Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200-3, PC200-8, PC200LC-8, PC210LC-3, PC220-3, PC240LC-3, PC240LC-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC200-3, PC210LC-3, PC220-3, PC240LC-3, PC200-8, PC200LC-8, PC240LC-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

KEN00084-13 - Hydraulic Excavator PC200-8, PC200LC-8, PC240LC-8 Shop Manual.pdf
SEBM02050309 - Hydraulic Excavator PC200-3, PC210LC-3, PC220-3, PC240LC-3 Shop Manual.pdf
KEAM042800 - Hydraulic Excavator PC200-8, PC200LC-8, PC240LC-8 Operation & Maintenance Manual.pdf
KPAM042800 - Escavadeiras Hidráulicas PC200-8, PC200LC-8, PC240LC-8 Manual de Operação e Manutenção.pdf

Total Pages: 2,621 pages
File Format: PDF
Language: English

KEAM042800 - Hydraulic Excavator PC200-8, PC200LC-8, PC240LC-8 Operation & Maintenance Manual....2
  FOREWORD....4
    BEFORE READING THIS MANUAL....5
    SAFETY INFORMATION....6
    INTRODUCTION....7
      USE OF MACHINE....7
      DIRECTIONS OF MACHINE....7
      VISIBILITY FROM OPERATOR'S SEAT....7
      PROTECTIVE STRUCTURE....7
    PRODUCT INFORMATION....8
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....8
      EPA REGULATIONS, ENGINE NUMBER PLATE....8
      SERVICE METER LOCATION....9
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....9
  CONTENTS....10
    FOREWORD....10
    SAFETY....10
    OPERATION....11
    MAINTENANCE....13
    SPECIFICATIONS....15
    ATTACHMENTS AND OPTIONS....15
    INDEX....17
    COLOPHON....17
  SAFETY....18
    SAFETY....19
    SAFETY LABELS....21
      LOCATION OF SAFETY LABELS....22
      SAFETY LABELS....23
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....30
      PRECAUTIONS BEFORE STARTING OPERATION....30
      PREPARATIONS FOR SAFE OPERATION....30
      FIRE PREVENTION....32
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....33
      DO NOT GET CAUGHT IN WORK EQUIPMENT....35
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....35
      PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS....36
      UNAUTHORIZED MODIFICATION....37
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....37
      PRECAUTIONS RELATED TO CAB GLASS....37
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....37
    PRECAUTIONS FOR OPERATION....38
      PRECAUTIONS FOR JOBSITE....38
      STARTING ENGINE....40
      OPERATION....42
      TRANSPORTATION....50
      TOWING....51
      LIFTING OBJECTS WITH BUCKET....52
    PRECAUTIONS FOR MAINTENANCE....53
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....53
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE....57
  OPERATION....64
    MACHINE VIEW ILLUSTRATIONS....65
      OVERALL MACHINE VIEW....65
      CONTROLS AND GAUGES....66
    DETAILED CONTROLS AND GAUGES....68
      MONITORING SYSTEM....68
        Basic Operation of Machine Monitor....69
        Emergency Monitors....74
        Caution Monitors....76
        Basic Check Monitors....79
        Meter Display Portion....81
        Monitor Switches Portion....89
        Handling Function Switches....98
      SWITCHES....134
      CONTROL LEVERS AND PEDALS....139
      SUN ROOF....142
      WINDSHIELD....142
      EMERGENCY ESCAPE HAMMER....148
      DOOR LOCK....148
      CAP WITH LOCK....149
      DRINK BOX....151
      MAGAZINE BOX....151
      ASHTRAY....151
      AIR CONDITIONER CONTROLS....152
        Air Conditioner Control Panel....152
        Method of Operation....157
        Use Air Conditioner with Care....164
        Inspection and maintenance of Air Conditioner Equipped Machine....164
      RADIO....165
        Control Panel....165
        Controls of Radio....167
        Use Radio with Care....169
      AUXILIARY ELECTRIC POWER....170
        24V Power Source....170
        12V Power Source....170
      FUSE....171
      FUSIBLE LINK....172
      CONTROLLER....172
      TOOL BOX....172
      GREASE PUMP HOLDER....172
      FIRE EXTINGUISHER....173
    MACHINE OPERATIONS AND CONTROLS....174
      BEFORE STARTING ENGINE....174
        Walk-around Checks....174
        Checks Before Starting....176
        Adjustment....186
        Seat Belt....192
        Operations Before Starting Engine....193
      STARTING ENGINE....195
      AFTER STARTING ENGINE....198
        Breaking-in the New Machine....199
        Engine Warm Up....199
        Hydraulic Equipment Warm Up....201
        Operation After Completion Of Warm-Up Operation....207
      STOPPING THE ENGINE....209
