Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-10 PDF

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Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-10  – PDF DOWNLOAD

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Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-10  – PDF DOWNLOAD

Language : English
Pages : 2214
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-10  – PDF DOWNLOAD

• SERIAL NUMBERS 700001 and up

Cover . 1
00 Index and Foreword 3
Index 4
Abbreviation List 16
Foreword, Safety, Basic Information 19
How to Read the Shop Manual 19
Safety Notice for Operation 21
Precautions to Prevent Fire 29
Procedures If Fire Occurs 30
Precautions When You Dispose of Waste Materials 31
Precautions When You Handle Hydraulic Equipment 32
Precautions When You Disconnect and Connect Pipings 35
Precautions When You Handle Electrical Equipment . 42
Precautions When You Handle Fuel System Equipment 44
Precautions When You Handle Intake System Equipment 45
Practical Use of KOMTRAX . 46
Disconnect and Connect Push-Pull Type Coupler 47
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 47
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 48
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 49
Precautions for Disconnection and Connection of Connectors . 51
How to Disconnect and Connect Deutsch Connector 55
How to Disconnect and Connect Slide Lock Type Connector 56
How to Disconnect and Connect Connector with Lock to Pull 58
How to Disconnect and Connect Connector with Lock to Push 59
How to Disconnect and Connect Connector with Housing to Rotate . 61
How to Read the Codes for Electric Cable . 62
Explanation of Terms for Maintenance Standard 66
Standard Tightening Torque Table . 69
Conversion Table . 76
01 Specifications 81
Table of Contents 82
Specifications . 83
Specification Drawing 83
Specification Drawing: PC200-10M0 83
Working Range Drawings . 85
Working Range: PC200-10M0 85
Specifications . 87
Specifications PC200-10M0 87
Weight Table . 90
Weight Table: PC200-10M0 . 90
Fuel, Coolant and Lubricant to Meet Ambient Temperature 92
10 Structure and Function 95
Table of Contents 96
Boot-up System . 99
Layout Drawing of Boot-up System . 99
System Operating Lamp System . 100
System Diagram of System Operating Lamp System . 100
Function of Operation Lamp System 100
Operation of System Operating Lamp . 100
Battery Disconnect Switch 101
Function of Battery Disconnect Switch 101
Operation of Battery Disconnect Switch . 101
Engine System 102
Layout Drawing of Engine System 102
Engine Control System 103
System Diagram of Engine Control . 103
Operation of Engine Control System . 103
Auto-Deceleration System . 105
System Diagram of Auto-Deceleration System . 105
Function of Auto-Deceleration System . 105
Operation of Auto-Deceleration System 106
Engine Automatic Warm-up System 107
System Diagram of Engine Automatic Warm-up System 107
Function of Engine Automatic Warm-up System 108
Operation of Engine Automatic Warm-up System . 108
Overheat Prevention System . 109
Overheat Prevention System Diagram . 109
Function of Overheat Prevention System . 110
Operation of Overheat Prevention System 110
Turbocharger Protection System . 112
Function of Turbocharger Protection System . 112
Cooling System . 113
Layout Drawing of Cooling System . 113
Specifications of Cooling System . 114
Control System . 115
Layout Drawing of Control System . 115
Machine Monitor System . 117
System Diagram of Machine Monitor System . 117
Function of Machine Monitor System . 117
KOMTRAX System . 119
System Diagram of KOMTRAX System . 119
Function of KOMTRAX System . 119
Component Parts of Control System 120
Machine Monitor 120
Gateway Function Controller 131
Pump Controller 134
Resistor for PC-EPC Valve 138
CAN Terminating Resistor . 138
Engine Controller 139
Fuel Control Dial 143
Hydraulic System . 144
Layout Drawing of Hydraulic System . 144
CLSS . 147
System Diagram of CLSS . 147
Function of CLSS . 148
Pressure Compensation Control 165
Engine and Pump Combined Control System 166
Engine and Pump Combined Control System Diagram 166
Function of Engine and Pump Combined Control System 167
Pump and Valve Control System 171
Pump and Valve Control System Diagram 171
Function of Pump and Valve Control System 172
Component Parts of Hydraulic System 174
Hydraulic Tank . 174
Main Pump 176
Control Valve 196
Work Equipment System 240
Layout Drawing of Work Equipment System 240
One-Touch Power Maximizing System 244
System Diagram of One-Touch Power Maximizing System 244
Function of One-Touch Power Maximizing System 245
PPC Lock System 246
System Diagram of PPC Lock . 246
Function of PPC Lock System 247
Attachment Oil Flow Adjuster System 248
Attachment Oil Flow Adjuster System Diagram 248
Function of Attachment Oil Flow Adjuster System 249
Component Parts of Work Equipment System . 250
Work Equipment and Swing PPC Valve . 250
