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Komatsu PC200LC-8 Hydraulic Excavator Shop Manual A90301 and up – PDF DOWNLOAD
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Komatsu PC200LC-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : PC200LC-8 A90301 and up
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Description
Komatsu PC200LC-8 Hydraulic Excavator Shop Manual A90301 and up
FILE DETAILS:
Komatsu PC200LC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200LC-8
Serial Number: A90301 and up
Book Code: CEBM025500
Language: English
Pages: 1060
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200LC-8 Hydraulic Excavator Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This 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. In addition, this section gives the judgement standards when inspecting disassembled parts.
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.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC200LC-8 Hydraulic Excavator Shop Manual
CEBM025500 PC200LC-8 LATIN AMERICA....................................................................... 1 CONTENTS............................................................................................. 2 GENERAL.............................................................................................. 5 HOW TO READ THE SHOP MANUAL.......................................................................... 6 Volumes.......................................................................................... 6 Distribution And Updating........................................................................ 6 Filing Method.................................................................................... 6 Revised Edition Mark............................................................................. 6 Revisions........................................................................................ 6 Symbols.......................................................................................... 6 HOISTING INSTRUCTIONS................................................................................ 7 Hoisting......................................................................................... 7 Wire Ropes....................................................................................... 7 PUSH PULL COUPLER.................................................................................... 8 Type 1........................................................................................... 8 Disconnection................................................................................ 8 Connection................................................................................... 8 Type 2........................................................................................... 9 Disconnection................................................................................ 9 Connection................................................................................... 9 Type 3........................................................................................... 10 Disconnection................................................................................ 10 Connection................................................................................... 10 COATING MATERIALS.................................................................................... 11 STANDARD TIGHTENING TORQUE........................................................................... 14 Standard Tightening Torque Of Bolts And Nuts..................................................... 14 Tightening Torque Of Hose Nuts................................................................... 15 Tightening Torque Of Split Flange Bolts.......................................................... 15 Tightening Torque For Flared Nuts................................................................ 15 Table Of Tightening Torques For O-ring Boss Piping Joints........................................ 16 Table Of Tightening Torques For O-ring Boss Plugs................................................ 16 Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)........................... 16 ELECTRIC WIRE CODE................................................................................... 17 Classification By Thickness...................................................................... 17 Classification By Color And Code................................................................. 17 CONVERSION TABLES.................................................................................... 18 Method Of Using The Conversion Table............................................................. 18 01 GENERAL............................................................................................... 25 SPECIFICATION AND TECHNICAL DATA..................................................................... 26 Specification Dimension Drawings................................................................. 26 Working Range Diagram............................................................................ 27 Specifications................................................................................... 28 Weight Table..................................................................................... 30 Table Of Fuel, Coolant And Lubricants............................................................ 32 Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil.............. 33 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......................................................... 35 ENGINE AND COOLING SYSTEM............................................................................ 39 Engine Related Parts............................................................................. 39 Radiator, Oil Cooler, Aftercooler and Fuel Cooler................................................ 40 POWER TRAIN.......................................................................................... 41 Power Train...................................................................................... 41 Final Drive...................................................................................... 42 Swing Machinery.................................................................................. 44 Swing Circle..................................................................................... 46 UNDERCARRIAGE AND FRAME.............................................................................. 48 Track Frame And Recoil Spring.................................................................... 48 Standard Shoe................................................................................ 49 Idler............................................................................................ 50 Carrier Roller................................................................................... 52 Track Roller..................................................................................... 54 Track Shoe....................................................................................... 56 Triple Grouser Shoe.......................................................................... 59 HYDRAULIC SYSTEM..................................................................................... 60 Hydraulic Equipment Layout Drawing............................................................... 60 Hydraulic Tank And Filter........................................................................ 62 Hydraulic Pump................................................................................... 64 Type: HPV95+95............................................................................... 64 Operation of pump............................................................................ 69 Control of delivery.......................................................................... 70 LS Valve..................................................................................... 71 PC Valve..................................................................................... 77 LS (PC)-EPC Valve............................................................................ 84 Pilot Oil Filter................................................................................. 87 For breaker.................................................................................. 87 Control Valve.................................................................................... 89 Outline...................................................................................... 89 General View................................................................................. 90 Sectional View............................................................................... 92 CLSS............................................................................................. 102 Outline of CLSS.............................................................................. 102 LS Differential Pressure and Pump Swash Plate Angle.......................................... 103 Functions and Operation by Valve................................................................. 