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
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