1st-Line Attachment PPC Valve (with EPC Valve) . 254
2nd-Line Attachment PPC Valve 258
Solenoid Valve . 262
Attachment Circuit Selector Valve (For High Pressure) 264
Attachment Circuit Selector Valve (For Low Pressure) . 266
Pilot Circuit Accumulator 268
Attachment Circuit Accumulator . 268
Swing System . 271
Layout Drawing of Swing System . 271
Swing Control System Diagram . 273
Function of Swing Control System . 273
Component Parts of Swing System 277
Swing Motor 277
Swing Machinery 283
Swing Circle . 286
Travel System 287
Layout Drawing of Travel System 287
System Diagram of Travel Control System 289
Function of Travel Control System 290
Component Parts of Travel System . 291
Travel Motor . 291
Final Drive 302
Travel PPC Valve . 303
Center Swivel Joint 308
Function of Swing Circle . 310
Undercarriage and Frame 311
Layout Drawing of Undercarriage 311
Specifications of Undercarriage 311
Work Equipment . 313
Structure of Work Equipment 313
Work Equipment Clearance Adjustment Shim . 314
Function of Work Equipment Clearance Adjustment Shim . 314
Bucket Clearance Adjustment Shim . 315
Function of Bucket Clearance Adjustment Shim . 315
CAB Related Parts 316
ROPS CAB . 316
Structure of ROPS CAB 316
Function of ROPS CAB . 316
CAB Mount 317
Structure of CAB Mount . 317
Function of CAB Mount 318
CAB Tipping Stopper 319
Structure of CAB Tipping Stopper . 319
Function of CAB Tipping Stopper 319
20 Standard Value Table 321
Table of Contents 322
Standard Value Table for Engine 323
Standard Value Table for Engine: PC200-10M0 323
Standard Value Table for Machine: PC200-10M0 . 327
Machine Posture and Procedures to Measure Performance 340
30 Testing and Adjusting . 343
Table of Contents 344
Precautions Before Work 347
Related Information on Testing and Adjusting . 348
Tools for Testing and Adjusting 348
Sketch of Tools for Testing and Adjusting 353
Engine and Cooling System 355
Examine Engine Speed . 355
How to Examine Engine High Idle Speed 355
How to Examine Engine Low Idle Speed . 355
How to Examine Engine Speed at 2 Pump Relief . 355
Test Engine Speed at 2 Pumps Relief and One-touch Power Maximizing . 356
How to Examine Engine Speed with Auto-Deceleration . 356
Examine Boost Pressure . 358
How to Examine Boost Pressure on Machine Monitor . 358
How to Examine Boost Pressure by Testing Tool 359
Examine Exhaust Gas Color 361
How to Examine Exhaust Gas Color with the Handy Smoke Checker 361
How to Examine Exhaust Gas Color with Smoke Meter 362
Examine and Adjust Valve Clearance . 364
How to Examine Valve Clearance . 364
How to Adjust Valve Clearance 365
Examine Compression Pressure . 367
How to Examine Compression Pressure 367
Examine Blowby Pressure 370
How to Examine Blowby Pressure on Machine Monitor (Machine with Blowby Pressure Sensor (OPT)) 370
How to Examine Blowby Pressure (Machine Without Blowby Pressure Sensor) 371
Examine Engine Oil Pressure 373
How to Examine Engine Oil Pressure . 373
Examine Fuel Pressure 375
How to Examine Fuel Pressure . 376
Examine Fuel Discharge, Return and Leakage . 381
How to Examine Fuel Discharge, Return, and Leakage . 382
Bleed Air from Fuel System . 386
How to Bleed Air from Fuel System 386
Examine Fuel Circuit for Leakage . 388
How to Examine Fuel System for Leakage . 388
Handle Cylinder Cut-out Mode Operation . 390
Handle No-Injection Cranking Operation . 391
Examine and Adjust Air Conditioner Compressor Belt Tension . 392
How to Examine Air Conditioner Compressor Belt . 392
How to Adjust Air Conditioner Compressor Belt 392
Power Train 394
Examine Swing Circle Bearing Clearance . 394
How to Examine Swing Circle Bearing Clearance 394
Undercarriage and Frame 395
Examine and Adjust Track Tension . 395
How to Examine Track Tension . 395
How to Adjust Track Tension 395
Hydraulic System . 397
Release Remained Pressure in Hydraulic Circuit . 397
How to Release Remained Pressure from Hydraulic Tank . 397
How to Release Remained Pressure in Hydraulic Cylinder Circuit . 397
How to Release Remained Pressure for Machines Without Anti-drop Valve 397
How to Release Remained Pressure for Machines with Boom Anti-drop Valve 397
How to Release Remained Pressure from Swing Motor Circuit 399
How to Release Remained Pressure from Travel Motor Circuit . 399
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 400
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 400
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 407
Examine Oil Pressure of Control Circuit 409
How to Examine Oil Pressure in Control Circuit . 409
Examine and adjust oil pressure in pump PC control circuit . 411
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 411
How to Examine PC-EPC Valve Outlet Pressure 412
How to Adjust Oil Pressure in Pump PC Control Circuit 413
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 415
How to Examine LS Differential Pressure with Machine Monitor . 415
How to Examine LS Differential Pressure by Testing Tool 417