106 Hydraulic Circuit Diagram and the Name of Valves............................................. 106 Unload Valve................................................................................. 108 Introduction Of LS Pressure.................................................................. 110 LS Bypass Plug............................................................................... 111 Pressure Compensation Valve.................................................................. 112 Integrated Pressure Compensation Valve....................................................... 113 Pressure Compensation Valve Inner Shuttle Valve.............................................. 115 Boom Regeneration Circuit.................................................................... 117 Arm Regeneration Circuit..................................................................... 119 Merge-divider Valve.......................................................................... 121 LS Select Valve.............................................................................. 124 Self Pressure Reducing Valve................................................................. 125 Travel Junction Valve........................................................................ 128 Travel PPC Shuttle Valve..................................................................... 130 Boom Drift Prevention Valve.................................................................. 133 Arm Drift Prevention Valve (if equipped)..................................................... 136 Quick Return Valve........................................................................... 140 Lift Check Valve............................................................................. 143 Main Relief Valve............................................................................ 144 2-stage Safety-suction Valve................................................................. 145 Swing Motor...................................................................................... 148 Torque Values................................................................................ 149 Specifications............................................................................... 149 Swing Holding Brake.......................................................................... 152 Relief Valve Portion......................................................................... 153 Outline...................................................................................... 153 Reverse Prevention Valve..................................................................... 154 Center Swivel Joint.......................................................................... 158 Travel Motor................................................................................. 160 Operation Of Motor........................................................................... 164 Operation of Parking Brake................................................................... 166 Brake Valve.................................................................................. 168 Operation When Pressurized Oil is Supplied................................................... 168 Operation of Brake During Traveling Downhill................................................. 169 PPC Valve........................................................................................ 172 Work Equipment and Swing PPC Valve........................................................... 172 Travel PPC Valve............................................................................. 178 Pressure reducing valve function............................................................. 182 Travel Signal/steering Function.............................................................. 184 Service PPC Valve (With EPC Valve)........................................................... 190 EPC valve.................................................................................... 192 When Signal Current Is 0..................................................................... 194 When Signal Current is Very Small............................................................ 194 When Signal Current Is Maximum............................................................... 195 Service PPC Valve................................................................................ 196 Valve Control.................................................................................... 198 Lever Positions.............................................................................. 199 Solenoid Valve................................................................................... 200 When Solenoid is De-energized................................................................ 201 When Solenoid is Energized................................................................... 202 PPC Accumulator.................................................................................. 203 Specifications............................................................................... 203 CRN (Canadian certified) PPC Accumulator......................................................... 203 Return Oil Filter................................................................................ 204 Attachment Circuit Selector Valve................................................................ 205 When Attachment Other Than Breaker is Installed.............................................. 206 When Breaker is Installed.................................................................... 206 Hydraulic Cylinder............................................................................... 208 PC200LC-8.................................................................................... 208 WORK EQUIPMENT....................................................................................... 210 Dimensions of Components......................................................................... 210 PC200LC-8.................................................................................... 211 CAB AND ITS ATTACHMENTS.............................................................................. 217 Air Conditioner Piping........................................................................... 217 ELECTRICAL SYSTEM.................................................................................... 218 Engine Control................................................................................... 218 Operation of system.......................................................................... 218 Component........................................................................................ 219 Fuel Control Dial............................................................................ 219 Engine Controller............................................................................ 220 Coolant Temperature Sensor................................................................... 223 Oil Pressure Switch.......................................................................... 223 Rotation Sensor.............................................................................. 224 Boost Pressure and Temperature Sensor........................................................ 224 WIF (Water-in-fuel Detection) Sensor......................................................... 225 Engine Oil Level Sensor...................................................................... 225 Electrical Control System........................................................................ 227 Machine Control System Diagram............................................................... 227 MONITOR SYSTEM....................................................................................... 251 Machine Monitor.................................................................................. 252 Input And Output Signals..................................................................... 253 Monitor Control, Display Portion................................................................. 255 Precautions on the Machine Monitor Display................................................... 256 Monitor Items and Display.................................................................... 257 Switches......................................................................................... 261 Buzzer Cancel Switch......................................................................... 261 Auto-deceleration Switch..................................................................... 261 Guidance Icon And Function Switch............................................................ 261 Working Mode Selector Switch................................................................. 263 Travel Speed Selector Switch................................................................. 263 Window Washer Switch......................................................................... 264 Wiper Switch................................................................................. 264 Air Conditioner Control Switch............................................................... 