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Komatsu PC200 -8, Shop Manual

The Komatsu PC200-8 is a powerful and reliable excavator, perfect for any construction site. For maintenance and repairs, be sure to download the free Shop Manual from manualshive.com. This manual provides detailed instructions and diagrams to keep your PC200-8 running smoothly for years to come. Download your manual today!

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SEN00093-20

00 Index and foreword

10

PC200, 220-8

Engine and cooling system

SEN00660-05

Removal and installation of fuel supply pump assembly .............................................................

2

Removal and installation of fuel injector assembly......................................................................

6

Removal and installation of engine front seal..............................................................................

14

Removal and installation of engine rear seal ..............................................................................

17

Removal and installation of cylinder head assembly...................................................................

20

Removal and installation of radiator assembly............................................................................

34

Removal and installation of hydraulic oil cooler assembly ..........................................................

37

Removal and installation of aftercooler assembly .......................................................................

39

Removal and installation of fuel cooler assembly .......................................................................

42

Removal and installation of engine and hydraulic pump assembly .............................................

43

Power train

SEN00661-03

Removal and installation of final drive assembly.........................................................................

2

Disassembly and assembly of final drive assembly ....................................................................

4

Removal and installation of swing motor and swing machinery assembly ..................................

29

Disassembly and assembly of swing motor and swing machinery assembly .............................

31

Removal and installation of swing circle assembly .....................................................................

41

Undercarriage and frame

SEN00662-05

Disassembly and assembly of carrier roller assembly ................................................................

2

Disassembly and assembly of track roller assembly...................................................................

5

Removal and installation of idler, recoil spring assembly ............................................................

7

Disassembly and assembly of idler assembly.............................................................................

8

Disassembly and assembly of recoil spring assembly ................................................................

11

Removal and installation of sprocket...........................................................................................

13

Expansion and installation of track shoe assembly .....................................................................

14

Removal and installation of revolving frame assembly ...............................................................

16

Removal and installation of counterweight assembly..................................................................

18

Hydraulic system

SEN00663-04

Removal and installation of center swivel joint assembly............................................................

2

Disassembly and assembly of center swivel joint assembly .......................................................

4

Removal and installation of hydraulic tank assembly ..................................................................

5

Removal and installation of control valve assembly....................................................................

9

Disassembly and assembly of control valve assembly ...............................................................

14

Removal and installation of hydraulic pump assembly................................................................

18

Removal and installation of oil seal in hydraulic pump input shaft ..............................................

22

Disassembly and assembly of work equipment PPC valve assembly ........................................

23

Disassembly and assembly of travel PPC valve assembly .........................................................

25

Disassembly and assembly of hydraulic cylinder assembly........................................................

28

Work equipment

SEN00664-03

Removal and installation of work equipment assembly...............................................................

2

Removal and installation of anti-drop valve assembly for boom .................................................

5

Removal and installation of anti-drop valve assembly for arm ....................................................

8

Disassembly and assembly of anti-drop valve assembly ............................................................

10

Cab and its attachments

SEN00665-03

Removal and installation of operator's cab assembly .................................................................

2

Removal and installation of operator cab glass (stuck glass) .....................................................

5

Removal and installation of front window assembly....................................................................

15

Removal and installation of floor frame assembly.......................................................................

22

Electrical system

SEN00666-05

Removal and installation of air conditioner unit assembly...........................................................

2

Removal and installation of KOMTRAX communication modem assembly ................................

5

Removal and installation of monitor assembly ............................................................................

6

Removal and installation of pump controller assembly ...............................................................

8

Removal and installation of engine controller assembly .............................................................

10

Summary of Contents for PC200 -8

Page 1: ...HYDRAULIC EXCAVATOR SEN00084 20 PC200 8 PC200LC 8 PC220 8 PC220LC 8 SERIAL NUMBERS PC200 300001 PC200LC 300001 PC220 70001 PC220LC 70001 and up...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...8 PC200LC 8 PC220 8 PC220LC 8 Machine model Serial number PC200 8 300001 and up PC200LC 8 300001 and up PC220 8 70001 and up PC220LC 8 70001 and up 00 Index and foreword 1 Index Composition of shop ma...