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 418
How to Examine LS-EPC Valve Outlet Pressure 420
How to Adjust LS Valve . 421
Examine Outlet Pressure of Solenoid Valve 422
How to Examine Outlet Pressure of Solenoid Valve . 422
Operating Condition of Solenoid Valve 424
Examine PPC Valve Outlet Pressure 426
How to Examine PPC Valve Outlet Pressure on Machine Monitor 426
How to Examine PPC Valve Outlet Pressure by Testing Tool . 427
Adjust Play of Work Equipment and Swing PPC Valve 430
How to Adjust play of work equipment and swing PPC valve . 430
Examine parts which cause hydraulic drift of work equipment 431
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 431
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 431
How to Examine Parts Which Cause Hydraulic Drift of Boom Hydraulic Drift Prevention Valve 432
How to Examine Parts Which Cause Hydraulic Drift of PPC Valve 432
Examine Oil Leakage 433
How to Examine Oil Leakage from Boom Cylinder 433
How to Examine Oil Leakage from Arm Cylinder . 434
How to Examine Oil Leakage from Bucket Cylinder 435
How to Examine Oil Leakage from Swing Motor 435
How to Examine Oil Leakage from Travel Motor . 436
Bleed Air from Hydraulic System 438
How to Bleed Air from Main Pump 439
How to Bleed Air from Cylinder . 440
How to Bleed Air from Swing Motor 441
How to Bleed Air from Travel Motor . 441
CAB Related Parts 443
Examine CAB Tipping Stopper 443
How to Examine Cab Tipping Stopper . 443
How to Adjust Mirrors 444
How to Adjust Machine Left Front Mirror (A) 444
Adjust regular position of machine left front mirror (A) . 445
How to Adjust Machine Right Front Mirror (B) . 446
How to Adjust Regular Position of Machine Right Front Mirror (B) . 446
How to Adjust Machine Right Side Mirror (C) 447
Electrical System 449
Set and Operate Machine Monitor 449
Operator Mode 453
Function to Show Technician Identification Status Screen . 453
Function to Show Operator Identification Input Screen 453
Examine Function by LCD (Liquid Crystal Display) . 454
Examine Function of Service Meter 454
How to Set Usage Limitation and Change Maintenance Password 454
Service Mode . 457
How to Operate Service Mode 457
How to See Pre-defined Monitoring Information 458
How to Examine Monitoring Information 463
Abnormality Record Menu 470
How to See Maintenance Record 473
Maintenance Mode Setting . 475
How to Set Phone Number Entry 479
Default Setting Menu . 480
Testing Menu . 489
Adjustment Menu 492
No-Injection Cranking Operation 504
KOMTRAX Settings Menu 507
How to Show Service Message 509
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 511
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) . 517
Adjust Rearview Camera Angle . 519
How to Adjust Rearview Camera Angle 519
Handle Voltage Circuit of Engine Controller 521
Examine Diodes . 522
How to Examine Diodes by Digital Tester 522
How to Examine Diodes by Analog Tester . 522
Pm Clinic 523
Pm Clinic Service 523
Pm Clinic Check Sheet: PC200-10M0 526
40 Troubleshooting . 535
Table of Contents 536
Precautions Before Work 542
Related Information for Troubleshooting 543
Precautions for Troubleshooting 543
Sequence of Events in Troubleshooting 544
Checks Before Troubleshooting 546
Inspection Procedure Before Troubleshooting 548
Walk-Around Check 548
Examine Engine Related Parts . 549
Examine Work Equipment and Undercarriage . 551
Examine Electric Equipment . 552
How to Connect Adapter for Troubleshooting Controller 557
How to Connect Adapter for Troubleshooting Machine Monitor . 557
How to Connect Adapter to Troubleshoot Pump Controller . 559
How to Connect Adapter to Troubleshoot KOMTRAX Terminal 563
How to Connect Adapter for Troubleshooting Engine Controller . 565
How to Connect Adapter to Troubleshoot Engine Intermediate Connector . 566
Disconnect and Connect Connector with Lock to Push . 568
How to Disconnect and Connect Deutsch Connector 568
How to Disconnect and Connect BOSCH Connector 568
How to Disconnect and Connect AMP Connector 569
How to Disconnect and Connect SUMITOMO Connector . 570
How to Disconnect and Connect Connector with Lock to Pull 571
How to Disconnect and Connect DELPHI Connector and PACKARD Connector . 571
How to Disconnect and Connect Slide Type Connector . 572
How to Disconnect and Connect Framatome Connector 572
How to Disconnect and Connect TYCO Connector . 573
How to Disconnect and Connect Connector with Housing to Rotate . 574
Procedure for Troubleshooting 575
Information Shown in Troubleshooting . 576
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 579
Connector List and Layout 582
Connector Contact Connection Table . 594
T-Branch Box and T-Branch Adapter Table 636
Fuse Location and Connection Table . 642
Drawing of Short Circuit Electrical Connector for Troubleshooting 644
Failure Code Table . 646
Troubleshooting by Failure Code (Display of Code) 654
Failure Code [602KNX] 654
Failure Code [6AZ0ZG] 657
Failure Code [879AKA] 661
