Komatsu PC200-8E0 PC200LC-8E0 Hydraulic Excavator Shop Manual SEN05221-07 PDF

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Komatsu PC200-8E0 PC200LC-8E0 Hydraulic Excavator Shop Manual SEN05221-07 – PDF DOWNLOAD

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Komatsu PC200-8E0 PC200LC-8E0 Hydraulic Excavator Shop Manual SEN05221-07  – PDF DOWNLOAD

Language : English
Pages : 1320
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200-8E0 PC200LC-8E0 Hydraulic Excavator Shop Manual SEN05221-07  – PDF DOWNLOAD

SERIAL NUMBERS

• PC200- 1001      and up
  PC200LC- 1001 and up

Cover 1
00 Index and Foreword 0
100 Index 3
Composition of shop manual . 4
Table of contents 6
200 Foreword and general information . 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of hydraulic components . 27
Method of disconnecting and connecting push-pull type coupler 29
Handling of electric equipment . 32
How to read electric wire code . 42
Precautions when performing work . 47
Handling of hybrid devices and high-voltage wirings 50
Standard tightening torque table . 58
Conversion table . 62
01 Specification . 0
100 Specification and technical data . 69
Outline of hybrid system . 70
Specification dimension drawings . 71
Working range diagram 72
Specifications . 73
Weight table . 76
Table of fuel, coolant and lubricants 78
10 Structure, function andmaintenance standard . 0
100 Engine and cooling system 81
Engine related parts . 82
Radiator, oil cooler, aftercooler and fuel cooler 83
200 Hybrid Relation 85
Configuration and safety functions of hybrid system 86
Cooling system of hybrid component . 90
Motor generator 92
Swing electric motor . 93
Electric control unit 94
High-voltage wiring (power cable) 95
300 Power train 97
Power train 98
Final drive 100
Swing machinery 102
Swing circle . 104
400 Undercarriage and frame 107
Track frame and recoil spring 108
Idler 110
Carrier roller . 112
Track roller . 113
Track shoe . 114
501 Hydraulic system, Part 1 . 119
Hydraulic components layout drawing 120
Hydraulic tank and filter 122
Hydraulic pump . 124
502 Hydraulic system, Part 2 . 147
Control valve 148
CLSS . 159
Functions and operation by valve . 164
503 Hydraulic system, Part 3 . 197
Center swivel joint 198
Travel motor . 200
PPC valve 211
Valve control 226
Solenoid valve . 228
Accumulator 230
Hydraulic cylinder . 231
600 Work equipment . 235
Dimensions of components . 236
700 Cab and its attachments 243
Air conditioner piping . 244
800 Electrical system 247
Engine control . 248
Electrical control system 256
Monitor system . 281
Sensors 306
KOMTRAX system . 309
20 Standard value table 0
100 Standard service value table . 313
Standard value table for engine related parts 314
Standard value table for chassis related parts . 315
30 Testing and adjusting . 0
101 Testing and adjusting, Part 1 327
Tools for testing, adjusting and troubleshooting . 329
Testing engine speed . 333
Testing boost pressure . 335
Checking exhaust gas color . 336
Adjusting valve clearance 337
Testing compression pressure . 339
Testing blowby pressure 342
Testing engine oil pressure 343
Handling fuel system parts . 344
Releasing remaining pressure from fuel system 344
Testing fuel system pressure . 345
Cylinder cut-out test mode operation . 347
No injection cranking operation 347
Testing fuel return rate and leakage . 348
Bleeding air from fuel circuit . 352
Testing fuel circuit for leakage . 353
Handling of controller high-voltage circuit 354
Testing and adjusting air conditioner compressor belt tension 355
Replacement of fan belt 356
Testing swing circle bearing clearance . 357
Testing and adjusting track tension 358
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits . 360
Testing source pressure of control circuit . 363
Testing and adjusting oil pressure in pump PC control circuit 364
Testing and adjusting oil pressure in pump LS control circuit 367
Testing solenoid valve output pressure . 371
Testing PPC valve output pressure 374
Adjusting play of work equipment and swing PPC valves 376
Checking parts which cause hydraulic drift of work equipment . 377
Releasing remaining pressure from hydraulic circuit 379
Testing oil leakage 380
Bleeding air from each part 382
Checking cab tipping stopper . 384
Adjusting mirrors 385
Angle adjustment of rear view camera . 387
Testing swing brake 388
Cleaning and replacement of oil filter of electric swing motor . 390
Operation check of swing emergency stop switch . 391