Page 4: ...n the order shown below and utilize them accord ingly Section Title Form Number Shop Manual contents binder binder label and tabs SEN00084 20 00 Index and foreword SEN00085 20 Index SEN00093 20 q Fore...

Page 5: ...leshooting of electrical system E mode SEN00244 04 Troubleshooting of hydraulic and mechanical system H mode SEN00245 03 Troubleshooting of engine S mode SEN00246 02 50 Disassembly and assembly SEN006...

Page 6: ...ion drawings 2 Working range diagram 3 Specifications 4 Weight table 8 Table of fuel coolant and lubricants 12 10 Structure function and maintenance standard Engine related parts SEN00096 01 Engine re...

Page 7: ...ng and troubleshooting 3 Sketch of special tool 6 Testing engine speed 7 Testing intake air pressure boost pressure 8 Testing exhaust gas color 9 Adjusting valve clearance 10 Testing compression press...

Page 8: ...Engine Controller Lock Caution 1 4 Failure code 989M00 Engine Controller Lock Caution 2 4 Failure code 989N00 Engine Controller Lock Caution 3 5 Failure code AA10NX Air Cleaner Clogging 5 Failure cod...

Page 9: ...lure code CA2185 Throt Sens Sup Volt High Error 39 Failure code CA2186 Throt Sens Sup Volt Low Error 40 Failure code CA2249 Rail Press Very Low Error 41 Failure code CA2311 IMV Solenoid Error 42 Failu...

Page 10: ...ON before starting engine basic check item lights up 8 E 3 Engine does not start Engine does not turn 10 E 4 Preheater does not operate 14 E 5 Automatic warm up system does not operate in cold season...

Page 11: ...igh 23 H 22 Travel system does not move only one side 24 H 23 Upper structure does not swing 25 H 24 Swing acceleration or swing speed is low 27 H 25 Upper structure overruns remarkably when it stops...

Page 12: ...nd installation of revolving frame assembly 16 Removal and installation of counterweight assembly 18 Hydraulic system SEN00663 04 Removal and installation of center swivel joint assembly 2 Disassembly...

Page 13: ...EN00112 03 Hydraulic circuit diagram PC200 200LC 8 3 Hydraulic circuit diagram PC220 220LC 8 5 Hydraulic circuit diagram PC200 200LC 8 PC220 220LC 8 7 Electrical diagrams and drawings SEN00113 09 Elec...

Page 14: ...12 SEN00093 20 PC200 220 LC 8 Hydraulic excavator Form No SEN00093 20 2017 KOMATSU All Rights Reserved Printed in Japan 02 17 01...

Page 15: ...1 Foreword and general information Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of...

Page 16: ...ear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding par...

Page 17: ...slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the...

Page 18: ...e hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in...

Page 19: ...le the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the groun...

Page 20: ...in your eyes or contacts your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Re...

Page 21: ...e standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them T...

Page 22: ...ted with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are neces...

Page 23: ...y is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a T...

Page 24: ...s in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the...

Page 25: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely...

Page 26: ...er does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector...

Page 27: ...pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip p...

Page 28: ...is will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For conn...

Page 29: ...e 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are se...

Page 30: ...the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use...

Page 31: ...onnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the pow...

Page 32: ...sassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings...

Page 33: ...w oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and...

Page 34: ...2V140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor...

Page 35: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor wi...

Page 36: ...up 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn...

Page 37: ...dicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material...

Page 38: ...23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor N...

Page 39: ...ue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White...

Page 40: ...use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit...

Page 41: ...he cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for th...

Page 42: ...If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler...

Page 43: ...er 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig...

Page 44: ...hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to disc...

Page 45: ...Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and...

Page 46: ...r bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34...

Page 47: ...idth across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10...

Page 48: ...series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter...

Page 49: ...e are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 2 1 02 0 20 10 12 2...

Page 50: ...so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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