      MACHINE OPERATION....210
        Preparations for Moving the Machine....210
        Moving Machine Forward....211
        Moving Machine Backward....212
        Stopping Machine....213
      STEERING THE MACHINE....214
        Steering....214
      SWINGING....216
      WORK EQUIPMENT CONTROLS AND OPERATIONS....217
      WORKING MODE....219
      PROHIBITED OPERATIONS....221
      GENERAL OPERATION INFORMATION....224
      TRAVELING ON SLOPES....226
      ESCAPE FROM MUD....228
        Track on One Side Stuck....228
        Tracks on Both Sides Stuck....228
      RECOMMENDED APPLICATIONS....229
        Backhoe Work....229
        Shovel Work....229
        Ditching Work....229
        Loading Work....230
      BUCKET REPLACEMENT AND INVERSION....231
        Replacement....231
        Inversion....233
      PARKING MACHINE....235
      MACHINE INSPECTION AFTER DAILY WORK....236
      LOCKING....237
    TRANSPORTATION....238
      TRANSPORTATION PROCEDURE....238
      LOADING AND UNLOADING WITH TRAILER....239
        Loading....240
        Securing Machine....243
        Unloading....246
      LIFTING MACHINE....248
        Standard Specification Machine....248
        Machines With Lifting Hook....249
    COLD WEATHER OPERATION....251
      COLD WEATHER OPERATION INFORMATION....251
        Fuel and Lubricants....251
        Cooling System Coolant....251
        Battery....252
      AFTER DAILY WORK COMPLETION....253
      AFTER COLD WEATHER SEASON....253
    LONG TERM STORAGE....254
      BEFORE STORAGE....254
      DURING STORAGE....254
      AFTER STORAGE....255
      STARTING MACHINE AFTER LONG-TERM STORAGE....255
    TROUBLES AND ACTIONS....256
      RUNNING OUT OF FUEL....256
      PHENOMENA THAT ARE NOT FAILURES....256
      TOWING THE MACHINE....257
      LIGHTWEIGHT TOWING HOLE....258
      SEVERE JOB CONDITION....258
      DISCHARGED BATTERY....259
        Battery Removal and Installation....259
        Battery Charges....260
        Starting Engine with Booster Cables....261
      OTHER TROUBLE....263
        Electrical System....263
        Chassis....264
        Engine....265
        Electronic Control System....267
        Point of Contact to Telephone when Error Occurs....268
  MAINTENANCE....270
    MAINTENANCE INFORMATION....271
    OUTLINE OF SERVICE....273
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....273
        OIL....273
        FUEL....274
        COOLANT AND WATER FOR DILUTION....274
        GREASE....275
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....275
        STORING OIL AND FUEL....276
        FILTERS....276
      ELECTRIC SYSTEM MAINTENANCE....276
    WEAR PARTS....277
      WEAR PARTS LIST....278
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT....279
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....281
    TIGHTENING TORQUE SPECIFICATIONS....282
      TIGHTENING TORQUE LIST....282
    SAFETY CRITICAL PARTS....283
      SAFETY CRITICAL PARTS LIST....284
    MAINTENANCE SCHEDULE....286
      MAINTENANCE SCHEDULE CHART....286
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....288
    MAINTENANCE PROCEDURE....289
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)....289
      INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)....289
      WHEN REQUIRED....290
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....290
        CLEAN INSIDE OF COOLING SYSTEM....296
        CHECK AND TIGHTEN TRACK SHOE BOLTS....300
        CHECK AND ADJUST TRACK TENSION....301
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....303
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....306
        ADJUST BUCKET CLEARANCE....308
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....309
        CHECK AND MAINTENANCE AIR CONDITIONER....310
        WASH WASHABLE FLOOR....311
        CHECK GAS SPRING....314
        BLEEDING AIR FROM HYDRAULIC SYSTEM....315
      CHECK BEFORE STARTING....317
      EVERY 100 HOURS MAINTENANCE....318
        LUBRICATING....318
      EVERY 250 HOURS MAINTENANCE....320
        CHECK LEVEL OF BATTERY ELECTROLYTE....320
        CHECK LEVEL OF BATTERY ELECTROLYTE....321
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....323
      EVERY 500 HOURS MAINTENANCE....324
        LUBRICATE SWING CIRCLE....324
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....325
        REPLACE FUEL PRE-FILTER CARTRIDGE....327
        CHECK SWING PINION GREASE LEVEL, ADD GREASE....329
