Komatsu PC200-8E0 and PC200LC-8E0 (SN from 01001) Hybrid Excavators (Japan) Workshop Manual (SEN05221-05)

Illustrated factory Workshop Manual for Komatsu Hybrid Excavators Models PC200-8E0 and PC200LC-8E0.

This manual will assist you in diagnosing, repairing, and adjusting for your hybrid excavator.
You can use a Windows, Mac, or Android device to view this manual. You only need to have a PDF reader installed.

Covered Models (Japan):
   PC200-8E0 (SN: 01001-)
   PC200LC-8E0 (SN: 01001-)

Format: PDF, 1284 pages
Language: English
Table of Contents:
   Index and Foreword
      Index
      Composition of shop manual
      Table of contents
      Foreword and general information
      Safety notice
      How to read the shop manual
      Explanation of terms for maintenance standard
      Handling of hydraulic components
      Method of disassembling and connecting push-pull type coupler
      Handing of electric equpment
      How to read electric wire code
      Precautions when carrying out work
      Handling of hybrid devices and high-voltage wirings
      Standard tightening torque table
      Conversion table
   Specification
      Specification and technical data
      Outline of hybrid system
      Specification dimension drawings
      Working range diagram
      Specifications
      Weight table
      Table of fuel, coolant and lubricants
   Structure,function and maintenance standard
      Engine and cooling system
      Engine related parts
      Radiator, oil cooler, aftercooler and fuel cooler
      Hyblid Relation
      Configuration and safety functions of hybrid system
      Cooling system of hybrid component
      Motor generator
      Swing electric motor
      Electric control unit
      High-voltage wiring (power cable)
      Power train
      Final drive
      Swing machinery
      Swing circle
      Undercarriage and frame
      Track frame and recoil spring
      Idler
      Carrier roller
      Track roller
      Track shoe
      Hydraulic system, Part 1
      Hydraulic components layout drawing
      Hydraulic tank and filter
      Hydraulic pump
      Hydraulic system, Part 2
      Control valve
      CLSS
      Functions and operation by valve
      Hydraulic system, Part 3
      Center swivel joint
      Travel motor
      PPC valve
      Valve control
      Solenoid valve
      Accumulator
      Hydraulic cylinder
      Work equipment
      Dimensions of components
      Cab and its attachments
      Air conditioner piping
      Electrical system
      Engine control
      Electrical control system
      Monitor system
      Sensors
      KOMTRAX system
   Standard value table
      Standard service value table
      Standard value table for engine related parts
      Standard value table for chassis related parts
   Testing and adjusting
      Testing and adjusting, Part 1
      Tools for testing, adjusting and troubleshooting
      Testing engine speed
      Testing boost pressure
      Checking exhaust gas color
      Adjusting valve clearance
      Testing compression pressure
      Testing blowby pressure
      Testing engine oil pressure
      Handling fuel system parts
      Releasing remaining pressure from fuel system
      Testing fuel system pressure
      Cylinder cut-out test mode operation
      No injection cranking operation
      Testing fuel return rate and leakage
      Bleeding air from fuel circuit
      Testing fuel circuit for leakage
      Handling of controller high-voltage circuit
      Testing and adjusting air conditioner compressor belt tension
      Replacement of fan belt
      Testing swing circle bearing clearance
      Testing and adjusting track tension .
      Testing and adjusting hydraulic oil pressure in work equipment and trave
      Testing source pressure of control circuit
      Testing and adjusting oil pressure in pump PC control circuit
      Testing and adjusting oil pressure in pump LS control circuit
      Testing solenoid valve output pressure
      Testing PPC valve output pressure
      Adjusting play of work equipment and swing PPC valves
      Checking parts which cause hydraulic drift of work equipment
      Releasing remaining pressure from hydraulic circuit
      Testing oil leakage
      Bleeding air from each part
      Checking cab tipping stopper
      Adjusting mirrors
      Angle adjustment of rear view camera
      Testing swing brake
      Cleaning and replacement of oil filter of electric swing motor
      Operation check of swing emergency stop switch
      Testing and adjusting, Part 2
      Special functions of machine monitor
      Testing and adjusting, Part 3
      Handling voltage circuit of engine controller
      Precautions related to hybrid machines
      Preparation work for troubleshooting of electrical system
      Procedure for testing diodes
      Pm Clinic service
   Troubleshooting
      Failure code table and fuse locations
