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KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBERS
PC200- B30001
PC200LC-B30001
PC240LC-B10001 - PUBLICATION NUMBER:KEN00084-13
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Description
KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
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
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