102 Testing and adjusting, Part 2 395
Special functions of machine monitor . 396
103 Testing and adjusting, Part 3 455
Handling voltage circuit of engine controller 456
Precautions related to hybrid machines . 457
Preparation work for troubleshooting of electrical system 458
Procedure for testing diodes . 464
Pm Clinic service 465
40 Troubleshooting . 0
100 Failure code table and fuse locations 473
Failure code table . 474
Fuse locations . 480
200 General Information on troubleshooting . 487
Points to remember when troubleshooting 488
Sequence of events in troubleshooting 489
Check before troubleshooting . 490
Classification and procedures for troubleshooting 491
Probable problems and troubleshooting No . 493
Information in troubleshooting table . 495
Connection table for connector pin numbers . 497
T-adapter and box table 533
301 Troubleshooting by failure code, Part 1 537
Failure code [989L00] Engine Controller Lock Caution 1 . 539
Failure code [989M00] Engine Controller Lock Caution 2 . 539
Failure code [989N00] Engine Controller Lock Caution 3 . 540
Failure code [AA10NX] Air Cleaner Clogging . 541
Failure code [AB00KE] Charge Voltage Low . 542
Failure code [B@BAZG] Eng Oil Press Low 544
Failure code [B@BAZK] Eng oil level low 544
Failure code [B@BCNS] Eng Water Overheat . 545
Failure code [B@BCZK] Eng Water Level Low 545
Failure code [B@HANS] Hydr oil overheat 546
Failure code [CA111] EMC Critical Internal Failure . 547
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 547
Failure code [CA122] Chg Air Press Sensor High Error . 548
Failure code [CA123] Chg Air Press Sensor Low Error 550
Failure code [CA131] Throttle Sensor High Error 552
Failure code [CA132] Throttle Sensor Low Error . 554
Failure code [CA144] Coolant temp. sensor high error . 556
Failure code [CA145] Coolant temp. sensor low error 558
Failure code [CA153] Chg Air Temp Sensor High Error 560
Failure code [CA154] Chg Air Temp Sensor Low Error . 562
Failure code [CA155] Chg Air Temp High Speed Derate 564
Failure code [CA187] Sens Supply 2 Volt Low Error 566
Failure code [CA221] Ambient Press Sens High Error . 568
Failure code [CA222] Ambient Press Sens Low Error 570
Failure code [CA227] Sens Supply 2 Volt High Error . 572
Failure code [CA234] Eng Overspeed . 573
Failure code [CA238] Ne Speed Sens Supply Volt Error . 574
Failure code [CA271] IMV/PCV1 Short Error 575
Failure code [CA272] IMV/PCV1 Open Error . 576
Failure code [CA322] Inj #1 (L#1) Open/Short Error . 578
Failure code [CA324] Inj #3 (L#3) Open/Short Error . 580
Failure code [CA331] Inj #2(L#2) Open/Short Error 582
Failure code [CA332] Inj #4 (L#4) Open/Short Error . 584
302 Troubleshooting by failure code, Part 2 587
Failure code [CA342] Calibration Code Incompatibility 589
Failure code [CA351] Injectors Drive Circuit Error . 589
Failure code [CA352] Sens Supply 1 Volt Low Error 590
Failure code [CA386] Sens Supply 1 Volt High Error . 592
Failure code [CA428] Water in Fuel Sensor High Error . 594
Failure code [CA429] Water in Fuel Sensor Low Error 596
Failure code [CA435] Eng Oil Press Sw Error 598
Failure code [CA441] Battery Voltage Low Error . 600
Failure code [CA442] Battery Voltage High Error 602
Failure code [CA449] Rail Press Very High Error 604
Failure code [CA451] Rail Press Sensor High Error 606
Failure code [CA452] Rail Press Sensor Low Error . 608
Failure code [CA488] Chg Air Temp High Torque Derate . 610
Failure code [CA553] Rail Press High Error . 610
Failure code [CA559] Rail Press Low Error 611
Failure code [CA689] Eng Ne Speed Sensor Error . 612
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 614
Failure code [CA757] All Continuous Data Lost Error 616
Failure code [CA778] Eng Bkup Speed Sensor Error . 618
Failure code [CA1633] KOMNET Datalink Timeout Error 620
Failure code [CA2185] Throt Sens Sup Volt High Error . 621
Failure code [CA2186] Throt Sens Sup Volt Low Error 622
Failure code [CA2249] Rail Press Very Low Error 623
Failure code [CA2311] IMV Solenoid Error . 623
Failure code [CA2555] Grid Htr Relay Volt High Error . 624
Failure code [CA2556] Grid Htr Relay Volt Low Error 626
Failure code [D19JKZ] Personal Code Relay Abnormality 628
Failure code [D862KA] GPS Antenna Discon . 630
Failure code [DA22KK] Pump Solenoid Power Low Error 632
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 634
Failure code [DA26KP] 5V Sensor 2 Power Abnormality 638