      Failure code table
      Fuse locations
      General Information on troubleshooting
      Points to remember when troubleshooting
      Sequence of events in troubleshooting
      Check before troubleshooting
      Classification and procedures for troubleshooting
      Probable problems and troubleshooting No
      Information in troubleshooting table
      Connection table for connector pin numbers
      T-adapter and box table
      Troubleshooting by failure code
      Troubleshooting of electrical system (E-mode) SEN05
      Before performing troubleshooting of electrical system
      Information in troubleshooting table
      Troubleshooting of electrical system (E-mode) SEN05
      Before performing troubleshooting of electrical system
      Information in troubleshooting table
      Troubleshooting of hydraulic and mechanical system (H-mode) SEN
      System diagram of hydraulic and mechanical system
      Information in troubleshooting table
      Troubleshooting of engine (S-mode) SEN
      Method of using troubleshooting chart
      Troubleshooting of Hybrid system (Y-mode)
      Precautions related to hybrid machine
   Disassembly and assembly
      General information on disassembly and assembly
      How to read this manual
      Precautions related to hybrid machine
      Coating materials list
      Special tools list
      Sketches of special tools
      Engine and cooling system
      Removal and installation of fuel supply pump assembly
      Removal and installation of fuel injector assembly
      Removal and installation of engine front seal
      Removal and installation of engine rear seal
      Removal and installation of cylinder head assembly
      Removal and installation of radiator assembly
      Removal and installation of hydraulic oil cooler assembly
      Removal and installation of aftercooler assembly
      Removal and installation of fuel cooler assembly
      Removal and installation of engine/motor-generator/hydraulic pump assembly
      Removal and installation of fuel tank assembly
      Hyblid Relation
      Draining and adding coolant and bleeding air for hybrid system
      Removal and installation of hybrid radiator assembly
      Removal and installation of water pump assembly for hybrid system
      Removal and installation of inverter assembly
      Removal and installation of inverter and capacitor assembly
      Draining and adding generator lubricating oil
      Removal and installation of tandempump assembly
      Removal and installation of motor-generator and housing assembly
      Removal and installation of swing electric motor assembly
      Power train
      Removal and installation of final drive assembly
      Disassembly and assembly of final drive assembly.
      Removal and installation of \\"swing electric motor and swing machinery assemb
      Disassembly and assembly of swing machinery assembly
      Removal and installation of swing circle assembly
      Undercarriage and frame
      Disassembly and assembly of carrier roller assembly
      Disassembly and assembly of track roller assembly
      Disassembly and assembly of idler assembly
      Disassembly and assembly of recoil spring assembly
      Removal and installation of sprocket
      Expansion and installation of track shoe assembly
      Removal and installation of revolving frame assembly
      Removal and installation of counterweight assembly
      Hydraulic system
      Removal and installation of centerswivel joint assembly
      Disassembly and assembly of center swivel joint assembly
      Removal and installation of hydraulic tank assembly
      Removal and installation of control valve assembly
      Disassembly and assembly of control valve assembly
      Removal and installation of hydraulic pump assembly
      Removal and installation of oil sealin hydraulic pump input shaft
      Disassembly and assembly of work equipment PPCvalve assembly
      Disassembly and assembly of travel PPC valve assembly
      Disassembly and assembly of hydraulic cylinder assembly
      Work equipment Body
      Removal and installation of work equipment assembly
      Cab and its attachments
      Removal and installation of operator's cab assembly
      Removal and installation of operator cab glass (stuck glass)
      Removal and installation of front window assembly
      Removal and installation of floor frame assembly
      Removal and installation of air conditioner unit assembly
      Electric system
      Removal and installation of KOMTRAX terminal
      Removal and installation of monitor assembly
      Removal and installation of pump controller assembly
      Removal and installation of enginecontroller assembly
   Diagrams and Drawings
      Hydraulic diagrams and drawings
      Hydraulic circuit diagram
      Electrical diagrams and drawings
      Electrical circuit diagram
      Connector list and sterogram.