Failure Code [879AKB] 663
Failure Code [879BKA] 665
Failure Code [879BKB] 668
Failure Code [879CKA] 671
Failure Code [879CKB] 673
Failure Code [879DKZ] 675
Failure Code [879EMC] 678
Failure Code [879FMC] 680
Failure Code [879GKX] 682
Failure Code [989L00] 685
Failure Code [989M00] 687
Failure Code [989N00] 689
Failure Code [A900FR] 690
Failure Code [A900N6] 691
Failure Code [A900NY] 692
Failure Code [AA10NX] 693
Failure Code [AB00KE] 696
Failure Code [B@BAZG] 700
Failure Code [B@BAZK] 701
Failure Code [B@BCZK] 704
Failure Code [B@BCNS] 706
Failure Code [B@BCQA] 707
Failure Code [B@HANS] 709
Failure Code [CA111] . 712
Failure Code [CA115] . 713
Failure Code [CA122] . 714
Failure Code [CA123] . 716
Failure Code [CA131] . 718
Failure Code [CA132] . 720
Failure Code [CA135] . 722
Failure Code [CA141] . 725
Failure Code [CA144] . 728
Failure Code [CA145] . 730
Failure Code [CA153] . 732
Failure Code [CA154] . 734
Failure Code [CA155] . 736
Failure Code [CA187] . 737
Failure Code [CA221] . 739
Failure Code [CA222] . 741
Failure Code [CA227] . 743
Failure Code [CA234] . 744
Failure Code [CA238] . 745
Failure Code [CA271] . 747
Failure Code [CA272] . 749
Failure Code [CA322] . 751
Failure Code [CA324] . 753
Failure Code [CA331] . 755
Failure Code [CA332] . 757
Failure Code [CA342] . 759
Failure Code [CA351] . 760
Failure Code [CA352] . 761
Failure Code [CA386] . 763
Failure Code [CA428] . 764
Failure Code [CA429] . 766
Failure Code [CA435] . 768
Failure Code [CA441] . 770
Failure Code [CA442] . 772
Failure Code [CA449] . 773
Failure Code [CA451] . 774
Failure Code [CA452] . 776
Failure Code [CA488] . 778
Failure Code [CA553] . 779
Failure Code [CA559] . 780
Failure Code [CA689] . 782
Failure Code [CA731] . 784
Failure Code [CA757] . 786
Failure Code [CA778] . 787
Failure Code [CA2185] 792
Failure Code [CA2186] 794
Failure Code [CA2249] 796
Failure Code [CA2311] 797
Failure Code [CA2555] 798
Failure Code [CA2556] 801
Failure Code [D110KB] 803
Failure Code [D19JKZ] 807
Failure Code [D811MC] 811
Failure Code [D862KA] 812
Failure Code [D8ALKA] 814
Failure Code [D8ALKB] 818
Failure Code [D8AQKR] 821
Failure Code [D8ARKR] 831
Failure Code [D8G1KT] 837
Failure Code [D8G6KT] 838
Failure Code [DA20MC] 839
Failure Code [DA22KK] 840
Failure Code [DA25KP] 845
Failure Code [DA26KP] 849
Failure Code [DA29KQ] 855
Failure Code [DA2LKA] 860
Failure Code [DA2LKB] 864
Failure Code [DA2QKR] 867
Failure Code [DA2RKR] 878
Failure Code [DAF0MB] 887
Failure Code [DAF0MC] 888
Failure Code [DAF8KB] 889
Failure Code [DAF9KQ] 891
Failure Code [DAFGMC] 893
Failure Code [DAFLKA] 895
Failure Code [DAFLKB] 899
Failure Code [DAFQKR] 902
Failure Code [DAZ9KQ] 912
Failure Code [DAZQKR] 914
Failure Code [DB2QKR] 923
Failure Code [DDPAKA] 933
Failure Code [DGH2KA] 936
Failure Code [DGH2KB] 939
Failure Code [DHA4KA] 942
Failure Code [DHE5MA] 945
Failure Code [DHPAMA] 949
Failure Code [DHPBMA] 953
Failure Code [DHS3MA] 957
Failure Code [DHS4MA] 961
Failure Code [DHS8MA] 965
Failure Code [DHS9MA] 969
Failure Code [DHSAMA] 973
Failure Code [DHSBMA] 977
Failure Code [DHSCMA] 981
Failure Code [DHSDMA] 985
Failure Code [DHSFMA] 989
Failure Code [DHSGMA] 993
Failure Code [DHSHMA] 997
Failure Code [DHSJMA] 1001
Failure Code [DJG1KX] 1005
Failure Code [DKR2MA] 1008
Failure Code [DKR2NX] 1012
Failure Code [DR31KX] 1014
Failure Code [DV20KB] 1015
Failure Code [DW43KA] 1018
Failure Code [DW43KB] 1021
Failure Code [DW43KY] 1024
Failure Code [DW45KA] 1026
Failure Code [DW45KB] 1030
Failure Code [DW45KY] 1034
Failure Code [DW91KA] 1037
Failure Code [DW91KB] 1039
Failure Code [DW91KY] 1042
Failure Code [DWA2KA] 1044
Failure Code [DWA2KB] 1046
Failure Code [DWA2KY] 1049
Failure Code [DWK0KA] 1051
Failure Code [DWK0KB] 1053
Failure Code [DWK0KY] 1056
Failure Code [DWK2KA] 1058
Failure Code [DWK2KB] 1060
Failure Code [DWK2KY] 1063
Failure Code [DWK8KA] 1065
Failure Code [DWK8KB] 1067
Failure Code [DWK8KY] 1070
Failure Code [DXA8KA] 1072
Failure Code [DXA8KB] 1075
Failure Code [DXA9KA] 1079
Failure Code [DXA9KB] 1082
Failure Code [DXE0KA] 1086
Failure Code [DXE0KB] 1089
Failure Code [DXE4KA] 1092
Failure Code [DXE4KB] 1095
Failure Code [DXE4KY] 1098
Failure Code [DXE5KA] 1100
Failure Code [DXE5KB] 1103
Failure Code [DXE6KA] 1106
Failure Code [DXE6KB] 1109
Failure Code [DY20KA] 1112
Failure Code [DY20MA] 1116
Failure Code [DY2CKB] 1120
Failure Code [DY2DKB] 1125
Failure Code [DY2EKB] 1128
Failure Code [F313KA] 1131
Failure Code [F313KB] 1133
Failure Code [F318KB] 1136
Failure Code [F318KY] 1139
Failure Code [F@BBZL] 1141
Troubleshooting of Electrical System (E-Mode) 1144
Engine Does Not Start (Engine Does Not Crank) 1144
Manual Preheating System Does Not Operate 1154
Automatic Preheating System Does Not Operate .1158
While Preheating is in Operation, Preheating Monitor Does Not Come On 1162
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1167
While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1172