264 Camera Screen Display Function............................................................... 265 Service Meter/Time Selector Function......................................................... 266 Maintenance Function......................................................................... 266 User Mode.................................................................................... 268 Breaker/Attachment Setting................................................................... 268 Changing Breaker Mode Setting................................................................ 269 Changing Attachment Mode Setting............................................................. 271 Message Display.............................................................................. 272 Screen Adjustment............................................................................ 273 Clock Adjustment............................................................................. 273 Language Setting............................................................................. 274 Economy Mode Adjustment...................................................................... 274 Idle Stop Guidance Function.................................................................. 275 Service Meter Check Function................................................................. 275 Display LCD Check Function................................................................... 275 User Code/Failure Code Display Function...................................................... 276 SENSOR............................................................................................... 277 Fuel Level Sensor................................................................................ 277 Air Cleaner Clogging Sensor...................................................................... 278 Coolant Level Sensor............................................................................. 278 KOMTRAX TERMINAL SYSTEM.............................................................................. 279 KOMTRAX Communication ORBCOMM.................................................................... 280 TH300........................................................................................ 280 Input And Output Signals..................................................................... 280 20 STANDARD VALUE TABLES................................................................................. 281 STANDARD SERVICE VALUE TABLE......................................................................... 283 Standard Service Value Table for Engine.......................................................... 283 Standard Value Table for Chassis Related Parts................................................... 284 Machine Position for Measurement................................................................. 291 Control Valve: Spool Stroke.................................................................. 291 Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing................... 291 Swing 2: Hydraulic Drift Of Swing............................................................ 291 Travel 1: Travel Speed (Without Load)........................................................ 291 Travel 2: Travel Speed (Actual Run), Travel Deviation........................................ 292 Travel 3: Travel Deviation................................................................... 292 Travel 4: Hydraulic Drift Of Travel.......................................................... 292 Work Equipment 1: Hydraulic Drift Of Work Equipment.......................................... 292 Work Equipment 2: Boom Speed................................................................. 293 Work Equipment 3: Arm Speed.................................................................. 293 Work Equipment 4: Bucket Speed............................................................... 293 Work Equipment 5: Boom Time Lag.............................................................. 293 Work Equipment 6: Arm Time Lag............................................................... 294 Work Equipment 7: Bucket Time Lag............................................................ 294 Work Equipment 8: Characteristics Of PC Flow Control Valve................................... 294 30 TESTING AND ADJUSTING................................................................................. 295 SPECIAL TOOL LIST.................................................................................... 298 Sketch Of Special Tool........................................................................... 301 ENGINE COMPONENTS.................................................................................... 302 Determining A Defective Cylinder................................................................. 302 Procedures................................................................................... 302 Determining Cylinder Group................................................................... 302 Isolating the Defective Cylinder............................................................. 302 Water Pump Leakage............................................................................... 303 Engine Speed..................................................................................... 308 Intake Air Pressure (Boost Pressure)............................................................. 310 Exhaust Gas Color................................................................................ 311 Valve Clearance.................................................................................. 313 Compression Pressure............................................................................. 315 Blow-by Pressure................................................................................. 317 Engine Oil Pressure.............................................................................. 318 Handling Fuel System Parts....................................................................... 319 Releasing Residual Pressure From Fuel System................................................. 319 Fuel Pressure.................................................................................... 320 Fuel Return Rate And Leakage..................................................................... 323 Bleeding Air From Fuel Circuit................................................................... 328 Fuel Circuit - Checking For Leakage.............................................................. 329 AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................. 330 Checking......................................................................................... 330 Adjusting........................................................................................ 330 FAN BELT............................................................................................. 331 SWING CIRCLE BEARING CLEARANCE....................................................................... 332 TRACK SHOE TENSION................................................................................... 334 Checking......................................................................................... 334 Adjusting........................................................................................ 334 OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS........................................... 336 Measuring........................................................................................ 336 Adjusting........................................................................................ 339 CONTROL CIRCUIT BASIC PRESSURE....................................................................... 341 OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.............................................................. 343 Measuring........................................................................................ 343 Adjusting........................................................................................ 345 Pump PC Valve................................................................................ 345 OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.............................................................. 346 Measuring........................................................................................ 346 Adjusting........................................................................................ 350 LS valve..................................................................................... 350 SOLENOID VALVE OUTPUT PRESSURE....................................................................... 351 PPC VALVE OUTPUT PRESSURE............................................................................ 354 Connecting Points Of PPC Piping.................................................................. 354 Adjusting Play of Work Equipment and Swing PPC Valves............................................ 356 WORK EQUIPMENT HYDRAULIC DRIFT....................................................................... 