Failure code [DA29KQ] Model Selection Abnormality 640
303 Troubleshooting by failure code, Part 3 643
Failure code [DA2RMC] CAN Discon (Pump Con Detected) . 646
Failure code [DAF8KB] Short circuit in camera power supply . 648
Failure code [DAFGMC] GPS Module Error . 650
Failure code [DAFRMC] CAN Discon (Monitor Detected) 652
Failure code [DGH2KB] Hydr Oil Sensor Short 654
Failure code [DHPAMA] F Pump Press Sensor Abnormality 656
Failure code [DHPBMA] R Pump Press Sensor Abnormality 658
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 660
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality . 662
Failure code [DHS5KK] Travel Speed PPC Sensor Abnormality 664
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 666
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 668
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 670
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality . 672
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Shrt Cir 674
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir 675
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir . 676
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir . 677
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir 678
Failure code [DW43KA] Travel Speed Sol Discon 680
Failure code [DW43KB] Travel Speed Sol Short . 682
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir 684
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir . 685
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir . 686
Failure code [DW91KA] Travel Junction Sol Discon . 688
Failure code [DW91KB] Travel Junction Sol Short 690
Failure code [DWK0KA] 2-stage Relief Sol Discon 692
Failure code [DWK0KB] 2-stage Relief Sol Short . 694
304 Troubleshooting by failure code, Part 4 697
Failure code [DXA8KA] PC-EPC (F) Sol Discon 698
Failure code [DXA8KB] PC-EPC (F) Sol Short . 700
Failure code [DXA9KA] PC-EPC (R) Sol Discon 702
Failure code [DXA9KB] PC-EPC (R) Sol Short . 704
Failure code [DXE0KA] LS-EPC Sol Discon 706
Failure code [DXE0KB] LS-EPC Sol Short . 708
Failure code [DXE5KA] Merge-divider Main Sol Discon 710
Failure code [DXE5KB] Merge-divider Main Sol Short . 712
Failure code [DXE6KA] Merge-divider LS Sol Discon 714
Failure code [DXE6KB] Merge-divider LS Sol Short . 716
Failure code [DY20KA] Wiper Working Abnormality 718
Failure code [DY20MA] Wiper Parking Abnormali 720
Failure code [DY2CKA] Washer Drive Discon 722
Failure code [DY2CKB] Washer Drive Short . 724
Failure code [DY2DKB] Wiper Drive (For) Short 726
Failure code [DY2EKB] Wiper Drive (Rev) Short 728
305 Troubleshooting by failure code, Part 5 731
Precautions related to hybrid machines . 734
Common troubleshooting of hybrid components and high voltage wiring (high voltage section) . 739
Failure code [DHV3KZ] HYB Arm Dig PPC Pr. Sen. Opn/Short Cir . 754
Failure code [DHV9KZ] HYB boom Lower PPC Pr. Sen. Opn/Shrt Cir . 756
Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt . 758
Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen Opn/Short Cir . 761
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/Short Cir 764
Failure code [DW45KA] Swing Brake Sol. Valve Open Cir 766
Failure code [DW45KB] Swing Brake Sol. Valve Short Cir . 770
Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir . 772
Failure code [GA01KA] Power Cable Interlock Open Circuit . 774
Failure code [GA02KZ] DC Line Open/Short Circuit . 776
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster 777
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster 778
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster 780
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster 784
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster 785
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster 786
Failure code [GA09KP] Low DC SW Output Volt. After Booster . 787
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster . 788
Failure code [GA0BKZ] AC Line Open/Short Circuit . 789
Failure code [GA11KK] HYB Cont. Low Supply Voltage . 790
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure 793
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON . 794
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF 795
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure . 796
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure 798
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir . 801
Failure code [GA16KK] Low HYB Cont. VDD Suppl. Volt 802
