Komatsu PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic Excavator Shop Manual - SEN06109-00

This complete service repair workshop manual PDF download for the Komatsu PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model - Serial Numbers :
PC200 - 400001 and up
PC200LC - 400001 and up
PC220 - 100001 and up
PC220LC - 100001 and up


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Maintenance standard
- Standard value table
- Testing and adjusting
- Troubleshooting
- Disassembly and assembly
- Appendix
- Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN06109-00
Total Pages : 1252


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SEN06109-00 PC200-8M0, PC200LC-8M0, PC220-8M0, PC220LC-8M0 CRAWLER EXCAVATORS

00 Index and foreword
100 Index
Composition of shop manual
Table of contents
200 Foreword and general information
Foreword, safety and general information
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
100 Specification and technical data
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
100 Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
200 Power train
Power train
Final drive
Swing machinery
Swing circle
300 Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
401 Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Pilot oil filter
402 Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
403 Hydraulic system, Part 3
Swing motor
Center swivel joint
Travel motor
PPC valve
Valve control
Solenoid valve
PPC accumulator
Return oil filter
Attachment circuit selector valve
Hydraulic cylinder
500 Work equipment
Work equipment
Dimensions of arm
Dimensions of bucket
600 Electrical system
Engine control
Electrical control system
Machine monitor system
Sensor
KOMTRAX system

20 Standard value table
100 Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

30 Testing and adjusting
101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Handling reduced cylinder mode operation
Handling no-injection cranking operation
Testing fuel discharge, return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling controller high voltage circuit
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Testing swing circle bearing clearance
Testing and adjusting track tension
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing control circuit source pressure
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
Testing parts which cause hydraulic drift of work equipment
Releasing remaining pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Testing cab tipping stopper
Adjusting mirrors
Installation and adjustment of mirrors
Angle adjustment of rear view camera
102 Testing and adjusting, Part 2
Special functions of machine monitor
103 Testing and adjusting, Part 3
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service