While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1174
Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation 1176
Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation .1178
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation .1180
Charge Level Monitor Comes On in Red While Engine is in Operation 1182
Fuel Level Monitor Comes On in Red While Engine is in Operation 1186
Water Separator Monitor Comes On in Red While Engine is in Operation .1187
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1188
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation .1190
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation .1191
Fuel Gauge Does Not Move from Minimum or Maximum .1193
Display of Fuel Gauge is Different from Actual Fuel Level 1196
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1198
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1199
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 1201
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1204
Machine Monitor Shows Incorrect Model 1206
Some Areas of Machine Monitor Screen are Not Shown .1207
Function Switch Does Not Operate .1208
Automatic Warm-up System Does Not Operate (in Cold Weather) 1209
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 1211
Auto-Decelerator is Not Operated or Canceled with Lever 1212
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 1215
When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1216
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated .1217
Travel Speed Does Not Change Even When You Change Travel Speed .1218
Alarm Buzzer Does Not Stop .1220
Service Meter is Not Shown While Starting Switch is in OFF Position 1221
Service Mode Cannot be Selected 1222
All Work Equipment, Swing, Travel Do Not Operate .1223
All Work Equipment, Swing, Travel Cannot be Locked .1227
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position .1229
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated .1233
One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor is Not Shown .1236
One-Touch Power Maximizing Function is Not Cancelled .1240
Travel Alarm Does Not Operate During Travel 1242
Travel Alarm Does Not Stop When Machine Stops 1245
Horn Does Not Sound 1247
Horn Does Not Stop .1251
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated 1253
Windshield Wiper Does Not Operate When Wiper Switch is Operated 1254
When Window Washer Switch is Operated, Window Washer Does Not Operate 1257
Boom Raise is Not Shown Normally with Monitoring Function 1260
Boom Lower is Not Shown Normally with Monitoring Function 1261
Arm OUT is Not Shown Correctly with Monitoring Function 1262
Arm IN is Not Shown Normally with Monitoring Function 1263
Bucket DUMP is Not Shown Correctly with Monitoring Function 1264
Bucket CURL is Not Shown Correctly with Monitoring Function 1265
Swing is Not Shown Normally with Monitoring Function .1266
Travel is Not Shown Normally with Monitoring Function 1267
Service is Not Shown Correctly with Monitoring Function 1268
Attachment Hydraulic Circuit Cannot be Changed .1271
KOMTRAX System Does Not Operate Correctly 1273
Quick Coupler Does Not Work 1275
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1280
Information Shown in Troubleshooting Table (H-Mode) 1280
All Work Equipment, Swing and Travel Do Not Work .1281
All Work Equipment, Swing, and Travel Lack Speed or Power 1283
Fine Control Performance or Response is Unsatisfactory .1294
Unusual Noise is Heard from Around Hydraulic Pump 1299
Engine Speed Drops Largely or Engine Stops .1301
Boom Speed or Power is Low .1310
Arm Speed or Power is Low 1322
Bucket Speed or Power is Low .1333
Work Equipment Does Not Move in Single Operation .1343
Hydraulic Drift of Boom is Large .1347
Hydraulic Drift of Arm is Large 1349
Hydraulic Drift of Bucket is Large .1353
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves .1356
Time Lag of Work Equipment is Large 1358
One-Touch Power Maximizing Function Does Not Operate .1365
Attachment Circuit Cannot be Changed .1368
Oil Flow in Attachment Circuit Cannot be Changed .1370
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1372
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely .1374
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1375
Machine Does Not Travel Straight .1376
Machine is Not Steered Well or Steering Power is Low .1387
Travel Speed is Low 1402
One of Tracks Does Not Run .1413
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1422
Upper Structure Does Not Swing in Two Directions of Right and Left .1425
Machine Swings Only in One Direction .1430
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left .1433
Swing Acceleration or Swing Speed is Low in Only One Direction .1440
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) .1444
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) .1446
Shock is Large When Upper Structure Stops Swing Operation 1450
