table......................................................... 952 H-1 Work equipment, swing and traveling speed are all slow, or there is no force....................... 953 H-2 Engine speed drops significantly or engine stalls.................................................. 956 H-3 All work equipment, swinging and traveling are not available....................................... 958 H-4 Unusual noise is heard from around hydraulic pump.................................................. 959 H-5 Auto-deceleration function does not work........................................................... 961 H-6 Fine control performance or response is poor....................................................... 962 H-7 Boom speed or power is low......................................................................... 963 H-8 Arm speed or power is low.......................................................................... 967 H-9 Bucket speed or power is low....................................................................... 971 H-10 Work equipment does not move in a single operation................................................ 973 H-11 Hydraulic drift of work equipment is significant.................................................. 974 H-12 Time lag of work equipment is large............................................................... 978 H-13 When certain work equipment is relieved hydraulically, other work equipment will move............. 980 H-14 One-touch power maximization function does not operate............................................ 981 H-15 When operations of work equipment are combined, equipment with heavier loads will move slower..... 982 H-16 Boom RAISE is slow during the Swing + Boom RAISE operation........................................ 983 H-17 When combining swing and travel operations, travel speed will drop significantly.................. 984 H-18 Travel deviation is detected...................................................................... 985 H-19 Travel speed is slow.............................................................................. 987 H-20 Machine is not steered well or steering power is low.............................................. 990 H-21 Travel speed does not change, or travel speed is too slow or fast................................. 994 H-22 One track does not run............................................................................ 996 H-23 Machine does not swing............................................................................ 998 H-24 Swing acceleration or swing speed is low..........................................................1001 H-25 Upper structure overruns excessively when it stops swinging.......................................1004 H-26 Resulting shock is large when the upper structure stops swinging..................................1007 H-27 Unusual loud noise is heard when the upper structure stops swinging...............................1008 H-28 Swing hydraulic drift on a slope is significant...................................................1009 H-29 Attachment circuit cannot be changed..............................................................1012 H-30 Oil flow in the attachment circuit cannot be changed..............................................1013 Troubleshooting of engine (S-mode).........................................................................1015 Method of using troubleshooting chart..................................................................1018 S-1 Starting performance is poor.......................................................................1022 S-2 Engine does not start..............................................................................1023 S-3 Engine does not pick up smoothly...................................................................1026 S-4 Engine stops during operations.....................................................................1027 S-5 Engine does not rotate smoothly....................................................................1028 S-6 Engine lack output (or lacks power)................................................................1029 S-7 Exhaust smoke is black (incomplete combustion).....................................................1030 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................1031 S-9 Oil becomes contaminated quickly...................................................................1032 S-10 Fuel consumption is excessive.....................................................................1033 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................1034 S-12 Oil pressure drops................................................................................1035 S-13 Oil level rises (Entry of coolant/fuel)...........................................................1036 S-14 Coolant temperature becomes too high (overheating)................................................1037 S-15 Abnormal noise is made............................................................................1038 S-16 Vibration is excessive............................................................................1039 50 Disassembly and assembly....................................................................................1041 General information on disassembly and assembly............................................................1041 How to read this manual................................................................................1042 Coating materials list.................................................................................1044 Special tools list.....................................................................................1047 Sketches of special tools..............................................................................1052 Engine and cooling system..................................................................................1059 Removal and installation of fuel supply pump assembly..................................................1060 Removal and installation of fuel injector assembly.....................................................1067 Removal and installation of engine front seal..........................................................1079 Removal and installation of engine rear seal...........................................................1086 Removal and installation of cylinder head assembly.....................................................1090 Removal and installation of radiator assembly..........................................................1111 Removal and installation of hydraulic oil cooler assembly..............................................1117 Removal and installation of aftercooler assembly.......................................................1122 Removal and installation of fuel cooler assembly.......................................................1128 Removal and installation of engine and hydraulic pump assembly.........................................1131 Power train................................................................................................1157 Removal and installation of final drive assembly.......................................................1158 Disassembly and assembly of final drive assembly.......................................................1163 Removal and installation of swing motor and swing machinery assembly...................................1191 Disassembly and assembly of swing motor and swing machinery assembly...................................1197 Removal and installation of swing circle assembly......................................................1209 Undercarriage and frame....................................................................................1213 Disassembly and assembly of carrier roller assembly....................................................1214 Disassembly and assembly of track roller assembly......................................................1218 Removal and installation of idler and recoil spring assembly...........................................1221 Disassembly and assembly of idler assembly.............................................................1224 Disassembly and assembly of recoil spring assembly.....................................................1229 Removal and installation of sprocket...................................................................1232 Separation and connection of track assembly............................................................1234 Removal and installation of revolving frame assembly...................................................1240 Removal and installation of counterweight assembly.....................................................1247 Hydraulic system...........................................................................................1253 Removal and installation of center swivel joint assembly...............................................1254 Disassembly and assembly of center swivel joint assembly...............................................1261 Removal and installation of hydraulic tank assembly....................................................1263 Removal and installation of control valve assembly.....................................................1273 Disassembly and assembly of control valve assembly.....................................................1289 Removal and installation of hydraulic pump assembly....................................................1295 Removal and installation of hydraulic pump input shaft oil seal........................................1305 Disassembly and assembly of work equipment PPC valve assembly..........................................1306 Disassembly and assembly of travel PPC valve assembly..................................................1308 Disassembly and assembly of hydraulic cylinder assembly................................................1311 Work equipment.............................................................................................1319 Removal and installation of work equipment assembly....................................................1320 Removal and installation of boom anti-drop valve assembly..............................................1326 Removal and installation of arm anti-drop valve assembly...............................................1330 Disassembly and assembly of anti-drop valve assembly...................................................1334 Cab and its attachments....................................................................................1337 Removal and installation of operator's cab assembly....................................................1338 Removal and installation of operator's cab glass (adhered window glass)................................1349 Removal and installation of front window assembly......................................................1362 Removal and installation of floor frame assembly.......................................................1371 Electrical system..........................................................................................1381 Removal and installation of air conditioner unit assembly..............................................1382 Removal and installation of KOMTRAX terminal assembly..................................................1391 Removal and installation of machine monitor assembly...................................................1394 Removal and installation of pump controller assembly...................................................1397 Removal and installation of engine controller assembly.................................................1401 90 Diagrams and drawings.......................................................................................1407 Hydraulic diagrams and drawings............................................................................1407 Hydraulic circuit diagram..............................................................................1409 Hydraulic circuit diagram (Boom RAISE).................................................................1410 Hydraulic circuit diagram (Swing LEFT).................................................................1411 Hydraulic circuit diagram (Boom RAISE + Swing LEFT)....................................................1412 Hydraulic circuit diagram..............................................................................1413 Hydraulic circuit diagram..............................................................................1414 Electrical diagrams and drawings...........................................................................1417 Electrical circuit diagram.............................................................................1419 Electrical circuit diagram for air conditioner.........................................................1425 Connector/electrical wiring connection table...........................................................1426 Connector arrangement diagram..........................................................................1456 Wiring harness diagram.................................................................................1457
DESCRIPTION:
KOMATSU PC200-8 PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00084C0-21 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A Always wear safety glasses when hitting parts with a hammer.
B Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 29/12/24