40 Troubleshooting
100 Failure code table and fuse locations
Failure codes table
Fuse locations
200 General Information on troubleshooting
Symptom and troubleshooting numbers
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
301 Troubleshooting by failure code, Part 1
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989L00] Engine Controller Lock Caution1
Failure code [989M00] Engine Controller Lock Caution2
Failure code [989N00] Engine Controller Lock Caution3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [[email protected]] Eng Oil Press Low
Failure code [[email protected]] Engine Oil Level Low
Failure code [[email protected]] Eng Water Overheat
Failure code [[email protected]] Radiator Coolant Level Low
Failure code [[email protected]] Hyd Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens 2 Supply Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
302 Troubleshooting by failure code, Part 2
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] lMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Open Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error
303 Troubleshooting by failure code, Part 3
Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA26KP] 5V Sensor 2 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2QKR] CAN2 Discon (Pump Con)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF9KQ] Model Selection Abnormality
Failure code [DAFGMC] GPS Module Error
Failure code [DAFQKR] CAN2 Discon
Failure code [DAZ9KQ] A/C Model Selection Abnormality
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
304 Troubleshooting by failure code, Part 4
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW91KA] Travel Neutral Sol Open Circuit
Failure code [DW91KB] Travel Neutral Sol Short Circuit
305 Troubleshooting by failure code, Part 5
Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DWK2KA] Variable Back Press Sol Open Circuit
Failure code [DWK2KB] Variable Back Press Sol Short Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE4KA] Attachment Flow EPC Open Circuit
Failure code [DXE4KB] Attachment Flow EPC Short Circuit
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short
400 Troubleshooting of electrical system (E-mode)
Fuse locations
Information contained in troubleshooting table
E-1 Engine does not start (Engine does not crank)
E-2 Preheater does not operate
E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up.
E-5 Precaution monitor lights up while engine is running
E-6 Emergency stop monitor lights up while engine is running
E-7 Fuel level gauge does not indicate properly
E-8 Engine coolant temperature gauge does not indicate properly
E-9 Hydraulic oil temperature gauge does not indicate properly
E-10 Displays on machine monitor are different from those for actual machine
E-11 Some areas of machine monitor screen are not displayed
E-12 Function switch does not operate
E-13 Automatic warm-up system does not operate (in cold season)
E-14 Auto-decelerator does not operate properly
E-15 Working mode does not change
E-16 Travel speed does not change
E-17 Alarm buzzer cannot be canceled
E-18 When starting switch is turned OFF, service meter is not displayed
E-19 Service mode cannot be selected
E-20 Any of work equipment, swing and travel do not operate or cannot be locked
E-21 Swing holding brake does not operate properly
E-22 One-touch power maximizing function does not operate properly
E-23 Travel alarm does not sound or does not stop sounding
E-24 Horn does not sound or does not stop
E-25 Windshield wiper and window washer do not operate
E-26 BOOM DOWN indicator is not displayed properly with monitoring function
E-27 ARM DUMP indicator is not displayed properly with monitoring function
E-28 ARM IN indicator is not displayed properly with monitoring function
E-29 BOOM RAISE indicator is not displayed properly with monitoring function
E-30 BUCKET CURL indicator is not displayed properly with monitoring function
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function
E-32 SWING indicator is not displayed properly with monitoring function
E-33 TRAVEL indicator is not displayed properly with monitoring function
E-34 ATTACHMENT indicator is not displayed properly with monitoring function
E-35 Attachment hydraulic circuit cannot be changed
E-36 KOMTRAX system does not operate properly
500 Troubleshooting of hydraulic and mechanical system (H-mode)
System diagram of hydraulic and mechanical system
Failure mode and cause table
Information in troubleshooting table
H-1 Speed or power of whole work equipment, swing, and travel is low
H-2 Engine speed lowers significantly or engine stalls
H-3 Work equipment, swing, and travel systems do not work
H-4 Unusual noise comes out from around hydraulic pump
H-5 Fine control performance or response is low
H-6 Speed or power of boom is low
H-7 Speed or power of arm is low
H-8 Speed or power of bucket is low
H-9 Work equipment does not move in its single operation
H-10 Hydraulic drift of work equipment is large
H-11 Time lag of work equipment is large
H-12 Other work equipment moves when one of work equipment is relieved
H-13 One-touch power maximizing function does not work
H-14 In combined operation of work equipment, equipment having heavier load moves slower.
H-15 In combined operation of swing and boom RAISE, boom rising speed is low
H-16 Travel speed drops largely in combined operation of swing and travel
H-17 Machine does not travel straight
H-18 Travel speed is low
H-19 Machine is hard to steer or travel power is low
H-20 Travel speed does not change or travel speed is low/high
H-21 One of tracks does not run
H-22 Upper structure does not swing
H-23 Swing acceleration is poor or swing speed is low
H-24 Upper structure overruns remarkably when it stops swinging
H-25 Shock is large when upper structure stops swinging
H-26 Large sound is made when upper structure stops swinging
H-27 Hydraulic drift of swing is large
H-28 Attachment circuit cannot be changed
H-29 Oil flow in attachment circuit cannot be controlled
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Startability is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine runs rough or is unstable
S-6 Engine lacks power
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated early
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (coolant or fuel in oil)
S-14 Coolant temperature rises too high (overheating)
S-15 Unusual noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
100 General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
200 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 oil seal
Removal and installation of engine rear oil 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 and hydraulic pump assembly
300 Power train
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
400 Undercarriage and frame
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler
Disassembly and assembly of idler cushion
Removal and installation of sprocket
Separation and connection of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
500 Hydraulic system
Removal and installation of center swivel 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
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve
Disassembly and assembly of work equipment cylinder
600 Work equipment
Removal and installation of work equipment assembly
700 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
800 Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of KOMTRAX terminal assembly

80 Appendix
100 Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser and Modulator
Sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement procedure

90 Diagrams and drawings
100 Hydraulic diagrams and drawings
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
200 Electrical diagrams and drawings
Symbols in electric circuit diagram
Electrical circuit diagram
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