Large Unusual Noise is Heard When Upper Structure Stops 1452
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) .1455
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1457
Fan Speed is Abnormal (Too High or Low, or Does Not Move) 1461
Unusual Noise is Heard from Around Fan .1463
Troubleshooting of Engine (S-Mode) .1464
Information Shown in Troubleshooting Table (S-Mode) 1464
Engine Does Not Crank When Starting Switch is Turned to Start Position .1465
Engine Cranks but No Exhaust Smoke Comes Out .1466
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1467
Engine Startability is Unsatisfactory 1469
Engine Does Not Pick Up Smoothly .1471
Engine Stops During Operation 1473
Engine Does Not Rotate Smoothly 1475
Engine Lacks Output (or Lacks Power) .1476
Exhaust Smoke is Black .1478
Engine Oil Consumption is Excessive 1480
Engine Oil Becomes Dirty Quickly .1481
Fuel Consumption is Excessive 1482
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1483
Engine Oil Pressure Drops 1484
Fuel Mixes Into Engine Oil .1485
Water Mixes Into Engine Oil (Milky) 1486
Coolant Temperature Increases Too High (Overheat) 1487
Unusual Noise is Heard .1488
Vibration is Excessive .1489
Air Cannot be Bled from Fuel Circuit .1490
50 Disassembly and Assembly 1491
Table of Contents 1492
Precautions Before Work 1495
Related Information on Disassembly and Assembly 1496
How to Read This Manual 1496
Coating Materials List .1497
Special Tool List 1502
Sketches of Special Tools 1512
Prepare 1517
Drain and Add Coolant 1517
How to Drain Coolant .1517
How to Add Coolant .1518
Drain and Add Hydraulic Oil 1520
How to Drain Hydraulic Oil .1520
How to Add Hydraulic Oil .1521
Drain and Add Fuel .1524
How to Drain Fuel 1524
How to Add Fuel 1525
Collect and Refill Refrigerant .1528
How to Collect Refrigerant .1528
How to Refill Refrigerant 1528
Engine and Cooling System 1529
Remove and Install Supply Pump Assembly 1529
How to Remove Supply Pump Assembly .1530
How to Install Supply Pump Assembly 1534
Remove and Install Injector Assembly .1538
How to Remove Injector Assembly 1539
How to Install Injector Assembly .1543
Remove and Install Cylinder Head Assembly 1550
How to Remove Cylinder Head Assembly .1553
How to Install Cylinder Head Assembly 1563
Remove and Install Radiator Assembly .1582
How to Remove Radiator Assembly 1582
How to Install Radiator Assembly .1585
Remove and Install Hydraulic Oil Cooler Assembly .1588
How to Remove Hydraulic Oil Cooler Assembly 1589
How to Install Hydraulic Oil Cooler Assembly .1592
Remove and Install Aftercooler Assembly 1595
How to Remove Aftercooler Assembly .1595
How to Install Aftercooler Assembly 1597
Remove and Install Engine and Main Pump Assembly .1600
How to Remove Engine and Main Pump Assembly 1601
How to Install Engine and Main Pump Assembly .1616
Remove and Install Engine Front Oil Seal .1631
How to Remove Engine Front Oil Seal 1631
How to Install Engine Front Oil Seal .1633
Remove and Install Engine Rear Oil Seal 1636
How to Remove Engine Rear Oil Seal .1636
How to Install Engine Rear Oil Seal 1638
Remove and Install Engine Hood Assembly 1642
How to Remove Engine Hood Assembly .1642
How to Install Engine Hood Assembly 1644
Remove and Install Fuel Tank Assembly 1646
How to Remove Fuel Tank Assembly .1647
How to Install Fuel Tank Assembly 1651
Power Train 1657
Remove and Install Travel Motor and Final Drive Assembly .1657
How to Remove Travel Motor and Final Drive Assembly 1657
How to Install Travel Motor and Final Drive Assembly .1659
Disassemble and Assemble Final Drive Assembly 1661
How to Disassemble Final Drive Assembly 1662
How to Assemble Final Drive Assembly .1667
Remove and Install Swing Motor and Swing Machinery Assembly 1679
How to Remove Swing Motor and Swing Machinery Assembly .1680
How to Install Swing Motor and Swing Machinery Assembly 1682
Disassemble and Assemble Swing Machinery Assembly 1686
How to Disassemble Swing Machinery Assembly 1687
How to Assemble Swing Machinery Assembly .1693
Remove and Install Swing Circle Assembly .1702
How to Remove Swing Circle Assembly 1702
How to Install Swing Circle Assembly .1702
Undercarriage and Frame 1704
Separate and Connect Track Assembly 1704
How to Separate Track Assembly .1704
How to Install Track Assembly 1706
Remove and Install Sprocket 1710
How to Remove Sprocket .1710
How to Install Sprocket 1710
Remove and Install Idler and Idler Cushion Assembly 1712
How to Remove Idler and Idler Cushion Assembly .1712
How to Install Idler and Idler Cushion Assembly 1713
Disassemble and Assemble Idler Assembly 1714
How to Disassemble Idler Assembly 1714
How to Assemble Idler Assembly .1716
Disassemble and Assemble Idler Cushion Assembly 1723
How to Disassemble Idler Cushion Assembly 1724
How to Assemble Idler Cushion Assembly .1725
Disassemble and Assemble Track Roller Assembly .1727
How to Disassemble Track Roller Assembly .1727
How to Assemble Track Roller Assembly 1728