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure . 803
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit 804
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit . 805
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded . 806
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure 807
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt . 808
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure 809
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con 810
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction . 811
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation . 812
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled 813
Failure code [GA1AKZ] Gen. Mot. Dr. Temp. Sens. Opn/Short Cir 814
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction 815
Failure code [GA1CNS] Motor-generator driver IPM overheat 816
Failure code [GA1DMA] Gen. Motro Driver IPM1 Abnormality . 817
Failure code [GA1EMA] Gen. Motor Driver IPM 2 Abnormality 818
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure 819
Failure code [GA1FMA] Abnormal Swing Motor Driver 820
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU 821
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure 822
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal . 823
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfuuction . 824
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded 825
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op 826
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled . 827
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir . 828
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir . 829
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir . 830
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir 831
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir 832
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat . 833
Failure code [GA1PNV] Swg Mot. Driver IPM Ph-U Not Warm up . 834
Failure code [GA1QNV] Swg Mot. Driver IPM Ph-V Not Warm Up . 835
Failure code [GA1RNV] Swng Mot. Driver IPM Ph-W Not Warm Up 836
Failure code [GA1SFS] Contactor Locked . 837
Failure code [GA1SMC] Contactor Failure 838
Failure code [GA1TKG] Capacitor HVPS Abnormal Voltage 839
Failure code [GA1TKP] Capacitor Low Output Voltage . 840
Failure code [GA1TNS] Capacitor Overheat . 844
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir . 846
Failure code [GA1VFS] Capacitor Contactor Locked . 848
Failure code [GA1VMC] Capacitor Contactor Failure 850
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ 851
Failure code [GA1YNS] Booster Inductor Overheat 852
Failure code [GA1YNV] Booster Inductor Not Warming Up 853
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ 854
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat 855
Failure code [GA1ZNV] Booster IGBT Temp. Sens. Not Warm Up . 856
Failure code [GA21KB] Booster IGBT Short Circuit . 857
Failure code [GA22NS] Booster IGBT Junction Overheat . 858
Failure code [GA60MC] Generator Motor Failure 859
Failure code [GA60MD] Gen. Mot. Defective Movement . 860
Failure code [GA60N1] Generator Motor Overrun 861
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir 862
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat 864
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir . 865
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir 866
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction 867
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir . 868
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir 869
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction 870
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir . 871
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir 872
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction 873
Failure code [GA70KB] HYB Swing Motor Short Circuit 874
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion 875
Failure code [GA70NS] HYB Swing Motor Overheat . 876
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir 878
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction . 880
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op . 882
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ 884
400 Troubleshooting of electrical system (E-mode) 887
Before performing troubleshooting of electrical system . 889
Information in troubleshooting table . 891