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS....330
        (only machines equipped with air conditioner)....330
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS....332
        REPLACE BREATHER ELEMENT IN HYDRAULIC TANK....334
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....335
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....336
      EVERY 1000 HOURS MAINTENANCE....337
        REPLACE HYDRAULIC OIL FILTER ELEMENT....337
        CHANGE OIL IN SWING MACHINERY CASE....338
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....339
        REPLACE FUEL MAIN FILTER CARTRIDGE....340
        INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR....343
        CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS....346
        CHECK FAN BELT TENSION AND REPLACE FAN BELT....346
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)....346
      EVERY 2000 HOURS MAINTENANCE....347
        CHANGE OIL IN FINAL DRIVE CASE....347
        CLEAN HYDRAULIC TANK STRAINER....348
        CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)....349
        CHECK ALTERNATOR....353
        CHECK ENGINE VALVE CLEARANCE, ADJUST....353
      EVERY 4000 HOURS MAINTENANCE....354
        CHECK WATER PUMP....354
        CHECK VIBRATION DAMPER....354
        CHECK STARTING MOTOR....354
        REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)....355
        CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....356
        CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....356
        CHECK OPERATING CONDITION OF COMPRESSOR....357
      EVERY 5000 HOURS MAINTENANCE....358
        CHANGE OIL IN HYDRAULIC TANK....358
      EVERY 8000 HOURS MAINTENANCE....359
        REPLACE HIGH-PRESSURE PIPING CLAMP....359
        REPLACE FUEL SPRAY PREVENTION CAP....359
  SPECIFICATIONS....360
    SPECIFICATIONS....361
  ATTACHMENTS AND OPTIONS....364
    GENERAL PRECAUTIONS FOR SAFETY....365
      PRECAUTIONS WHEN SELECTING....365
      READ THE INSTRUCTION MANUAL THOROUGHLY....365
      PRECAUTIONS WHEN REMOVING OR INSTALLING....365
      PRECAUTIONS WHEN USING....365
    BUCKET WITH HOOK....366
      HOOK CONDITION....366
      PROHIBITED OPERATIONS....366
    MACHINE READY FOR ATTACHMENT....367
      LOCATIONS....367
      HYDRAULIC CIRCUIT....371
        Switching Hydraulic Circuit....371
        Adjusting Oil Flow....371
        Switching Between Breaker and General Attachment....371
        Hydraulic Circuit Connection....372
        Oil Flow Path....373
        Replace Additional Breaker Filter Element....374
        Replace Additional Breaker Pilot Filter Element....376
      ATTACHMENT REMOVAL AND INSTALLATION....378
        Attachment Removal....378
        Attachment Installation....380
      ATTACHMENT OPERATIONS....382
        When Using Breaker....382
        When Using General Attachment Such as Crusher....384
      LONG TERM STORAGE....385
      SPECIFICATIONS....385
    ATTACHMENT GUIDE....386
      ATTACHMENT COMBINATIONS....386
      TRACK SHOES SELECTION....389
      BUCKET TEETH SELECTION....390
        Teeth Selection....390
        Selection Guide for Horizontal or Vertical Pin Type Tooth....390
      HANDLING OF RUBBER PAD SHOE AND ROAD LINER....391
        Working Environment....391
        Working Conditions....391
        Storage and Maintenance....392
        Extent of Damage to Rubber....392
        Check Road Liner....392
        Replace Road Liner....392
      TRAPEZOIDAL BUCKET....393
      HANDLING EXTENSION ARM....395
      HANDLING CLAMSHELL BUCKET....396
    RECOMMENDED ATTACHMENT OPERATIONS....397
      HYDRAULIC BREAKER....397
    HANDLING MACHINES EQUIPPED WITH KOMTRAX....401
      BASIC PRECAUTIONS....401
  INDEX....402
    SINDEX....404
      <A>....404
      <B>....404
      <C>....404
      <D>....404
      <E>....404
      <F>....404
      <G>....404
      <H>....404
      <I>....404
      <L>....404
      <M>....405
      <O>....405
      <P>....405
      <R>....405
      <S>....405
      <T>....405
      <U>....405
      <V>....405
      <W>....405
      <Y>....406
  COLOPHON....408
KEN00084-13 - Hydraulic Excavator PC200-8, PC200LC-8, PC240LC-8 Shop Manual....410
  COVER....410
  00 Index and foreword....412
    Index....412
      Composition of shop manual....413
      Table of contents....415
    Foreword and general information....424
      Safety notice....425
      How to read the shop manual....430
