Komatsu HYDRAULIC EXCAVATOR PC200 -8M0 PC200LC-8M0 PC220 -8M0 PC220LC-8M0 Shop Manual SEN06109-13 PDF

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Komatsu HYDRAULIC EXCAVATOR PC200 -8M0 PC200LC-8M0 PC220 -8M0 PC220LC-8M0 Shop Manual SEN06109-13- PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC200 -8M0 PC200LC-8M0 PC220 -8M0 PC220LC-8M0 Shop Manual SEN06109-13- PDF DOWNLOAD

Language : English
Pages :1450
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC200 -8M0 PC200LC-8M0 PC220 -8M0 PC220LC-8M0 Shop Manual SEN06109-13- PDF DOWNLOAD

SERIAL NUMBERS
PC200- 400001
PC200LC- 400001
PC220- 100001
PC220LC- 100001
and up

General precautions 

• Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. q Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. q Locate a place in the repair workshop to keep the tools and removed parts.
• Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. q When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer.
• 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. q When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment. q Only qualified workers must perform the work and operation which require license or qualification. q Keep the tools in good condition.
• And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc. q If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. q Before starting work, warm up your body thoroughly to start work under good condition. q Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC200 -8M0 PC200LC-8M0 PC220 -8M0 PC220LC-8M0 Shop Manual SEN06109-13- PDF DOWNLOAD