Disassemble and Assemble Carrier Roller Assembly .1730
How to Disassemble Carrier Roller Assembly .1730
How to Assemble Carrier Roller Assembly 1732
Remove and Install Revolving Frame Assembly 1735
How to Remove Revolving Frame Assembly .1736
How to Install Revolving Frame Assembly 1739
Remove and Install Counterweight Assembly 1742
How to Remove Counterweight Assembly .1742
How to Install Counterweight Assembly 1743
Hydraulic System .1745
Remove and Install Center Swivel Joint Assembly 1745
How to Remove Center Swivel Joint Assembly .1746
How to Install Center Swivel Joint Assembly 1749
Disassemble and Assemble Center Swivel Joint Assembly 1753
How to Disassemble Center Swivel Joint Assembly 1753
How to Assemble Center Swivel Joint Assembly .1754
Remove and Install Hydraulic Tank Assembly .1757
How to Remove Hydraulic Tank Assembly 1758
How to Install Hydraulic Tank Assembly .1762
Remove and Install Main Pump Assembly 1769
How to Remove Main Pump Assembly .1770
How to Install Main Pump Assembly 1777
Remove and Install Control Valve Assembly 1787
How to Remove Control Valve Assembly .1788
How to Install Control Valve Assembly 1800
Disassemble and Assemble Control Valve Assembly 1813
How to Replace Pressure Compensation Valve Seal Ring .1813
Disassemble and Assemble Work Equipment PPC Valve Assembly .1816
How to Disassemble Work Equipment PPC Valve Assembly .1816
Disassemble and Assemble Travel PPC Valve Assembly .1817
How to Disassemble Travel PPC Valve Assembly .1817
How to Assemble Travel PPC Valve Assembly 1818
Remove and Install Work Equipment Assembly .1820
How to Remove Work Equipment Assembly 1821
How to Install Work Equipment Assembly .1824
Disassemble and Assemble Work Equipment Cylinder Assembly 1827
How to Disassemble Work Equipment Cylinder Assembly 1828
How to Assemble Work Equipment Cylinder Assembly .1833
CAB Related Parts 1842
Remove and Install Operator Cab Assembly .1842
How to Remove Operator Cab Assembly 1843
How to Install Operator Cab Assembly .1853
Remove and Install Operator Cab Glass (Adhered Glass) 1863
How to Remove Operator Cab Glass (Adhered Glass) .1865
How to Install Operator Cab Glass (Adhered Glass) 1865
Remove and Install Front Window Assembly .1876
How to Remove Front Window Assembly 1876
How to Install Front Window Assembly .1879
Remove and Install Floor Frame Assembly 1885
How to Remove Floor Frame Assembly .1886
How to Install Floor Frame Assembly 1892
Remove and Install Air Conditioner Unit Assembly .1900
How to Remove Air Conditioner Unit Assembly 1901
How to Install Air Conditioner Unit Assembly .1909
Remove and Install Operator Seat .1917
How to Remove Operator Seat 1917
How to Install Operator Seat .1918
How to Remove and Install Seat Belt 1920
How to Remove Seat Belt 1920
How to Install Seatbelt 1921
Remove and Install Work Equipment Control Lever Assembly .1922
How to Remove Work Equipment Control Lever Assembly 1922
How to Install Work Equipment Control Lever Assembly .1927
Remove and Install Front Wiper Assembly 1935
How to Remove Front Wiper Assembly .1935
How to Install Front Wiper Assembly 1940
Remove and Install Engine Controller Assembly 1948
How to Remove Engine Controller Assembly .1949
How to Install Engine Controller Assembly 1950
Remove and Install Pump Controller Assembly 1952
How to Remove Pump Controller Assembly .1952
How to Install Pump Controller Assembly 1954
Remove and Install Machine Monitor Assembly 1958
How to Remove Machine Monitor Assembly .1958
How to Install Machine Monitor Assembly 1961
Remove and Install KOMTRAX Terminal Assembly .1965
How to Remove KOMTRAX Terminal Assembly 1965
How to Install KOMTRAX Terminal Assembly .1968
60 Maintenance Standard 1971
Table of Contents 1972
Explanation of Terms for Maintenance Standard 1973
Engine and Cooling System 1975
Maintenance Standard for Engine Mount 1975
Maintenance Standard for Cooling System 1976
Power Train 1977
Maintenance Standard for Swing Circle 1977
Maintenance Standard for Swing Machinery .1978
Maintenance Standard for Final Drive .1981
Maintenance Standard for Sprocket 1983
Sprocket Tooth Profile Full-Scale Drawing 1984
Undercarriage and Frame 1985
Maintenance Standard for Track Frame and Idler Cushion .1985
Maintenance Standard for Idler .1986
Maintenance Standard for Track Roller 1988
Maintenance Standard for Carrier Roller 1990
Maintenance Standard for Track Shoes .1991
Maintenance Standard for Triple Shoes 1994
Maintenance Standard for Swamp Shoes .1995
Maintenance Standard for Road Liner 1996
Hydraulic System .1997
Maintenance Standard for Hydraulic Tank 1997
Maintenance Standard for Main Pump .1998
Maintenance Standard for LS-EPC Valve 2000
Maintenance Standard for PC-EPC Valve 2001
Maintenance Standard for Swing Motor .2002
Maintenance Standard for Travel Motor 2004
Maintenance Standard for Control Valve .2007
Maintenance Standard for PPC Valve (Work Equipment and Swing Operation) 2017