      Explanation of terms for maintenance standard....432
      Handling of electric equipment and hydraulic component....434
      Handling of connectors newly used for engines....443
      How to read electric wire code....446
      Precautions when carrying out operation....449
      Method of disassembling and connecting push-pull type coupler....452
      Standard tightening torque table....455
      Conversion table....459
  01 Specification....466
    Specification and technical data....466
      Specification dimension drawings....467
      Working range diagram....468
      Specifications....469
      Weight table....473
      Table of fuel, coolant and lubricants....477
    HYDRAULIC EXCAVATOR....480
      SHOP MANUAL....480
      PC200-8....480
      PC200LC-8....480
      PC240LC-8....480
        Machine model Serial number....480
  10 Structure, function and maintenance standard....480
    Engine and cooling system....480
      Engine related parts....481
      Radiator, oil cooler, aftercooler and fuel cooler....482
    Power train....484
      Power train....485
        Power train....485
        Final drive....487
        Swing machinery....493
        Swing circle....497
    Undercarriage and frame....500
      Undercarriage and frame....501
        Track frame and recoil spring....501
        Idler....503
        Carrier roller....505
        Track roller....506
        Track shoe....507
    Hydraulic system, Part 1....514
      Hydraulic system, Part 1....515
        Hydraulic equipment layout drawing....515
        Hydraulic tank and filter....517
        Hydraulic pump....519
        Pilot oil filter....541
    Hydraulic system, Part 2....544
      Hydraulic system, Part 2....545
        Control valve....545
        CLSS....558
        Functions and operation by valve....563
    Hydraulic system, Part 3....602
      Hydraulic system, Part 3....604
        Swing motor....604
        Center swivel joint....613
        Travel motor....615
        PPC valve....626
        Work equipment and swing PPC valve....626
        Travel PPC valve....632
        Service PPC valve (with EPC valve)....641
        Service PPC valve....647
        Valve control....649
        Solenoid valve....651
        PPC accumulator....653
        Return oil filter....654
        Attachment circuit selector valve....655
        Hydraulic cylinder....657
    Work equipment....662
      Work equipment....663
      Dimensions of arm....674
      Dimensions of bucket....676
    Cab and its attachments....680
      Cab and its attachments....681
        Air conditioner piping....681
    Electrical system....684
      Electrical system....685
        Engine control....685
        Electrical control system....693
        Monitor system....716
        Sensor....743
        KOMTRAX system....746
  20 Standard value table....750
    Standard service value table....750
      Standard value table for engine related parts....751
      Standard value table for chassis related parts....753
  30 Testing and adjusting....772
    Testing and adjusting, Part 1....772
      Tools for testing, adjusting, and troubleshooting....774
      Sketch of special tool....777
      Testing engine speed....778
      Testing intake air pressure (boost pressure)....779
      Testing exhaust gas color....780
      Adjusting valve clearance....781
      Testing compression pressure....783
      Testing blow-by pressure....784
      Testing engine oil pressure....785
      Handling fuel system parts....786
      Releasing residual pressure from fuel system....786
      Testing fuel pressure....787
      Testing fuel delivery, return and leak amount....790
      Bleeding air from fuel circuit....793
      Checking fuel circuit for leakage....794
      Checking and adjusting air conditioner compressor belt tension....795
      Replacing fan belt....796
      Testing swing circle bearing clearance....797
      Checking and adjusting track shoe tension....798
      Inspection and adjustment oil pressure in work equipment, swing, and travel circuits....800
      Testing control circuit source pressure....803
      Testing and adjusting oil pressure in pump PC control circuit....804
      Testing and adjusting oil pressure in pump LS control circuit....807
      Testing solenoid valve output pressure....812
      Testing PPC valve output pressure....815
      Adjusting play of work equipment and swing PPC valves....817
