Komatsu HYDRAULIC EXCAVATOR PC200-8,PC200LC-8,PC240LC-8 Shop Manual PDF

Description

Komatsu HYDRAULIC EXCAVATOR PC200-8,PC200LC-8,PC240LC-8 Shop Manual KEN00084-13 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC200-8,PC200LC-8,PC240LC-8 Shop Manual KEN00084-13 – PDF DOWNLOAD

Language : English
Pages : 1148
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC200-8,PC200LC-8,PC240LC-8 Shop Manual KEN00084-13 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC200- B30001
  PC200LC-B30001
  PC240LC-B10001

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
HYDRAULIC EXCAVATOR 71
SHOP MANUAL 71
PC200-8 71
PC200LC-8 71
PC240LC-8 71
Machine model Serial number 71
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
Power train 76
Final drive 78
Swing machinery 84
Swing circle . 88
Undercarriage and frame 91
Undercarriage and frame 92
Track frame and recoil spring 92
Idler 94
Carrier roller . 96
Track roller . 97
Track shoe . 98
Hydraulic system, Part 1 . 105
Hydraulic system, Part 1 . 106
Hydraulic equipment layout drawing . 106
Hydraulic tank and filter 108
Hydraulic pump . 110
Pilot oil filter . 132
Hydraulic system, Part 2 . 135
Hydraulic system, Part 2 . 136
Control valve 136
CLSS . 149
Functions and operation by valve . 154
Hydraulic system, Part 3 . 193
Hydraulic system, Part 3 . 195
Swing motor 195
Center swivel joint 204
Travel motor . 206
PPC valve 217
Work equipment and swing PPC valve . 217
Travel PPC valve . 223
Service PPC valve (with EPC valve) . 232
Service PPC valve 238
Valve control 240
Solenoid valve . 242
PPC accumulator 244
Return oil filter 245
Attachment circuit selector valve 246
Hydraulic cylinder . 248
Work equipment . 253
Work equipment . 254
Dimensions of arm 265
Dimensions of bucket . 267
Cab and its attachments 271
Cab and its attachments 272
Air conditioner piping . 272
Electrical system 275
Electrical system 276
Engine control . 276
Electrical control system 284
Monitor system . 307
Sensor . 334
KOMTRAX system . 337
20 Standard value table 341
Standard service value table . 341
Standard value table for engine related parts 342
Standard value table for chassis related parts . 344
30 Testing and adjusting . 363
Testing and adjusting, Part 1 363
Tools for testing, adjusting, and troubleshooting 365
Sketch of special tool . 368
Testing engine speed . 369
Testing intake air pressure (boost pressure) . 370
Testing exhaust gas color 371
Adjusting valve clearance 372
Testing compression pressure . 374
Testing blow-by pressure . 375
Testing engine oil pressure 376
Handling fuel system parts . 377
Releasing residual pressure from fuel system . 377
Testing fuel pressure 378
Testing fuel delivery, return and leak amount 381
Bleeding air from fuel circuit . 384
Checking fuel circuit for leakage 385
Checking and adjusting air conditioner compressor belt tension . 386
Replacing fan belt . 387
Testing swing circle bearing clearance . 388
Checking and adjusting track shoe tension 389
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits . 391
Testing control circuit source pressure 394
Testing and adjusting oil pressure in pump PC control circuit 395
Testing and adjusting oil pressure in pump LS control circuit 398
Testing solenoid valve output pressure . 403
Testing PPC valve output pressure 406
Adjusting play of work equipment and swing PPC valves 408
Checking parts which cause hydraulic drift of work equipment . 409
Releasing residual pressure from hydraulic circuit . 411
Testing oil leakage 412
Bleeding air from each part 415
Checking cab tipping stopper . 417
Adjusting mirrors 418
Installation and adjustment of mirrors . 419
Angle adjustment of rear view camera . 425
Testing and adjusting, Part 2 429
Special functions of machine monitor . 430
Testing and adjusting, Part 3 487
Handling voltage circuit of engine controller 488
Preparation work for troubleshooting of electrical system 489
Procedure for testing diodes . 494
Pm Clinic service 495
40 Troubleshooting . 505
Failure code table and fuse locations 505
Failure codes table 506
Fuse locations . 511
General information on troubleshooting . 517
Points to remember when troubleshooting 518
Sequence of events in troubleshooting 519
Check before troubleshooting . 520
Classification and procedures for troubleshooting 521
How to read electric wire code . 525
Connection table for connector pin numbers . 528
T- branch box and T- branch adapter table 564
Troubleshooting by failure code (Display of code), Part 1 569
Failure code [989L00] Engine Controller Lock Caution 1 . 572
Failure code [989M00] Engine Controller Lock Caution 2 . 572
Failure code [989N00] Engine Controller Lock Caution 3 . 573