SERIAL NUMBERS
PC200- 400001
PC200LC- 400001
PC220- 100001
PC220LC- 100001
and up

Cover 1
00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
200 Foreword and general information 17
Foreword, safety and general information 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 45
Precautions when performing operation 48
Practical use of KOMTRAX 51
Standard tightening torque table 52
List of abbreviation 56
Conversion table 61
01 Specification 67
100 Specification and technical data 67
Specification dimension drawings 68
Working range diagram 69
Specifications 70
Weight table 74
Table of fuel, coolant and lubricants 78
10 Structure, function and maintenance standard 81
100 Engine and cooling system 81
Engine related parts 82
Radiator, oil cooler, aftercooler and fuel cooler 83
200 Power train 85
Power train 86
Final drive 88
Swing machinery 92
Swing circle 96
300 Undercarriage and frame 99
Track frame and recoil spring 100
Idler 102
Carrier roller 104
Track roller 105
Track shoe 106
401 Hydraulic system, Part 1 113
Hydraulic equipment layout drawing 114
Hydraulic tank and filter 116
Hydraulic pump 118
Pilot oil filter 140
402 Hydraulic system, Part 2 143
Control valve 144
CLSS 155
Functions and operation by valve 159
403 Hydraulic system, Part 3 201
Swing motor 202
Center swivel joint 210
Travel motor 212
PPC valve 222
Valve control 242
Solenoid valve 244
PPC accumulator 246
Return oil filter 247
Return oil filter with clogging sensor 248
Attachment circuit selector valve 250
Hydraulic cylinder 252
500 Work equipment 257
Work equipment 258
Dimensions of arm 266
Dimensions of bucket 268
600 Electrical system 271
Engine control 272
Electrical control system 282
Machine monitor system 305
Sensor 326
KOMTRAX system 330
Clogging detection system of additional filter for breaker 333
20 Standard value table 335
100 Standard service value table 335
Standard value table for engine related parts 336
Standard value table for chassis related parts 338
30 Testing and adjusting 357
101 Testing and adjusting, Part 1 357
Tools for testing, adjusting, and troubleshooting 359
Sketch of special tool 363
Testing engine speed 364
Testing intake air pressure (boost pressure) 365
Testing exhaust gas color 366
Adjusting valve clearance 367
Testing compression pressure 369
Testing blowby pressure 372
Testing engine oil pressure 373
Handling fuel system parts 374
Releasing residual pressure from fuel system 374
Testing fuel pressure 375
Handling reduced cylinder mode operation 378
Handling no-injection cranking operation 378
Testing fuel discharge, return and leak amount 379
Bleeding air from fuel circuit 382
Testing fuel circuit for leakage 383
Handling controller high voltage circuit 384
Testing and adjusting air conditioner compressor belt tension 385
Replacing alternator belt 386
Testing swing circle bearing clearance 387
Testing and adjusting track tension 388
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 390
Testing control circuit source pressure 393
Testing and adjusting oil pressure in pump PC control circuit 394
Testing and adjusting oil pressure in pump LS control circuit 397
Testing solenoid valve output pressure 402
Testing PPC valve output pressure 405
Adjusting play of work equipment and swing PPC valves 407
Testing parts which cause hydraulic drift of work equipment 408
Releasing remaining pressure from hydraulic circuit 410
Testing oil leakage 411
Bleeding air from each part 414
Testing cab tipping stopper 416
Adjusting mirrors 417
Installation and adjustment of mirrors 418
Angle adjustment of rear view camera 421
102 Testing and adjusting, Part 2 425
Special functions of machine monitor 426
103 Testing and adjusting, Part 3 477
Handling voltage circuit of engine controller 478
Preparation work for troubleshooting of electrical system 479
Procedure for testing diodes 484
Handling battery disconnect switch 485
Pm Clinic service 486
40 Troubleshooting 497
100 Failure code table and fuse locations 497
Failure codes table 498
Fuse locations 505
200 General Information on troubleshooting 509
Symptom and troubleshooting numbers 510
Sequence of events in troubleshooting 512
Checks before troubleshooting 514
Classification and procedures for troubleshooting 516
Symptom and troubleshooting numbers 518
Information in troubleshooting table 520
Connector/electrical wiring connection table 522
Connector arrangement diagram 552
Connection table for connector pin numbers 558
T- branch box and T- branch adapter table 594
Troubleshooting method for open circuit in wiring harness of pressure sensor system 597
301 Troubleshooting by failure code, Part 1 601
Failure code [879AKA] 603
Failure code [879AKB] 603
Failure code [879BKA] 603
Failure code [879BKB] 603
Failure code [879CKA] 603
Failure code [879CKB] 603
Failure code [879DKZ] 604
Failure code [879EMC] 604
Failure code [879FMC] 604
Failure code [879GKX] 604
Failure code [989L00] 605