      Checking parts which cause hydraulic drift of work equipment....818
      Releasing residual pressure from hydraulic circuit....820
      Testing oil leakage....821
      Bleeding air from each part....824
      Checking cab tipping stopper....826
      Adjusting mirrors....827
      Installation and adjustment of mirrors....828
      Angle adjustment of rear view camera....834
    Testing and adjusting, Part 2....838
      Special functions of machine monitor....839
    Testing and adjusting, Part 3....896
      Handling voltage circuit of engine controller....897
      Preparation work for troubleshooting of electrical system....898
      Procedure for testing diodes....903
      Pm Clinic service....904
  40 Troubleshooting....914
    Failure code table and fuse locations....914
      Failure codes table....915
      Fuse locations....920
    General information on troubleshooting....926
      Points to remember when troubleshooting....927
      Sequence of events in troubleshooting....928
      Check before troubleshooting....929
      Classification and procedures for troubleshooting....930
      How to read electric wire code....934
      Connection table for connector pin numbers....937
      T- branch box and T- branch adapter table....973
    Troubleshooting by failure code (Display of code), Part 1....978
      Failure code [989L00] Engine Controller Lock Caution 1....981
      Failure code [989M00] Engine Controller Lock Caution 2....981
      Failure code [989N00] Engine Controller Lock Caution 3....982
      Failure code [AA10NX] Air Cleaner Clogging....982
      Failure code [AB00KE] Charge Voltage Low....983
      Failure code [B@BAZG] Eng Oil Press. Low....985
      Failure code [B@BAZK] Eng Oil Level Low....985
      Failure code [B@BCNS] Eng Water Overheat....986
      Failure code [B@BCZK] Eng Water Level Low....986
      Failure code [B@HANS] Hydr Oil Overheat....987
      Failure code [CA111] EMC Critical Internal Failure....987
      Failure code [CA115] Eng Ne and Bkup Speed Sens Error....988
      Failure code [CA122] Chg Air Press Sensor High Error....989
      Failure code [CA123] Chg Air Press Sensor Low Error....991
      Failure code [CA131] Throttle Sensor High Error....993
      Failure code [CA132] Throttle Sensor Low Error....995
      Failure code [CA144] Coolant Temp Sens High Error....997
      Failure code [CA145] Coolant Temp Sens Low Error....999
      Failure code [CA153] Chg Air Temp Sensor High Error....1001
      Failure code [CA154] Chg Air Temp Sensor Low Error....1003
      Failure code [CA155] Chg Air Temp High Speed Derate....1005
      Failure code [CA187] Sens Supply 2 Volt Low Error....1007
      Failure code [CA221] Ambient Press Sens High Error....1009
      Failure code [CA222] Ambient Press Sens Low Error....1011
      Failure code [CA227] Sens Supply 2 Volt High Error....1013
      Failure code [CA234] Eng Overspeed....1014
      Failure code [CA238] Ne Speed Sens Supply Volt Error....1015
      Failure code [CA271] IMV/PCV1 Short Error....1016
      Failure code [CA272] IMV/PCV1 Open Error....1017
      Failure code [CA322] Inj #1 Open/Short Error....1019
      Failure code [CA323] Inj #5 Open/Short Error....1021
      Failure code [CA324] Inj #3 Open/Short Error....1023
      Failure code [CA325] Inj #6 Open/Short Error....1025
      Failure code [CA331] Inj #2 Open/Short Error....1027
      Failure code [CA332] Inj #4 Open/Short Error....1029
    Troubleshooting by failure code (Display of code), Part 2....1032
      Failure code [CA342] Calibration Code Incompatibility....1034
      Failure code [CA351] Injectors Drive Circuit Error....1035
      Failure code [CA352] Sens Supply 1 Volt Low Error....1037
      Failure code [CA386] Sens Supply 1 Volt High Error....1039
      Failure code [CA428] Water in Fuel Sensor High Error....1041
      Failure code [CA429] Water in Fuel Sensor Low Error....1043
      Failure code [CA435] Eng Oil Press Sw Error....1045
      Failure code [CA441] Battery Voltage Low Error....1046
      Failure code [CA442] Battery Voltage High Error....1049
      Failure code [CA449] Rail Press Very High Error....1051
      Failure code [CA451] Rail Press Sensor High Error....1053
      Failure code [CA452] Rail Press Sensor Low Error....1055
      Failure code [CA488] Chg Air Temp High Torque Derate....1057
      Failure code [CA553] Rail Press High Error....1058
      Failure code [CA559] Rail Press Low Error....1059