Failure code [AA10NX] Air Cleaner Clogging . 573
Failure code [AB00KE] Charge Voltage Low . 574
Failure code [B@BAZG] Eng Oil Press. Low . 576
Failure code [B@BAZK] Eng Oil Level Low 576
Failure code [B@BCNS] Eng Water Overheat . 577
Failure code [B@BCZK] Eng Water Level Low 577
Failure code [B@HANS] Hydr Oil Overheat 578
Failure code [CA111] EMC Critical Internal Failure . 578
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 579
Failure code [CA122] Chg Air Press Sensor High Error . 580
Failure code [CA123] Chg Air Press Sensor Low Error 582
Failure code [CA131] Throttle Sensor High Error 584
Failure code [CA132] Throttle Sensor Low Error . 586
Failure code [CA144] Coolant Temp Sens High Error 588
Failure code [CA145] Coolant Temp Sens Low Error . 590
Failure code [CA153] Chg Air Temp Sensor High Error 592
Failure code [CA154] Chg Air Temp Sensor Low Error . 594
Failure code [CA155] Chg Air Temp High Speed Derate 596
Failure code [CA187] Sens Supply 2 Volt Low Error 598
Failure code [CA221] Ambient Press Sens High Error . 600
Failure code [CA222] Ambient Press Sens Low Error 602
Failure code [CA227] Sens Supply 2 Volt High Error . 604
Failure code [CA234] Eng Overspeed . 605
Failure code [CA238] Ne Speed Sens Supply Volt Error . 606
Failure code [CA271] IMV/PCV1 Short Error 607
Failure code [CA272] IMV/PCV1 Open Error . 608
Failure code [CA322] Inj #1 Open/Short Error . 610
Failure code [CA323] Inj #5 Open/Short Error . 612
Failure code [CA324] Inj #3 Open/Short Error . 614
Failure code [CA325] Inj #6 Open/Short Error . 616
Failure code [CA331] Inj #2 Open/Short Error . 618
Failure code [CA332] Inj #4 Open/Short Error . 620
Troubleshooting by failure code (Display of code), Part 2 623
Failure code [CA342] Calibration Code Incompatibility 625
Failure code [CA351] Injectors Drive Circuit Error . 626
Failure code [CA352] Sens Supply 1 Volt Low Error 628
Failure code [CA386] Sens Supply 1 Volt High Error . 630
Failure code [CA428] Water in Fuel Sensor High Error . 632
Failure code [CA429] Water in Fuel Sensor Low Error 634
Failure code [CA435] Eng Oil Press Sw Error 636
Failure code [CA441] Battery Voltage Low Error . 637
Failure code [CA442] Battery Voltage High Error 640
Failure code [CA449] Rail Press Very High Error 642
Failure code [CA451] Rail Press Sensor High Error 644
Failure code [CA452] Rail Press Sensor Low Error . 646
Failure code [CA488] Chg Air Temp High Torque Derate . 648
Failure code [CA553] Rail Press High Error . 649
Failure code [CA559] Rail Press Low Error 650
Failure code [CA689] Eng Ne Speed Sensor Error . 652
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 654
Failure code [CA757] All Continuous Data Lost Error 656
Failure code [CA778] Eng Bkup Speed Sensor Error . 658
Failure code [CA1633] KOMNET Datalink Timeout Error 660
Failure code [CA2185] Throt Sens Sup Volt High Error . 661
Failure code [CA2186] Throt Sens Sup Volt Low Error 662
Failure code [CA2249] Rail Press Very Low Error 663
Failure code [CA2311] IMV Solenoid Error . 664
Failure code [CA2555] Grid Htr Relay Volt High Error . 666
Failure code [CA2556] Grid Htr Relay Volt Low Error 668
Failure code [D19JKZ] Personal Code Relay Abnormality 670
Failure code [D862KA] GPS Antenna Discon . 672
Failure code [DA22KK] Pump Solenoid Power Low Error 673
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 675
Failure code [DA29KQ] Model Selection Abnormality 682
Troubleshooting by failure code (Display of code), Part 3 687
Failure code [DA2RMC] CAN Discon (Pump Con Detected) . 690
Failure code [DAF8KB] Short circuit in camera power supply . 696
Failure code [DAFGMC] GPS Module Error . 698
Failure code [DAFRMC] CAN Discon (Monitor Detected) 700
Failure code [DGH2KB] Hydr Oil Sensor Short 704
Failure code [DHPAMA] F Pump Press Sensor Abnormality 706
Failure code [DHPBMA] R Pump Press Sensor Abnormality 708
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 710
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality . 712
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 714
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 716
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 718
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality . 720
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) . 723
Failure code [DW43KA] Travel Speed Sol Discon 726
Failure code [DW43KB] Travel Speed Sol Short . 728
Failure code [DW45KA] Swing Brake Sol Discon . 730
Failure code [DW45KB] Swing Brake Sol Short 732
Failure code [DW91KA] Travel Junction Sol Discon . 734
Failure code [DW91KB] Travel Junction Sol Short 736
Failure code [DWA2KA] Service Sol Discon . 738