357 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT................................................... 359 OIL LEAKAGE.......................................................................................... 360 BLEEDING AIR FROM EACH PART.......................................................................... 363 CAB TIPPING STOPPER.................................................................................. 365 MIRRORS.............................................................................................. 366 REAR VIEW CAMERA..................................................................................... 369 Angle Adjustment................................................................................. 369 MACHINE MONITOR SPECIAL FUNCTIONS.................................................................... 371 Air Conditioner Specification.................................................................... 371 Upper Section of Machine Monitor................................................................. 372 Display Section.............................................................................. 372 Switch Section............................................................................... 372 Lower Section Of Machine Monitor................................................................. 372 Switch Section............................................................................... 372 Ordinary Functions and Special Functions of Machine Monitor...................................... 373 Operator Mode (Outline).......................................................................... 375 Display of KOMATSU Logo...................................................................... 376 Display of Inputting Password................................................................ 376 Display of Check of Breaker Mode............................................................. 376 Display of Check Before Starting............................................................. 377 Display of Warning After Check Before Starting............................................... 377 Display of Ending of Maintenance Interval.................................................... 377 Display of Check of Working Mode and Travel Speed............................................ 377 Display of Ordinary Screen................................................................... 378 Display of End Screen........................................................................ 378 Selection of Auto-Deceleration............................................................... 378 Selection of Working Mode.................................................................... 378 Selection of Travel Speed.................................................................... 380 Operation to Stop Alarm Buzzer............................................................... 380 Operation of Windshield Wiper................................................................ 380 Operation of Window Washer................................................................... 380 Operation of Air Conditioner/heater.......................................................... 380 Operation to Display Camera Mode (If Camera is Installed).................................... 381 Operation to Display Clock and Service Meter................................................. 382 Check of Maintenance Information............................................................. 382 Setting and Display of User Mode (Including KOMTRAX Messages for User)....................... 383 KOMTRAX Message.............................................................................. 384 Display of Energy-Saving Guidance............................................................ 384 Display of Caution Monitor................................................................... 384 Display of Automatic Judgment of Breaker..................................................... 384 Display of User Code and Failure Code........................................................ 385 Function of Checking Display of LCD (Liquid Crystal Display)................................. 386 Function of Checking Service Meter........................................................... 386 Function of Changing Attachment/Maintenance Password......................................... 386 Service Mode..................................................................................... 388 Monitoring................................................................................... 389 Monitoring Items Table....................................................................... 392 Abnormality Record (Mechanical Systems)...................................................... 395 Abnormality Record (Electrical Systems)...................................................... 396 Failure Codes Table.......................................................................... 398 Abnormality Record (Air-Conditioning System/ Heater System).................................. 402 Maintenance Record........................................................................... 403 Maintenance Mode Change...................................................................... 404 Phone Number Entry........................................................................... 406 Default (Key-on Mode)........................................................................ 407 Default (Unit)............................................................................... 408 Default (With/Without Attachment)............................................................ 409 Default (Attachment/Maintenance Password).................................................... 410 Default (Camera)............................................................................. 411 Default (ECO Display)........................................................................ 412 Default (Breaker Detect)..................................................................... 414 Adjustment (Pump Absorption Torque (F))...................................................... 415 Adjustment (Pump Absorption Torque (R))...................................................... 416 Adjustment (Low Speed)....................................................................... 417 Adjustment (Attachment Flow Adjustment)...................................................... 418 Cylinder Cut-Out............................................................................. 419 No Injection................................................................................. 420 Fuel Consumption............................................................................. 422 KOMTRAX Settings (Terminal Status)........................................................... 423 KOMTRAX Settings (GPS & Communication Status)................................................ 424 KOMTRAX Setting (MODEM S/N: TH300)........................................................... 425 Display of KOMTRAX message................................................................... 426 Long Distance Transport Mode..................................................................... 427 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER........................................................ 429 PREPARING FOR ELECTRICAL SYSTEM TROUBLESHOOTING...................................................... 429 PROCEDURE FOR TESTING DIODES......................................................................... 434 PM CLINIC SERVICE.................................................................................... 436 40 TROUBLESHOOTING....................................................................................... 445 GENERAL INFORMATION.................................................................................. 449 Points To Remember............................................................................... 449 Sequence Of Events In Troubleshooting............................................................ 451 Handling Electric Equipment and Hydraulic Components............................................. 452 New Connectors for Tier 3 Engines................................................................ 460 Check Before Troubleshooting..................................................................... 464 Classification And Troubleshooting Steps......................................................... 465 Troubleshooting Classification............................................................... 465 Troubleshooting steps........................................................................ 465 Information In Troubleshooting Table......................................................... 466 Related Circuit Diagram...................................................................... 467 Possible Problems and Troubleshooting No......................................................... 468 How To Read Electric Wire Code................................................................... 471 Connection Table For Connector Pin Numbers....................................................... 