Komatsu PC200LC-8 HYDRAULIC EXCAVATOR Shop Manual CEBM025500 PDF

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Komatsu PC200LC-8 HYDRAULIC EXCAVATOR Shop Manual CEBM025500  – PDF DOWNLOAD

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Komatsu PC200LC-8 HYDRAULIC EXCAVATOR Shop Manual CEBM025500  – PDF DOWNLOAD

Language : English
Pages : 1060
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200LC-8 HYDRAULIC EXCAVATOR Shop Manual CEBM025500  – PDF DOWNLOAD

• SERIAL NUMBERS     PC200LC-8 A90301 and up
  ENGINE                        SAA6D107E-1

CEBM025500 PC200LC-8 LATIN AMERICA 1
CONTENTS 2
SAFETY 0
Safety Notice 0
IMPORTANT SAFETY NOTICE 0
General Precautions 0
Preparations For Work 0
Precautions During Work 0
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

DESCRIPTION:

Komatsu PC200LC-8 HYDRAULIC EXCAVATOR Shop Manual CEBM025500  – PDF DOWNLOAD

• SERIAL NUMBERS     PC200LC-8 A90301 and up
  ENGINE                        SAA6D107E-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

G.B 22/ 12/24