      Failure code [CA689] Eng Ne Speed Sensor Error....1061
      Failure code [CA731] Eng Bkup Speed Sens Phase Error....1063
      Failure code [CA757] All Continuous Data Lost Error....1065
      Failure code [CA778] Eng Bkup Speed Sensor Error....1067
      Failure code [CA1633] KOMNET Datalink Timeout Error....1069
      Failure code [CA2185] Throt Sens Sup Volt High Error....1070
      Failure code [CA2186] Throt Sens Sup Volt Low Error....1071
      Failure code [CA2249] Rail Press Very Low Error....1072
      Failure code [CA2311] IMV Solenoid Error....1073
      Failure code [CA2555] Grid Htr Relay Volt High Error....1075
      Failure code [CA2556] Grid Htr Relay Volt Low Error....1077
      Failure code [D19JKZ] Personal Code Relay Abnormality....1079
      Failure code [D862KA] GPS Antenna Discon....1081
      Failure code [DA22KK] Pump Solenoid Power Low Error....1082
      Failure code [DA25KP] 5V Sensor 1 Power Abnormality....1084
      Failure code [DA29KQ] Model Selection Abnormality....1091
    Troubleshooting by failure code (Display of code), Part 3....1096
      Failure code [DA2RMC] CAN Discon (Pump Con Detected)....1099
      Failure code [DAF8KB] Short circuit in camera power supply....1105
      Failure code [DAFGMC] GPS Module Error....1107
      Failure code [DAFRMC] CAN Discon (Monitor Detected)....1109
      Failure code [DGH2KB] Hydr Oil Sensor Short....1113
      Failure code [DHPAMA] F Pump Press Sensor Abnormality....1115
      Failure code [DHPBMA] R Pump Press Sensor Abnormality....1117
      Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality....1119
      Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality....1121
      Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality....1123
      Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....1125
      Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality....1127
      Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality....1129
      Failure code [DHX1MA] Overload Sensor Abnormality (Analog)....1132
      Failure code [DW43KA] Travel Speed Sol Discon....1135
      Failure code [DW43KB] Travel Speed Sol Short....1137
      Failure code [DW45KA] Swing Brake Sol Discon....1139
      Failure code [DW45KB] Swing Brake Sol Short....1141
      Failure code [DW91KA] Travel Junction Sol Discon....1143
      Failure code [DW91KB] Travel Junction Sol Short....1145
      Failure code [DWA2KA] Service Sol Discon....1147
      Failure code [DWA2KB] Service Sol Short....1148
      Failure code [DWK0KA] 2-stage Relief Sol Discon....1149
      Failure code [DWK0KB] 2-stage Relief Sol Short....1151
    Troubleshooting by failure code (Display of code), Part 4....1154
      Failure code [DXA8KA] PC-EPC (F) Sol Discon....1155
      Failure code [DXA8KB] PC-EPC (F) Sol Short....1157
      Failure code [DXA9KA] PC-EPC (R) Sol Discon....1159
      Failure code [DXA9KB] PC-EPC (R) Sol Short....1161
      Failure code [DXE0KA] LS-EPC Sol Discon....1163
      Failure code [DXE0KB] LS-EPC Sol Short....1165
      Failure code [DXE4KA] Service Current EPC Discon....1167
      Failure code [DXE4KB] Service Current EPC Short....1169
      Failure code [DXE5KA] Merge-divider Main Sol Discon....1171
      Failure code [DXE5KB] Merge-divider Main Sol Short....1173
      Failure code [DXE6KA] Merge-divider LS Sol Discon....1175
      Failure code [DXE6KB] Merge-divider LS Sol Short....1177
      Failure code [DY20KA] Wiper Working Abnormality....1179
      Failure code [DY20MA] Wiper Parking Abnormality....1181
      Failure code [DY2CKA] Washer Drive Discon....1183
      Failure code [DY2CKB] Washer Drive Short....1185
      Failure code [DY2DKB] Wiper Drive (For) Short....1187
      Failure code [DY2EKB] Wiper Drive (Rev) Short....1189
    Troubleshooting of electrical system (E-mode)....1192
      Before carrying out troubleshooting of electrical system....1194
      Information in troubleshooting table....1196
      E-1 When starting switch turned ON, machine monitor displays nothing....1197
      E-2 When starting switch turned ON (before starting engine), basic check item lights up....1199
      E-3 Engine does not start (Engine does not turn)....1201
      E-4 Preheater does not operate....1205
      E-5 Automatic warm-up system does not operate (in cold season)....1209
      E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked....1211