E-1 When starting switch is turned to ON position, machine monitor displays nothing 892
E-2 When starting switch turned ON (before starting engine), basic check monitor lights up . 894
E-3 Engine does not start (Engine does not crank) 897
E-4 Preheater does not operate . 900
E-5 Automatic warm-up system does not operate (in cold season) . 902
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 904
E-7 Caution monitor lights up while engine is running 906
E-8 Emergency monitor lights up while engine is running 911
E-9 Engine coolant temperature gauge does not indicate normally 912
E-10 Hydraulic oil temperature gauge does not indicate normally 913
E-11 Fuel level gauge does not indicate normally . 915
E-12 Contents of display by machine monitor are different from applicable machine 917
E-13 Some areas of the machine monitor screen are not displayed 918
E-14 Function switch does not work . 919
E-15 Auto-deceleration does not operate normally . 920
E-16 Working mode does not change 921
E-17 Travel speed does not change 922
E-18 Alarm buzzer cannot be stopped 923
E-19 Windshield wiper and window washer do not operate . 924
E-20 One-touch power maximizing function does not operate normally . 926
E-21 Swing brake does not operate normally . 929
E-22 Travel alarm does not sound or does not stop sounding . 932
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 934
E-24 While starting switch is in OFF position, service meter is not displayed 945
E-25 Machine monitor cannot be set in service mode . 946
E-26 Monitoring function does not display lever control signal normally 947
E-27 KOMTRAX system does not operate normally 953
500 Troubleshooting of hydraulic and mechanical system (H-mode) 955
System diagram of hydraulic and mechanical system 958
Information in troubleshooting table . 960
H-1 Speed or power of all work equipment and travel is low . 961
H-2 Engine speed lowers significantly or engine stalls . 962
H-3 All work equipment and travel systems do not work 963
H-4 Abnormal sound comes out from around hydraulic pump 964
H-5 Auto-decelerator does not operate 965
H-6 Fine control performance or response is low 966
H-7 Speed or power of boom is low 967
H-8 Speed or power of arm is low . 968
H-9 Speed or power of bucket is low 969
H-10 Work equipment does not move in its single operation 970
H-11 Hydraulic drift of work equipment is large 971
H-12 Time lag of work equipment is large . 972
H-13 When part of work equipment is relieved singly, other parts of work equipment move 973
H-14 Power maximizing function does not work . 974
H-15 In compound operation of work equipment, speed of part loaded more is low . 975
H-16 When machine swings and travels simultaneously, travel speed is low . 976
H-17 Machine deviates during travel 977
H-18 Travel speed is low . 978
H-19 Machine is not steered well or steering power is low 979
H-20 Travel speed does not shift or travel speed is low or high 980
H-21 Travel system does not work (only one side) . 981
H-22 Upper structure does not swing 982
H-23 Swing acceleration or swing speed of upper structure is low . 983
H-24 Upper structure overruns remarkably when it stops swinging 984
H-25 Large shock is made when upper structure stops swinging . 985
H-26 Large sound is made when upper structure stops swinging . 986
H-27 Upper structure lowers largely by its own weight 987
600 Troubleshooting of engine (S-mode) . 989
Method of using troubleshooting chart 990
S-1 Starting performance is poor . 994
S-2 Engine does not start 995
S-3 Engine does not pick up smoothly . 998
S-4 Engine stops during operations . 999
S-5 Engine does not run smoothly .1000
S-6 Engine lacks output power 1001
S-7 Exhaust smoke is black (incomplete combustion) .1002
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1003
S-9 Oil becomes contaminated early .1004
S-10 Fuel consumption is excessive .1005
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 1006
S-12 Oil pressure drops 1007
S-13 Oil level rises (Entry of coolant/fuel) .1008
S-14 Coolant temperature becomes too high (overheating) 1009
S-15 Abnormal noise is made 1010
S-16 Vibration is excessive 1011
700 Troubleshooting of Hybrid system (Y-mode) 1013
Precautions related to hybrid machine 1014
Y-1 Hybrid monitor does not go off .1016
Y-2 Upper structure does not swing .1018
Y-3 Swing acceleration or swing speed is low .1020
Y-4 Upper structure overruns largely after swinging 1021
Y-5 Large shock is made when upper structure stops swinging 1022