474 T-boxes and T-adapters Table..................................................................... 507 FAILURE CODE (DISPLAY OF CODE)....................................................................... 510 Failure Codes Table.............................................................................. 510 Before Troubleshooting With Failure Code Displayed............................................... 515 Fuse Box Connection Table.................................................................... 515 Locations Of Fusible Links................................................................... 516 Location Of Fuse Box And Fuse Nos............................................................ 516 Trouble That Occurs When Power Supply Of Pump Controller Is Defective........................ 517 989L00 Engine Controller Lock Caution 1.......................................................... 519 989M00 Engine Controller Lock Caution 2.......................................................... 519 989N00 Engine Controller Lock Caution 3.......................................................... 520 AA10NX Air Cleaner Clogging...................................................................... 520 AB00KE Charge Voltage Low........................................................................ 522 B@BAZG Eng Oil Press. Low........................................................................ 524 B@BAZK Eng Oil Level Low......................................................................... 524 B@BCNS Eng Water Overheat........................................................................ 525 B@BCZK Eng Water Level Low....................................................................... 525 B@HANS Hydr Oil Overheat......................................................................... 526 CA111 EMC Critical Internal Failure.............................................................. 526 CA115 Eng Ne and Bkup Speed Sens Error........................................................... 527 CA122 Chg Air Press Sensor High Error............................................................ 528 CA123 Chg Air Press Sensor Low Error............................................................. 530 CA131 Throttle Sensor High Error................................................................. 532 CA132 Throttle Sensor Low Error.................................................................. 534 CA144 Coolant Temp Sens High Error............................................................... 536 CA145 Coolant Temp Sens Low Error................................................................ 538 CA153 Chg Air Temp Sensor High Error............................................................. 540 CA154 Chg Air Temp Sensor Low Error.............................................................. 542 CA155 Chg Air Temp High Speed Derate............................................................. 544 CA187 Sens Supply 2 Volt Low Error............................................................... 546 CA221 Ambient Press Sens High Error.............................................................. 548 CA222 Ambient Press Sens Low Error............................................................... 550 CA227 Sens Supply 2 Volt High Error.............................................................. 552 CA234 Eng Overspeed.............................................................................. 553 CA238 Ne Speed Sens Supply Volt Error............................................................ 554 CA271 IMV/PCV1 Short Error....................................................................... 555 CA272 IMV/PCV1 Open Error........................................................................ 556 CA322 Inj #1 Open/Short Error.................................................................... 558 CA323 Inj #5 Open/Short Error.................................................................... 560 CA324 Inj #3 Open/Short Error.................................................................... 562 CA325 Inj #6 Open/Short Error.................................................................... 564 CA331 Inj #2 Open/Short Error.................................................................... 566 CA332 Inj #4 Open/Short Error.................................................................... 568 CA342 Calibration Code Incompatibility........................................................... 570 CA351 Injectors Drive Circuit Error.............................................................. 572 CA352 Sens Supply 1 Volt Low Error............................................................... 574 CA386 Sens Supply 1 Volt High Error.............................................................. 576 CA428 Water in Fuel Sensor High Error............................................................ 578 CA429 Water in Fuel Sensor Low Error............................................................. 580 CA435 Eng Oil Press Sw Error..................................................................... 582 CA441 Battery Voltage Low Error.................................................................. 583 CA442 Battery Voltage High Error................................................................. 586 CA449 Rail Press Very High Error................................................................. 588 CA451 Rail Press Sensor High Error............................................................... 590 CA452 Rail Press Sensor Low Error................................................................ 592 CA488 Chg Air Temp High Torque Derate............................................................ 594 CA553 Rail Press High Error...................................................................... 595 CA559 Rail Press Low Error....................................................................... 596 CA689 Eng Ne Speed Sensor Error.................................................................. 598 CA731 Eng Bkup Speed Sens Phase Error............................................................ 600 CA757 All Continuous Data Lost Error............................................................. 602 CA778 Eng Bkup Speed Sensor Error................................................................ 604 CA2185 Throt Sens Sup Volt High Error............................................................ 607 CA2186 Throt Sens Sup Volt Low Error............................................................. 608 CA2249 Rail Press Very Low Error................................................................. 609 CA2311 IMV Solenoid Error........................................................................ 610 CA2555 Grid Htr Relay Volt High Error............................................................ 612 CA2556 Grid Htr Relay Volt Low Error............................................................. 614 D19JKZ Personal Code Relay Abnormality........................................................... 616 D862KA GPS Antenna Discon........................................................................ 618 DA22KK Pump Solenoid Power Low Error............................................................. 620 DA25KP 5V Sensor 1 Power Abnormality............................................................. 622 DA29KQ Model Selection Abnormality............................................................... 628 DA2RMC CAN Discon (Pump Con Detected)............................................................ 630 DAF8KB Short Circuit In Camera Power Supply...................................................... 638 DAFGMC GPS Module Error.......................................................................... 640 DAFRMC CAN Discon (Monitor Detected)............................................................. 641 DGH2KB Hyd Oil Sensor Short...................................................................... 648 DHPAMA F Pump Press Sensor Abnormality........................................................... 650 DHPBMA R Pump Press Sensor Abnormality........................................................... 652 DHS3MA Arm Curl PPC Press Sensor Abnormality..................................................... 654 DHS4MA Bucket Curl PPC Press Sensor Abnormality.................................................. 656 DHS8MA Boom Raise PPC Press Sensor Abnormality................................................... 658 DHSAMA Swing RH PPC Press Sensor Abnormality..................................................... 660 DHSBMA Swing LH PPC Press Sensor Abnormality..................................................... 662 DHSDMA Bucket Dump PPC Press Sensor Abnormality.................................................. 664 DHX1MA Overload Sensor Abnormality (Analog)...................................................... 666 DW43KA Travel Speed Sol Discon................................................................... 670 DW43KB Travel Speed Sol Short.................................................................... 672 DW45KA Swing Brake Sol Discon.................................................................... 674 DW45KB Swing Brake Sol Short..................................................................... 