Failure code [DWA2KB] Service Sol Short 739
Failure code [DWK0KA] 2-stage Relief Sol Discon 740
Failure code [DWK0KB] 2-stage Relief Sol Short . 742
Troubleshooting by failure code (Display of code), Part 4 745
Failure code [DXA8KA] PC-EPC (F) Sol Discon 746
Failure code [DXA8KB] PC-EPC (F) Sol Short . 748
Failure code [DXA9KA] PC-EPC (R) Sol Discon 750
Failure code [DXA9KB] PC-EPC (R) Sol Short . 752
Failure code [DXE0KA] LS-EPC Sol Discon 754
Failure code [DXE0KB] LS-EPC Sol Short . 756
Failure code [DXE4KA] Service Current EPC Discon . 758
Failure code [DXE4KB] Service Current EPC Short 760
Failure code [DXE5KA] Merge-divider Main Sol Discon 762
Failure code [DXE5KB] Merge-divider Main Sol Short . 764
Failure code [DXE6KA] Merge-divider LS Sol Discon 766
Failure code [DXE6KB] Merge-divider LS Sol Short . 768
Failure code [DY20KA] Wiper Working Abnormality 770
Failure code [DY20MA] Wiper Parking Abnormality 772
Failure code [DY2CKA] Washer Drive Discon 774
Failure code [DY2CKB] Washer Drive Short . 776
Failure code [DY2DKB] Wiper Drive (For) Short 778
Failure code [DY2EKB] Wiper Drive (Rev) Short 780
Troubleshooting of electrical system (E-mode) 783
Before carrying out troubleshooting of electrical system . 785
Information in troubleshooting table . 787
E-1 When starting switch turned ON, machine monitor displays nothing . 788
E-2 When starting switch turned ON (before starting engine), basic check item lights up 790
E-3 Engine does not start (Engine does not turn) . 792
E-4 Preheater does not operate . 796
E-5 Automatic warm-up system does not operate (in cold season) . 800
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 802
E-7 Precaution lights up while engine is running . 804
E-8 Emergency stop item lights up while engine is running 810
E-9 Engine coolant temperature gauge does not indicate normally 811
E-10 Hydraulic oil temperature gauge does not indicate normally 812
E-11 Fuel level gauge does not indicate normally . 815
E-12 Contents of display by machine monitor are different from applicable machine 817
E-13 Machine monitor does not display some items . 817
E-14 Function switch does not work . 817
E-15 Auto-decelerator does not operate normally 818
E-16 Working mode does not change 819
E-17 Travel speed does not change 820
E-18 Alarm buzzer cannot be stopped 821
E-19 Windshield wiper and window washer do not operate . 822
E-20 Power maximizing function does not operate normally . 824
E-21 Swing holding brake does not operate normally . 826
E-22 Travel alarm does not sound or does not stop sounding . 828
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 830
E-24 While starting switch is in OFF position, service meter is not displayed 841
E-25 Machine monitor cannot be set in service mode . 841
E-26 Monitoring function does not display lever control signal normally 842
E-27 KOMTRAX system does not operate normally 850
Troubleshooting of hydraulic and mechanical system (H-mode) 853
System diagram of hydraulic and mechanical system 856
Information in troubleshooting table . 858
H-1 Speed or power of whole work equipment, swing, and travel is low . 859
H-2 Engine speed lowers significantly or engine stalls . 861
H-3 Work equipment, swing, and travel systems do not work 862
H-4 Abnormal sound comes out from around hydraulic pump 862
H-5 Auto-decelerator does not operate 863
H-6 Fine control performance or response is low 863
H-7 Speed or power of boom is low 864
H-8 Speed or power of arm is low . 865
H-9 Speed or power of bucket is low 866
H-10 Work equipment does not move singly . 866
H-11 Hydraulic drift of work equipment is large 867
H-12 Time lag of work equipment is large . 869
H-13 When part of work equipment is relieved singly, other parts of work equipment move 869
H-14 Power maximizing function does not work . 870
H-15 In compound operation of work equipment, speed of part loaded more is low . 870
H-16 When machine swings and raises boom simultaneously, boom rising speed is low 871
H-17 When machine swings and travels simultaneously, travel speed is low . 871
H-18 Machine deviates during travel 872
H-19 Travel speed is low . 873
H-20 Machine is not steered well or steering power is low 874
H-21 Travel speed does not change or travel speed is low/high 875
H-22 Travel system does not move (only one side) . 876
H-23 Upper structure does not swing 877
H-24 Swing acceleration or swing speed is low 879
H-25 Upper structure overruns remarkably when it stops swinging 880
H-26 Large shock is made when upper structure stops swinging . 881
H-27 Large sound is made when upper structure stops swinging . 881