      E-7 Precaution lights up while engine is running....1213
      E-8 Emergency stop item lights up while engine is running....1219
      E-9 Engine coolant temperature gauge does not indicate normally....1220
      E-10 Hydraulic oil temperature gauge does not indicate normally....1221
      E-11 Fuel level gauge does not indicate normally....1224
      E-12 Contents of display by machine monitor are different from applicable machine....1226
      E-13 Machine monitor does not display some items....1226
      E-14 Function switch does not work....1226
      E-15 Auto-decelerator does not operate normally....1227
      E-16 Working mode does not change....1228
      E-17 Travel speed does not change....1229
      E-18 Alarm buzzer cannot be stopped....1230
      E-19 Windshield wiper and window washer do not operate....1231
      E-20 Power maximizing function does not operate normally....1233
      E-21 Swing holding brake does not operate normally....1235
      E-22 Travel alarm does not sound or does not stop sounding....1237
      E-23 Air conditioner does not operate normally (including air conditioner abnormality record)....1239
      E-24 While starting switch is in OFF position, service meter is not displayed....1250
      E-25 Machine monitor cannot be set in service mode....1250
      E-26 Monitoring function does not display lever control signal normally....1251
      E-27 KOMTRAX system does not operate normally....1259
    Troubleshooting of hydraulic and mechanical system (H-mode)....1262
      System diagram of hydraulic and mechanical system....1265
      Information in troubleshooting table....1267
      H-1 Speed or power of whole work equipment, swing, and travel is low....1268
      H-2 Engine speed lowers significantly or engine stalls....1270
      H-3 Work equipment, swing, and travel systems do not work....1271
      H-4 Abnormal sound comes out from around hydraulic pump....1271
      H-5 Auto-decelerator does not operate....1272
      H-6 Fine control performance or response is low....1272
      H-7 Speed or power of boom is low....1273
      H-8 Speed or power of arm is low....1274
      H-9 Speed or power of bucket is low....1275
      H-10 Work equipment does not move singly....1275
      H-11 Hydraulic drift of work equipment is large....1276
      H-12 Time lag of work equipment is large....1278
      H-13 When part of work equipment is relieved singly, other parts of work equipment move....1278
      H-14 Power maximizing function does not work....1279
      H-15 In compound operation of work equipment, speed of part loaded more is low....1279
      H-16 When machine swings and raises boom simultaneously, boom rising speed is low....1280
      H-17 When machine swings and travels simultaneously, travel speed is low....1280
      H-18 Machine deviates during travel....1281
      H-19 Travel speed is low....1282
      H-20 Machine is not steered well or steering power is low....1283
      H-21 Travel speed does not change or travel speed is low/high....1284
      H-22 Travel system does not move (only one side)....1285
      H-23 Upper structure does not swing....1286
      H-24 Swing acceleration or swing speed is low....1288
      H-25 Upper structure overruns remarkably when it stops swinging....1289
      H-26 Large shock is made when upper structure stops swinging....1290
      H-27 Large sound is made when upper structure stops swinging....1290
      H-28 Hydraulic drift of swing is large....1291
      H-29 Attachment circuit is not changed....1292
      H-30 Oil flow in attachment circuit cannot be controlled....1292
    Troubleshooting of engine (S-mode)....1294
      Method of using troubleshooting chart....1297
      S-1 Starting performance is poor....1301
      S-2 Engine does not start....1302
      S-3 Engine does not pick up smoothly....1305
      S-4 Engine stops during operations....1306
      S-5 Engine does not rotate smoothly....1307
      S-6 Engine lack output (or lacks power)....1308
      S-7 Exhaust smoke is black (incomplete combustion)....1309
      S-8 Oil consumption is excessive (or exhaust smoke is blue)....1310
      S-9 Oil becomes contaminated quickly....1311
      S-10 Fuel consumption is excessive....1312
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....1313
      S-12 Oil pressure drops....1314
      S-13 Oil level rises (Entry of coolant/fuel)....1315
      S-14 Coolant temperature becomes too high (overheating)....1316
