Komatsu Hydraulic Excavator PC200-8E0, PC200-8E0 Hybrid, PC200LC-8E0, PC200LC-8E0 Hybrid Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200-8E0, PC200-8E0 Hybrid, PC200LC-8E0, PC200LC-8E0 Hybrid, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200-8E0, PC200-8E0 Hybrid, PC200LC-8E0, PC200LC-8E0 Hybrid 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.
PRODUCT DETAILS:
Total Pages: 1,648 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN05221-05 - Hydraulic Excavator PC200-8E0 (Hybrid), PC200LC-8E0 (Hybrid) Shop Manual.pdf
TEN00387-00 - Hydraulic Excavator PC200LC-8E0 (Hybrid) Operation & Maintenance Manual.pdf
MAIN SECTIONS
Composition of shop manual
Section Title Form Number
Shop Manual, contents binder, binder label and tabs
00 Index and foreword
Index
Foreword and general information
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
100 Engine and cooling system
200 Hybrid Relation
300 Power train
400 Undercarriage and frame
501 Hydraulic system, Part 1
502 Hydraulic system, Part 2
503 Hydraulic system, Part 3
600 Work equipment
700 Cab and its attachments
800 Electrical system SEN05227-03
20 Standard value table
100 Standard service value table SEN05238-00
SEN05239-00
30 Testing and adjusting
101 Testing and adjusting, Part 1
102 Testing and adjusting, Part 2
103 Testing and adjusting, Part 3 SEN05240-02
40 Troubleshooting
100 Failure code table and fuse location
200 General information on troubleshooting
301 Troubleshooting by failure code, Part 1
302 Troubleshooting by failure code, Part 2
303 Troubleshooting by failure code, Part 3
304 Troubleshooting by failure code, Part 4
305 Troubleshooting by failure code, Part 5
400 Troubleshooting of electrical system (E-mode)
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05244-04
600 Troubleshooting of engine (S-mode)
700 Troubleshooting of Hybrid system (Y-mode)
50 Disassembly and assembly
100 General information on disassembly and assembly
200 Engine and cooling system
300 Hyblid Relation
400 Power train
500 Undercarriage and frame
600 Hydraulic system
700 Work equipment Body
800 Cab and its attachments
900 Electric system
90 Diagrams and drawings
100 Hydraulic diagrams and drawings
200 Electrical diagrams and drawings
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FOREWORD...2
BEFORE READING THIS MANUAL...3
SAFETY INFORMATION...5
INTRODUCTION...6
USE OF MACHINE...6
DIRECTIONS OF MACHINE...6
VISIBILITY FROM OPERATOR'S SEAT...6
OUTLINE OF HYBRID SYSTEM...7
STRUCTURE OF HYBRID SYSTEM...7
REDUCED FUEL CONSUMPTION ACHIEVED BY HYBRID SYSTEM...8
PRODUCT INFORMATION...9
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...9
EPA REGULATIONS, ENGINE NUMBER PLATE...9
SERVICE METER LOCATION...10
CONTENTS...11
SAFETY...16
SAFETY...17
SAFETY LABELS...20
LOCATION OF SAFETY LABELS...21
SAFETY LABELS...22
GENERAL PRECAUTIONS COMMON TO OPERATION ANDMAINTENANCE...31
PRECAUTIONS BEFORE STARTING OPERATION...31
PREPARATIONS FOR SAFE OPERATION...31
FIRE PREVENTION...33
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...34
DO NOT GET CAUGHT IN WORK EQUIPMENT...36
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...36
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
LIFTING OBJECTS WITH BUCKET...52
PRECAUTIONS FOR MAINTENANCE...53
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...53
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...57
PRECAUTIONS RELATED TO HYBRID SYSTEM...63
PRECAUTIONS FOR HIGH VOLTAGE, HIGH TEMPERATURE...63
PRECAUTIONS WHEN THERE IS BREAKAGE...63