676 DW91KA Travel Junction Sol Discon................................................................ 678 DW91KB Travel Junction Sol Short................................................................. 680 DWA2KA Service Sol Discon........................................................................ 682 DWA2KB Service Sol Short......................................................................... 683 DWK0KA 2-Stage Relief Sol Discon................................................................. 684 DWK0KB 2-Stage Relief Sol Short.................................................................. 686 DXA8KA PC-EPC (F) Sol Discon..................................................................... 688 DXA8KB PC-EPC (F) Sol Short...................................................................... 690 DXA9KA PC-EPC (R) Sol Discon..................................................................... 692 DXA9KB PC-EPC (R) Sol Short...................................................................... 694 DXE0KA LS-EPC Sol Discon......................................................................... 696 DXE0KB LS-EPC Sol Short.......................................................................... 698 DXE4KA Service Current EPC Discon................................................................ 700 DXE4KB Service Current EPC Short................................................................. 702 DXE5KA Merge-divider Main Sol Discon............................................................. 704 DXE5KB Merge-divider Main Sol Short.............................................................. 706 DXE6KA Merge-divider LS Sol Discon............................................................... 708 DXE6KB Merge-divider LS Sol Short................................................................ 710 DY20KA Wiper Working Abnormality................................................................. 712 DY20MA Wiper Parking Abnormality................................................................. 714 DY2CKA Washer Drive Discon....................................................................... 716 DY2CKB Washer Drive Short........................................................................ 718 DY2DKB Wiper Drive (For) Short................................................................... 720 DY2EKB Wiper Drive (Rev) Short................................................................... 722 ELECTRICAL SYSTEM (E-MODE)........................................................................... 724 Troubleshooting Table............................................................................ 724 E-1 No Machine Monitor Display When Starting Switch Is Turned On................................. 726 E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)........... 728 E-3 Engine Does Not Start........................................................................ 731 E-4 Preheater Does Not Operate................................................................... 736 E-5 Automatic Warm-up System Does Not Operate (In Cold Season)................................... 740 E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked.............. 742 E-7 Precaution Lights Up While Engine Is Running................................................. 744 E-8 Emergency Stop Item Lights Up While Engine Is Running........................................ 749 E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally.................................. 750 E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally.................................. 751 E-11 Fuel Level Gauge Does Not Indicate Normally................................................. 754 E-12 Machine Monitor Content Displays Are Different From Applicable Machine...................... 756 E-13 Machine Monitor Does Not Display Some Items................................................. 756 E-14 Function Switch Does Not Work............................................................... 756 E-15 Auto-decelerator Does Not Operate Normally.................................................. 757 E-16 Working Mode Does Not Change................................................................ 758 E-17 Travel Speed Does Not Change................................................................ 759 E-18 Alarm Buzzer Cannot be Stopped.............................................................. 760 E-19 Windshield Wiper and Window Washer Do Not Operate........................................... 762 E-20 Power Maximizing Function Does Not Operate Normally......................................... 764 E-21 Swing Holding Brake Does Not Operate Normally............................................... 766 E-22 Travel Alarm Does Not Sound or Does Not Stop................................................ 768 E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record).... 770 E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position....................... 792 E-25 Machine Monitor Cannot Be Set In Service Mode............................................... 792 E-26 Monitoring Function Does Not Display Lever Control Signal Normally.......................... 793 E-27 Komtrax System Does Not Operate Normally.................................................... 802 HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)............................................................. 804 System Diagram of Hydraulic and Mechanical System................................................ 804 Information In Troubleshooting Table............................................................. 806 H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow........................... 807 H-2 Engine Speed Drops Sharply or Engine Stalls.................................................. 809 H-3 Work Equipment, Swing, and Travel Systems Do Not Work........................................ 810 H-4 Abnormal Noise Is Heard Around Hydraulic Pump................................................ 810 H-5 Auto-decelerator Does Not Work............................................................... 811 H-6 Fine Control Mode Does Not Function or Responds Slow......................................... 811 H-7 Boom Moves Slowly or Lacks Power............................................................. 812 H-8 Arm Moves Slowly or Lacks Power.............................................................. 813 H-9 Bucket Moves Slowly or Lacks Power........................................................... 814 H-10 Work Equipment Does Not Move In Its Single Operation........................................ 814 H-11 Work Equipment Hydraulic Drift Is Too Fast.................................................. 815 H-12 Work Equipment Has Big Time Lag............................................................. 817 H-13 Other Work Equipment Moves When Relieving Single Circuit.................................... 817 H-14 Power Maximizing Function Does Not Work..................................................... 818 H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly......................... 818 H-16 In Swing and Boom Raise Operation, Boom Moves Slowly........................................ 819 H-17 In Swing and Travel Operation, Travel Speed Drops Sharply................................... 819 H-18 Machine Swerves In Travel................................................................... 820 H-19 Machine Travels Slowly...................................................................... 821 H-20 Machine Steers With Difficulty or Lacks Power............................................... 822 H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast...................................... 823 H-22 Track Shoe Does Not Turn (On One Side Only)................................................. 824 H-23 Machine Does Not Swing...................................................................... 825 H-24 Swing Acceleration Is Poor or Swing Speed Is Slow........................................... 827 H-25 Excessive Overrun When Stopping Swing....................................................... 829 H-26 There Is a Big Jolt When Stopping Swing..................................................... 830 H-27 Large Sound Is Made When Upper Structure Stops Swinging..................................... 830 H-28 Swing Hydraulic Drift Is Too Big............................................................ 831 H-29 Attachment Circuit Is Not Changed........................................................... 832 H-30 Oil Flow In Attachment Circuit Cannot Be Controlled......................................... 832 50 DISASSEMBLY AND ASSEMBLY.............................................................................. 833 HOW TO READ THIS SECTION............................................................................. 837 Removal And Installation Of Assemblies........................................................... 837 Special Tools................................................................................ 837 Removal...................................................................................... 