H-28 Hydraulic drift of swing is large . 882
H-29 Attachment circuit is not changed . 883
H-30 Oil flow in attachment circuit cannot be controlled . 883
Troubleshooting of engine (S-mode) . 885
Method of using troubleshooting chart 888
S-1 Starting performance is poor . 892
S-2 Engine does not start 893
S-3 Engine does not pick up smoothly . 896
S-4 Engine stops during operations . 897
S-5 Engine does not rotate smoothly 898
S-6 Engine lack output (or lacks power) 899
S-7 Exhaust smoke is black (incomplete combustion) . 900
S-8 Oil consumption is excessive (or exhaust smoke is blue) 901
S-9 Oil becomes contaminated quickly . 902
S-10 Fuel consumption is excessive . 903
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) . 904
S-12 Oil pressure drops 905
S-13 Oil level rises (Entry of coolant/fuel) . 906
S-14 Coolant temperature becomes too high (overheating) 907
S-15 Abnormal noise is made 908
S-16 Vibration is excessive 909
50 Disassembly and assembly 911
General information on disassembly and assembly 911
How to read this manual 912
Coating materials list . 914
Special tools list . 917
Sketches of special tools 922
Engine and cooling system 929
Removal and installation of fuel supply pump assembly 930
Removal and installation of fuel injector assembly . 934
Removal and installation of engine front seal 942
Removal and installation of engine rear seal . 945
Removal and installation of cylinder head assembly . 948
Removal and installation of radiator assembly 962
Removal and installation of hydraulic oil cooler assembly 965
Removal and installation of aftercooler assembly . 967
Removal and installation of fuel cooler assembly . 970
Removal and installation of engine and hydraulic pump assembly . 971
Power train 981
Removal and installation of final drive assembly . 982
Disassembly and assembly of final drive assembly . 984
Removal and installation of swing motor and swing machinery assembly .1009
Disassembly and assembly of swing motor and swing machinery assembly .1011
Removal and installation of swing circle assembly 1021
Undercarriage and frame 1023
Disassembly and assembly of carrier roller assembly 1024
Disassembly and assembly of track roller assembly 1027
Removal and installation of idler, recoil spring assembly 1029
Disassembly and assembly of idler assembly .1030
Disassembly and assembly of recoil spring assembly .1033
Removal and installation of sprocket .1035
Expansion and installation of track shoe assembly 1036
Removal and installation of revolving frame assembly .1038
Removal and installation of counterweight assembly .1040
Hydraulic system .1043
Removal and installation of center swivel joint assembly .1044
Disassembly and assembly of center swivel joint assembly .1046
Removal and installation of hydraulic tank assembly 1047
Removal and installation of control valve assembly .1051
Disassembly and assembly of control valve assembly .1056
Removal and installation of hydraulic pump assembly 1060
Removal and installation of oil seal in hydraulic pump input shaft .1064
Disassembly and assembly of work equipment PPC valve assembly 1065
Disassembly and assembly of travel PPC valve assembly 1067
Disassembly and assembly of hydraulic cylinder assembly 1070
Work equipment .1077
Removal and installation of work equipment assembly 1078
Cab and its attachments 1083
Removal and installation of operator’s cab assembly 1084
Removal and installation of operator cab glass (stuck glass) .1087
Removal and installation of front window assembly 1097
Removal and installation of floor frame assembly .1104
Electrical system 1109
Removal and installation of air conditioner unit assembly 1110
Removal and installation of KOMTRAX communication modem assembly .1113
Removal and installation of monitor assembly .1114
Removal and installation of pump controller assembly .1116
Removal and installation of engine controller assembly .1118
90 Diagrams and drawings .1121
Hydraulic diagrams and drawings 1121
Hydraulic circuit diagram (PC240LC-8) 5 1121
Hydraulic circuit diagram 1123
Hydraulic circuit diagram 1125
Electrical diagrams and drawings .1129
Electrical circuit diagram (1/6) .1131
Electrical circuit diagram (2/6) .1133
Electrical circuit diagram (3/6) .1135
Electrical circuit diagram (4/6) .1137
Electrical circuit diagram (5/6) .1139
Electrical circuit diagram (6/6) .1141
Connector arrangement diagram 1143
Electrical circuit diagram for air conditioner .1145

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC200-8,PC200LC-8,PC240LC-8 Shop Manual KEN00084-13 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC200- B30001
  PC200LC-B30001
  PC240LC-B10001

G.B 22/ 12/24