      S-15 Abnormal noise is made....1317
      S-16 Vibration is excessive....1318
  50 Disassembly and assembly....1320
    General information on disassembly and assembly....1320
      How to read this manual....1321
      Coating materials list....1323
      Special tools list....1326
      Sketches of special tools....1331
    Engine and cooling system....1338
      Removal and installation of fuel supply pump assembly....1339
      Removal and installation of fuel injector assembly....1343
      Removal and installation of engine front seal....1351
      Removal and installation of engine rear seal....1354
      Removal and installation of cylinder head assembly....1357
      Removal and installation of radiator assembly....1371
      Removal and installation of hydraulic oil cooler assembly....1374
      Removal and installation of aftercooler assembly....1376
      Removal and installation of fuel cooler assembly....1379
      Removal and installation of engine and hydraulic pump assembly....1380
    Power train....1390
      Removal and installation of final drive assembly....1391
      Disassembly and assembly of final drive assembly....1393
      Removal and installation of swing motor and swing machinery assembly....1418
      Disassembly and assembly of swing motor and swing machinery assembly....1420
      Removal and installation of swing circle assembly....1430
    Undercarriage and frame....1432
      Disassembly and assembly of carrier roller assembly....1433
      Disassembly and assembly of track roller assembly....1436
      Removal and installation of idler, recoil spring assembly....1438
      Disassembly and assembly of idler assembly....1439
      Disassembly and assembly of recoil spring assembly....1442
      Removal and installation of sprocket....1444
      Expansion and installation of track shoe assembly....1445
      Removal and installation of revolving frame assembly....1447
      Removal and installation of counterweight assembly....1449
    Hydraulic system....1452
      Removal and installation of center swivel joint assembly....1453
      Disassembly and assembly of center swivel joint assembly....1455
      Removal and installation of hydraulic tank assembly....1456
      Removal and installation of control valve assembly....1460
      Disassembly and assembly of control valve assembly....1465
      Removal and installation of hydraulic pump assembly....1469
      Removal and installation of oil seal in hydraulic pump input shaft....1473
      Disassembly and assembly of work equipment PPC valve assembly....1474
      Disassembly and assembly of travel PPC valve assembly....1476
      Disassembly and assembly of hydraulic cylinder assembly....1479
    Work equipment....1486
      Removal and installation of work equipment assembly....1487
    Cab and its attachments....1492
      Removal and installation of operator's cab assembly....1493
      Removal and installation of operator cab glass (stuck glass)....1496
      Removal and installation of front window assembly....1506
      Removal and installation of floor frame assembly....1513
    Electrical system....1518
      Removal and installation of air conditioner unit assembly....1519
      Removal and installation of KOMTRAX communication modem assembly....1522
      Removal and installation of monitor assembly....1523
      Removal and installation of pump controller assembly....1525
      Removal and installation of engine controller assembly....1527
  90 Diagrams and drawings....1530
    Hydraulic diagrams and drawings....1530
      Hydraulic circuit diagram (PC240LC-8) 5....1530
        Hydraulic circuit diagram....1532
        Hydraulic circuit diagram....1534
    Electrical diagrams and drawings....1538
      Electrical circuit diagram (1/6)....1540
      Electrical circuit diagram (2/6)....1542
      Electrical circuit diagram (3/6)....1544
      Electrical circuit diagram (4/6)....1546
      Electrical circuit diagram (5/6)....1548
      Electrical circuit diagram (6/6)....1550
      Connector arrangement diagram....1552
      Electrical circuit diagram for air conditioner....1554
KPAM042800 - Escavadeiras Hidráulicas PC200-8, PC200LC-8, PC240LC-8 Manual de Operação e Manutenção....1558
SEBM02050309 - Hydraulic Excavator PC200-3, PC210LC-3, PC220-3, PC240LC-3 Shop Manual....1960

Komatsu Hydraulic Excavator PC200, PC200LC, PC210LC, PC220, PC240LC Repair Service Manuals