837 Installation................................................................................. 837 Disassembly And Assembly Of Assemblies........................................................... 838 Special Tools................................................................................ 838 Disassembly.................................................................................. 838 Assembly..................................................................................... 839 SPECIAL TOOLS LIST................................................................................... 840 SKETCHES OF SPECIAL TOOLS............................................................................ 845 CONNECTOR REPAIR PROCEDURES.......................................................................... 850 Stripping Insulation............................................................................. 850 Wire Inspection.................................................................................. 850 Contact Terminal Removal (HD30 Type)............................................................. 851 Crimping Contact Terminal (HD30 Type)............................................................ 852 Insertion Of Contact Terminal (HD30 Type)........................................................ 853 Contact Terminal Removal (DT Type)............................................................... 854 Crimping Contact Terminal (DT Type).............................................................. 855 Insertion Of Contact Terminal (DT Type).......................................................... 856 ENGINE AND COOLING SYSTEM............................................................................ 857 Fuel Supply Pump Assembly........................................................................ 857 Special Tools................................................................................ 857 Removal...................................................................................... 857 Installation................................................................................. 861 Fuel Injector Assembly........................................................................... 863 Special Tools................................................................................ 863 Removal...................................................................................... 863 Installation................................................................................. 868 Engine Front Seal................................................................................ 873 Special Tools................................................................................ 873 Removal...................................................................................... 873 Installation................................................................................. 875 Engine Rear Seal................................................................................. 877 Special Tools................................................................................ 877 Removal...................................................................................... 877 Installation................................................................................. 878 Cylinder Head.................................................................................... 881 Special Tools................................................................................ 881 Removal...................................................................................... 881 Installation................................................................................. 889 Radiator......................................................................................... 899 Removal...................................................................................... 899 Installation................................................................................. 901 Hydraulic Oil Cooler............................................................................. 903 Removal...................................................................................... 903 Installation................................................................................. 905 Aftercooler Assembly............................................................................. 906 Removal...................................................................................... 906 Installation................................................................................. 908 Fuel Cooler...................................................................................... 909 Removal...................................................................................... 909 Installation................................................................................. 909 Engine And Hydraulic Pump........................................................................ 910 Special Tools................................................................................ 910 Removal...................................................................................... 910 Installation................................................................................. 919 POWER TRAIN.......................................................................................... 922 Final Drive...................................................................................... 922 Removal...................................................................................... 922 PC200LC-8 Final Drive............................................................................ 924 Special Tools................................................................................ 924 Disassembly.................................................................................. 924 Assembly..................................................................................... 927 Swing Motor and Swing Machinery.................................................................. 934 Removal...................................................................................... 934 Installation................................................................................. 936 Swing Motor and Swing Machinery.................................................................. 937 Special Tools................................................................................ 937 Disassembly.................................................................................. 937 Assembly..................................................................................... 942 Swing Circle Assembly............................................................................ 948 Removal...................................................................................... 948 Installation................................................................................. 948 UNDERCARRIAGE AND FRAME.............................................................................. 949 Carrier Roller................................................................................... 949 Special Tools................................................................................ 949 Disassembly.................................................................................. 949 Assembly..................................................................................... 950 Track Roller..................................................................................... 953 Special Tools................................................................................ 953 Disassembly.................................................................................. 953 Assembly..................................................................................... 953 Idler, Recoil Spring............................................................................. 955 Removal...................................................................................... 955 Installation................................................................................. 955 Idler............................................................................................ 956 Special Tools................................................................................ 956 Disassembly.................................................................................. 956 Assembly..................................................................................... 957 Recoil Spring.................................................................................... 960 Special Tools................................................................................ 960 Disassembly.................................................................................. 960 Assembly..................................................................................... 961 Sprocket......................................................................................... 963 Removal...................................................................................... 963 Installation................................................................................. 