PRECAUTIONS WHEN MACHINE IS IN WATER...63
PRECAUTIONS IN COLD AREAS...63
PRECAUTIONS WHEN SWING STOPS BECAUSE OF ABNORMALITY IN SYSTEM...64
PRECAUTIONS WHEN USING SWING EMERGENCY STOP SWITCH...64
PRECAUTIONS WITH ELECTROMAGNETIC WAVES...64
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...64
OPERATION...66
MACHINE VIEW ILLUSTRATIONS...67
OVERALL MACHINE VIEW...67
CONTROLS AND GAUGES...68
DETAILED CONTROLS AND GAUGES...70
MONITORING SYSTEM...70
SWITCHES...125
CONTROL LEVERS AND PEDALS...130
SUN ROOF...133
WINDSHIELD...133
EMERGENCY ESCAPE HAMMER...139
DOOR LOCK...139
CAP WITH LOCK...140
DRINK BOX...142
MAGAZINE BOX...142
ASHTRAY...142
AIR CONDITIONER CONTROLS...143
RADIO...156
AUXILIARY ELECTRIC POWER...161
FUSE...162
FUSIBLE LINK...163
CONTROLLER...163
TOOL BOX...163
GREASE PUMP HOLDER...163
FIRE EXTINGUISHER...164
HANDLING MACHINES EQUIPPED WITH KOMTRAX...165
MACHINE OPERATIONS AND CONTROLS...166
BEFORE STARTING ENGINE...166
STARTING ENGINE...187
AFTER STARTING ENGINE...190
STOPPING THE ENGINE...200
MACHINE OPERATION...201
STEERING THE MACHINE...205
SWINGING...207
WORK EQUIPMENT CONTROLS AND OPERATIONS...209
WORKING MODE...211
PROHIBITED OPERATIONS...213
GENERAL OPERATION INFORMATION...216
TRAVELING ON SLOPES...218
ESCAPE FROM MUD...220
RECOMMENDED APPLICATIONS...221
BUCKET REPLACEMENT AND INVERSION...223
PARKING MACHINE...227
MACHINE INSPECTION AFTER DAILY WORK...228
LOCKING...229
TRANSPORTATION...230
TRANSPORTATION PROCEDURE...230
LOADING AND UNLOADING WITH TRAILER...231
LIFTING MACHINE...240
COLD WEATHER OPERATION...243
COLD WEATHER OPERATION INFORMATION...243
AFTER DAILY WORK COMPLETION...245
AFTER COLD WEATHER SEASON...245
LONG TERM STORAGE...246
BEFORE STORAGE...246
DURING STORAGE...246
AFTER STORAGE...246
STARTING MACHINE AFTER LONG-TERM STORAGE...247
TROUBLES AND ACTIONS...248
RUNNING OUT OF FUEL...248
PHENOMENA THAT ARE NOT FAILURES...248
TOWING THE MACHINE...249
LIGHTWEIGHT TOWING HOLE...250
SEVERE JOB CONDITION...250
DISCHARGED BATTERY...251
WHEN ABNORMALITY OCCURS IN HYBRID SYSTEM...255
OTHER TROUBLE...258
MAINTENANCE...264
MAINTENANCE INFORMATION...265
OUTLINE OF SERVICE...267
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...267
ELECTRIC SYSTEM MAINTENANCE...270
HANDLING HYBRID EQUIPMENT AND HIGH-VOLTAGE WIRING...271
WEAR PARTS...272
WEAR PARTS LIST...272
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...273
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...275
TIGHTENING TORQUE SPECIFICATIONS...276
TIGHTENING TORQUE LIST...276
SAFETY CRITICAL PARTS...277
SAFETY CRITICAL PARTS LIST...278
MAINTENANCE SCHEDULE...279
MAINTENANCE SCHEDULE CHART...279
MAINTENANCE PROCEDURE...281
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...281
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)...281
WHEN REQUIRED...282
CHECK BEFORE STARTING...308
EVERY 100 HOURS MAINTENANCE...309
EVERY 250 HOURS MAINTENANCE...310
EVERY 500 HOURS MAINTENANCE...313
EVERY 1000 HOURS MAINTENANCE...329
EVERY 2000 HOURS MAINTENANCE...337
EVERY 4000 HOURS MAINTENANCE...343
EVERY 5000 HOURS MAINTENANCE...347
EVERY 8000 HOURS MAINTENANCE...348
LUBRICATION STANDARD CHART...349
SPECIFICATIONS...352
SPECIFICATIONS...353
ATTACHMENTS, OPTIONS...356
ATTACHMENTS AND OPTIONS...357
GENERAL PRECAUTIONS FOR SAFETY...357
PRECAUTIONS WHEN SELECTING...357
READ THE INSTRUCTION MANUAL THOROUGHLY...357
PRECAUTIONS WHEN REMOVING OR INSTALLING...357
PRECAUTIONS WHEN USING...358
BUCKET WITH HOOK...359
HOOK CONDITION...359
PROHIBITED OPERATIONS...359