Failure code [989M00] 606
Failure code [989N00] 607
Failure code [AA10NX] 608
Failure code [AB00KE] 610
Failure code [B@BAZG] 613
Failure code [B@BAZK] 614
Failure code [B@BCNS] 616
Failure code [B@BCZK] 617
Failure code [B@HANS] 619
Failure code [CA111] 620
Failure code [CA115] 621
Failure code [CA122] 622
Failure code [CA123] 625
Failure code [CA131] 628
Failure code [CA132] 631
Failure code [CA144] 634
Failure code [CA145] 637
Failure code [CA153] 640
Failure code [CA154] 643
Failure code [CA155] 646
Failure code [CA187] 647
Failure code [CA221] 649
Failure code [CA222] 652
Failure code [CA227] 655
Failure code [CA234] 656
Failure code [CA238] 657
Failure code [CA271] 659
Failure code [CA272] 661
302 Troubleshooting by failure code, Part 2 665
Failure code [CA322] 667
Failure code [CA323] 670
Failure code [CA324] 673
Failure code [CA325] 676
Failure code [CA331] 679
Failure code [CA332] 682
Failure code [CA342] 685
Failure code [CA351] 686
Failure code [CA352] 687
Failure code [CA386] 689
Failure code [CA428] 690
Failure code [CA429] 692
Failure code [CA435] 694
Failure code [CA441] 696
Failure code [CA442] 699
Failure code [CA449] 700
Failure code [CA451] 702
Failure code [CA452] 705
Failure code [CA488] 708
Failure code [CA553] 709
Failure code [CA559] 710
Failure code [CA689] 712
Failure code [CA731] 715
Failure code [CA757] 718
Failure code [CA778] 719
Failure code [CA2185] 724
Failure code [CA2186] 727
Failure code [CA2249] 729
Failure code [CA2311] 730
Failure code [CA2555] 731
Failure code [CA2556] 734
303 Troubleshooting by failure code, Part 3 739
Failure code [D110KB] 740
Failure code [D19JKZ] 742
Failure code [D811MC] 745
Failure code [D862KA] 746
Failure code [D8AQKR] 747
Failure code [DA22KK] 750
Failure code [DA25KP] 753
Failure code [DA26KP] 756
Failure code [DA29KQ] 759
Failure code [DA29KQ] 762
Failure code [DA2QKR] 764
Failure code [DAF0MB] 767
Failure code [DAF0MC] 767
Failure code [DAF8KB] 768
Failure code [DAF9KQ] 770
Failure code [DAFGMC] 771
Failure code [DAFQKR] 772
Failure code [DAZ9KQ] 773
Failure code [DAZQKR] 774
Failure code [DB2QKR] 775
Failure code [DGH2KB] 781
Failure code [DHA4KA] 783
Failure code [DHPAMA] 784
Failure code [DHPBMA] 787
304 Troubleshooting by failure code, Part 4 791
Failure code [DHS3MA] 792
Failure code [DHS4MA] 795
Failure code [DHS8MA] 798
Failure code [DHS9MA] 801
Failure code [DHSAMA] 804
Failure code [DHSBMA] 807
Failure code [DHSCMA] 810
Failure code [DHSDMA] 813
Failure code [DHSFMA] 816
Failure code [DHSGMA] 819
Failure code [DHSHMA] 822
Failure code [DHSJMA] 825
Failure code [DHX1MA] 828
Failure code [DR21KX] 832
Failure code [DR31KX] 834
Failure code [DV20KB] 835
Failure code [DW43KA] 837
Failure code [DW43KB] 839
Failure code [DW45KA] 841
Failure code [DW45KB] 844
Failure code [DW91KA] 847
Failure code [DW91KB] 849
305 Troubleshooting by failure code, Part 5 853
Failure code [DWA2KA] 854
Failure code [DWA2KB] 856
Failure code [DWK0KA] 858
Failure code [DWK0KB] 860
Failure code [DWK2KA] 862
Failure code [DWK2KB] 864
Failure code [DXA8KA] 866
Failure code [DXA8KB] 869
Failure code [DXA9KA] 872
Failure code [DXA9KB] 875
Failure code [DXE0KA] 878
Failure code [DXE0KB] 880
Failure code [DXE4KA] 882
Failure code [DXE4KB] 884
Failure code [DXE5KA] 886
Failure code [DXE5KB] 888
Failure code [DXE6KA] 890
Failure code [DXE6KB] 892
Failure code [DY20KA] 894
Failure code [DY20MA] 897
Failure code [DY2CKB] 900
Failure code [DY2DKB] 903
Failure code [DY2EKB] 905
400 Troubleshooting of electrical system (E-mode) 909
Before troubleshooting for electrical system 911
Information described in troubleshooting table 913
E-1 Engine does not start (engine does not rotate) 915
E-2 Preheating system does not work 924
E-3 Machine monitor displays nothing when starting switch is turned to ON position 930
E-4 When starting switch is turned to ON position (with engine stopped), basic check items light up 933
E-5 Caution item lights up while the engine is running 934
E-6 Caution item lights up while the engine is running 939
E-7 Fuel gauge does not indicate correct level 942
E-8 Engine coolant temperature gauge does not indicate correct temperature 945
E-9 Hydraulic oil temperature gauge does not indicate correct temperature 947
E-10 Contents of display on machine monitor are different from actual machine model 950
E-11 Some areas of machine monitor screen are not displayed 952
E-12 Function switch does not work 952
E-13 Automatic warm-up system does not work (in cold weather) 953
E-14 Auto-deceleration function does not work properly 955
E-15 Working mode does not change 957
E-16 Travel speed does not change 958
E-17 Alarm buzzer does not stop sounding 960
E-18 Service meter is not displayed while starting switch is in OFF position 960
E-19 Service mode cannot be selected 961
E-20 All work equipment, swing and travel do not work, or lock is not available 962
E-21 Swing parking brake does not work properly 965