Y-6 Large abnormal sound is made when upper structure stops swinging .1023
Y-7 Upper structure lowers largely by its own weight .1024
Y-8 Electric swing motor temperature increases abnormally 1025
Y-9 Motor-generator temperature increases abnormally .1027
Y-10 Inverter temperature increases abnormally .1028
Y-11 Capacitor temperature increases abnormally 1029
50 Disassembly and assembly 0
100 General information on disassembly and assembly 1031
How to read this manual 1032
Precautions related to hybrid machine 1034
Coating materials list .1035
Special tools list .1038
Sketches of special tools 1042
200 Engine and cooling system 1049
Removal and installation of fuel supply pump assembly 1050
Removal and installation of fuel injector assembly .1054
Removal and installation of engine front seal 1061
Removal and installation of engine rear seal .1063
Removal and installation of cylinder head assembly .1066
Removal and installation of radiator assembly 1083
Removal and installation of hydraulic oil cooler assembly 1085
Removal and installation of aftercooler assembly .1088
Removal and installation of fuel cooler assembly .1091
Removal and installation of engine/motor-generator/hydraulic pump assembly .1093
Removal and installation of fuel tank assembly .1108
300 Hyblid Relation 1113
Draining and adding coolant and bleeding air for hybrid system .1114
Removal and installation of hybrid radiator assembly .1119
Removal and installation of water pump assembly for hybrid system 1122
Removal and installation of inverter assembly 1125
Removal and installation of inverter and capacitor assembly 1129
Draining and adding generator lubricating oil 1135
Removal and installation of tandem pump assembly .1137
Removal and installation of motor-generator assembly .1140
Removal and installation of motor-generator and housing assembly .1147
Removal and installation of swing electric motor assembly 1157
400 Power train 1165
Removal and installation of final drive assembly .1166
Disassembly and assembly of final drive assembly .1167
Removal and installation of “swing electric motor and swing machinery assembly” 1175
Disassembly and assembly of swing machinery assembly .1179
Removal and installation of swing circle assembly 1193
500 Undercarriage and frame 1195
Disassembly and assembly of carrier roller assembly 1196
Disassembly and assembly of track roller assembly 1199
Disassembly and assembly of idler assembly .1201
Disassembly and assembly of recoil spring assembly .1204
Removal and installation of sprocket .1206
Expansion and installation of track shoe assembly 1207
Removal and installation of revolving frame assembly .1210
Removal and installation of counterweight assembly .1212
600 Hydraulic system .1215
Removal and installation of center swivel joint assembly .1216
Disassembly and assembly of center swivel joint assembly .1218
Removal and installation of hydraulic tank assembly 1219
Removal and installation of control valve assembly .1224
Disassembly and assembly of control valve assembly .1228
Removal and installation of hydraulic pump assembly 1232
Removal and installation of oil seal in hydraulic pump input shaft .1236
Disassembly and assembly of work equipment PPC valve assembly 1237
Disassembly and assembly of travel PPC valve assembly 1239
Disassembly and assembly of hydraulic cylinder assembly 1242
700 Work equipment Body 1249
Removal and installation of work equipment assembly 1250
800 Cab and its attachments 1255
Removal and installation of operator’s cab assembly 1256
Removal and installation of operator cab glass (stuck glass) .1260
Removal and installation of front window assembly 1269
Removal and installation of floor frame assembly .1276
Removal and installation of air conditioner unit assembly 1281
900 Electric system 1285
Removal and installation of KOMTRAX terminal .1286
Removal and installation of machine monitor assembly .1287
Removal and installation of pump controller assembly .1289
Removal and installation of engine controller assembly .1292
90 Diagrams and Drawings . 0
100 Hydraulic diagrams and drawings 1295
Hydraulic circuit diagram 1297
200 Electrical diagrams and drawings .1301
Electrical circuit diagram .1303
Connector list and diarogram .1317

DESCRIPTION:

Komatsu PC200-8E0 PC200LC-8E0 Hydraulic Excavator Shop Manual SEN05221-07  – PDF DOWNLOAD

SERIAL NUMBERS

• PC200- 1001      and up
  PC200LC- 1001 and up

G.B 27/12/24