Maintenance Standard for Travel PPC Valve 2020
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2023
Maintenance Standard for Attachment Oil Flow Adjuster EPC Valve 2024
Maintenance Standard for 2nd-Line Attachment PPC Valve .2025
Maintenance Standard for Solenoid Valve 2026
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) .2028
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2029
Maintenance Standard for Center Swivel Joint .2030
Work Equipment .2031
Maintenance Standard for Work Equipment Linkage 2031
Dimensions of Arm 2037
Dimensions of Bucket .2039
Maintenance Standard for Boom Cylinder .2041
Maintenance Standard for Arm Cylinder 2042
Maintenance Standard for Bucket Cylinder .2043
80 Others 2045
Table of Contents 2046
Precautions Before Work 2048
Air Conditioner System .2049
Precautions for Refrigerant 2049
Layout Drawing of Air Conditioner System .2050
Specifications of Air Conditioner 2052
Structure of Refrigeration Cycle .2053
Function of Refrigeration Cycle 2054
System Diagram of Air Conditioner 2055
Component Parts of Air Conditioner System 2056
Air Conditioner Unit .2056
Structure of Air Conditioner Unit 2057
Function of Air Conditioner Unit .2058
Component Parts of Air Conditioner Unit 2059
Air Conditioner Controller .2063
Structure of Air Conditioner Controller 2063
Function of Air Conditioner Controller .2063
Input and Output Signals of Air Conditioner Controller .2063
Compressor .2065
Structure of Compressor 2065
Specifications of Compressor .2065
Function of Compressor .2065
Operation of Compressor 2065
Condenser 2066
Structure of Condenser .2066
Specifications of Condenser 2066
Function of Condenser 2066
Air Conditioner Related Sensors 2068
Structure of Sunlight Sensor .2068
Function of Sunlight Sensor 2068
Structure of Outside Temperature Sensor 2068
Function of Outside Air Temperature Sensor .2068
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2069
Locations of Air Conditioner Parts and Layout of Connectors 2071
Examine Air Leakage (Duct Connection) 2075
How to Examine Air Leakage (Duct Connection) .2075
Examine Air Conditioner with Self-Diagnosis Function .2078
Examine Vent (Mode) Changeover .2079
How to Examine Vent (Mode) Changeover 2079
Examine Fresh/Recirc Air Changeover 2081
How to Examine Fresh/Recirc Air Changeover .2081
Examine Sunlight Sensor 2082
How to Examine Sunlight Sensor .2082
Examine Dual Pressure Switch .2083
How to Examine Dual Pressure Switch 2083
Examine Relay 2084
How to Examine Relay .2084
Simple Check of Refrigerant Level Through Sight Glass 2086
Procedure for Troubleshooting of Air Conditioner .2087
Information Shown in Troubleshooting Table .2088
Failure Code [879AKA] 2091
Failure Code [879AKB] 2093
Failure Code [879BKA] 2095
Failure Code [879BKB] 2098
Failure Code [879CKA] 2101
Failure Code [879CKB] 2103
Failure Code [879DKZ] 2105
Failure Code [879EMC] 2108
Failure Code [879FMC] 2110
Failure Code [879GKX] 2112
Air Conditioner Does Not Operate .2115
Defective Cooling 2118
Heater Does Not Operate 2127
Cool Air Does Not Come Out .2131
No Air Comes Out or Air Flow is Abnormal .2138
Fresh/Recirc Air Changeover Does Not Work 2142
Connect Service Tool .2146
How to Connect Service Tool 2147
Precautions for Disconnection and Connection of Air Conditioner Piping .2148
Handle Compressor Oil 2150
How to Replace Desiccant .2152
90 Circuit Diagrams 2155
Table of Contents 2156
How to Read the Codes for Electric Cable .2157
Hydraulic Circuit Diagram 2161
Symbols Used in Hydraulic Circuit Diagram 2161
Hydraulic Circuit Diagram 2165
Electrical Circuit Diagram .2167
Symbols Used in Electric Circuit Diagram .2167
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (1/7) 2171
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (2/7) 2173
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (3/7) 2175
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (4/7) 2177
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (5/7) 2179
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (6/7) 2181
Electrical Circuit Diagram (Applicable Machine: 700001 to 700005) (7/7) 2183
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (1/7) .2185
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (2/7) .2187
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (3/7) .2189
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (4/7) .2191
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (5/7) .2193
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (6/7) .2195
Electrical Circuit Diagram (Applicable Machine: 700006 and Up) (7/7) .2197
Index .2199

DESCRIPTION:

Komatsu PC200-10M0 Hydraulic Excavator Shop Manual SEN06867-10  – PDF DOWNLOAD

• SERIAL NUMBERS 700001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “Ad Blue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “Ad Blue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “Ad Blue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 26/12/24