963 Track Shoe....................................................................................... 964 Special Tools................................................................................ 964 Expanding Track Shoe......................................................................... 964 Installation of Track Shoe................................................................... 966 Revolving Frame.................................................................................. 967 Removal...................................................................................... 967 Installation................................................................................. 969 Counterweight.................................................................................... 970 Special Tools................................................................................ 970 Removal...................................................................................... 970 Installation................................................................................. 972 HYDRAULIC SYSTEM..................................................................................... 973 Center Swivel Joint.............................................................................. 973 Removal...................................................................................... 973 Installation................................................................................. 974 Special Tools................................................................................ 975 Disassembly.................................................................................. 975 Assembly..................................................................................... 976 Hydraulic Tank................................................................................... 977 Removal...................................................................................... 977 Installation................................................................................. 980 Control Valve.................................................................................... 981 Removal...................................................................................... 981 Installation................................................................................. 986 Special Tools................................................................................ 987 Precautions for Replacing Pressure Compensation Valve Seal................................... 988 Precautions for Assembling Control Valve..................................................... 990 Hydraulic Pump................................................................................... 993 Special Tools................................................................................ 993 Removal...................................................................................... 993 Installation................................................................................. 997 Oil Seal In Hydraulic Pump Input Shaft........................................................... 998 Special Tools................................................................................ 998 Removal...................................................................................... 998 Installation................................................................................. 998 Work Equipment PPC Valve......................................................................... 999 Disassembly.................................................................................. 999 Assembly..................................................................................... 999 Travel PPC Valve.................................................................................1001 Special Tools................................................................................1001 Disassembly..................................................................................1001 Assembly.....................................................................................1002 Hydraulic Cylinder...............................................................................1004 Special Tools................................................................................1004 Disassembly..................................................................................1005 Assembly.....................................................................................1007 WORK EQUIPMENT.......................................................................................1011 Work Equipment Assembly..........................................................................1011 Special Tools................................................................................1011 Removal......................................................................................1011 Installation.................................................................................1013 CAB AND ITS ATTACHMENTS..............................................................................1014 Operator's Cab...................................................................................1014 Removal......................................................................................1014 Installation.................................................................................1017 Operator Cab Glass (Fixed Glass).................................................................1018 Special Tools................................................................................1019 Removal......................................................................................1019 Installation.................................................................................1020 Front Window.....................................................................................1029 Removal......................................................................................1029 Installation.................................................................................1032 Floor Frame Assembly.............................................................................1037 Special Tools................................................................................1037 Removal......................................................................................1037 Installation.................................................................................1041 ELECTRICAL SYSTEM....................................................................................1042 Air Conditioner Unit Assembly....................................................................1042 Special Tools................................................................................1042 Removal......................................................................................1042 Installation.................................................................................1046 KOMTRAX Communication Modem......................................................................1047 Removal......................................................................................1047 Installation.................................................................................1047 Monitor..........................................................................................1048 Removal......................................................................................1048 Installation.................................................................................1049 Pump Controller..................................................................................1050 Removal......................................................................................1050 Installation.................................................................................1051 Engine Controller................................................................................1053 Removal......................................................................................1053 Installation.................................................................................1054 90 DIAGRAMS AND SCHEMATICS...............................................................................1055 HYDRAULIC SYSTEM.....................................................................................1057 Hydraulic Circuit Diagram........................................................................1057 ELECTRICAL SYSTEM....................................................................................1058 Electrical Circuit Diagram.......................................................................1058 Connector Arrangement Diagram....................................................................1059 Electrical Circuit Diagram for Air Conditioner...................................................1060
KOMATSU PC200LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL A90301 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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Ahmad Landon –