E-22 One-touch power maximizing function does not work properly 969
E-23 Travel alarm does not sound or does not stop sounding 972
E-24 Horn does not sound or does not stop sounding 974
E-25 Wiper or window washer does not operate 978
E-26 “Boom LOWER” is not displayed correctly via monitoring function 981
E-27 “Arm OUT” is not displayed correctly via monitoring function 981
E-28 “Arm IN” is not displayed correctly via monitoring function 982
E-29 “Boom RAISE” is not displayed correctly via monitoring function 982
E-30 “Bucket CURL” is not displayed correctly via monitoring function 982
E-31 “Bucket DUMP” is not displayed correctly via monitoring function 983
E-32 “Swing” is not displayed correctly via monitoring function 983
E-33 “Travel” is not displayed correctly via monitoring function 983
E-34 “Service” is not displayed correctly via monitoring function 984
E-35 Attachment hydraulic circuit cannot be changed 987
E-36 KOMTRAX system does not operate normally 988
E-37 Breaker clogging caution lamp lights up when breaker is not used 990
500 Troubleshooting of hydraulic and mechanical system (H-mode) 993
System diagram of hydraulic and mechanical system 996
Failure mode and cause table 998
Information in troubleshooting table1000
H-1 All work equipment, swing and travel speed are all slow, or there is no force1001
H-2 Engine speed drops significantly or engine stalls1004
H-3 All work equipment, swing and travel do not work1006
H-4 Unusual noise is heard from the vicinity of the hydraulic pump1007
H-5 Fine control performance or response is poor1008
H-6 Boom speed is low or power is insufficient1009
H-7 Arm speed is low or power is insufficient1013
H-8 Bucket speed is low or power is insufficient1017
H-9 Work equipment does not move in single operation1019
H-10 Hydraulic drift of work equipment is large1020
H-11 Time lag of work equipment is large1024
H-12 When certain work equipment is relieved hydraulically, other work equipment moves1025
H-13 One-touch power maximization function does not work1026
H-14 When combining operations of work equipment, equipment subject to heavier loads moves slower1027
H-15 Boom RAISE is slow in Swing + Boom RAISE operation1028
H-16 When combining swing and travel operations, travel speed drops significantly1029
H-17 Travel deviation is detected1030
H-18 Travel speed is slow1032
H-19 Machine does not steer well or steering power is low1035
H-20 Travel speed does not change, or travel speed is too slow or too fast1039
H-21 One track does not move1041
H-22 Machine does not swing1043
H-23 Swing acceleration or swing speed is low1046
H-24 Upper structure overruns excessively when it stops swinging1049
H-25 Shock is significant when upper structure stops swinging1052
H-26 An unusual loud noise is heard when the upper structure stops swinging1053
H-27 Swing drift on a slope is significant1054
H-28 Attachment circuit cannot be changed1057
H-29 Oil flow in the attachment circuit cannot be changed1058
600 Troubleshooting of engine (S-mode)1061
Method of using troubleshooting chart1062
S-1 Startability is poor1066
S-2 Engine does not start1067
S-3 Engine does not pick up smoothly1070
S-4 Engine stops during operation1071
S-5 Engine runs rough or is unstable1072
S-6 Engine lacks power1073
S-7 Exhaust smoke is black (incomplete combustion)1074
S-8 Oil consumption is excessive (or exhaust smoke is blue)1075
S-9 Oil becomes contaminated early1076
S-10 Fuel consumption is excessive1077
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)1078
S-12 Oil pressure drops1079
S-13 Oil level rises (coolant or fuel in oil)1080
S-14 Coolant temperature rises too high (overheating)1081
S-15 Unusual noise is made1082
S-16 Vibration is excessive1083
50 Disassembly and assembly1085
100 General information on disassembly and assembly1085
How to read this manual1086
Coating materials list1088
Special tools list1091
Sketches of special tools1096
200 Engine and cooling system1101
Removal and installation of fuel supply pump assembly1102
Removal and installation of fuel injector assembly1106
Removal and installation of engine front oil seal1113
Removal and installation of engine rear oil seal1118
Removal and installation of cylinder head assembly1121
Removal and installation of radiator assembly1136
Removal and installation of hydraulic oil cooler assembly1138
Removal and installation of aftercooler assembly1140
Removal and installation of fuel cooler assembly1143
Removal and installation of engine and hydraulic pump assembly1144
300 Power train1155
Removal and installation of final drive assembly1156
Disassembly and assembly of final drive assembly1158
Removal and installation of swing motor and swing machinery assembly1176
Disassembly and assembly of swing motor and swing machinery assembly1178
Removal and installation of swing circle assembly1188
400 Undercarriage and frame1191
Disassembly and assembly of carrier roller assembly1192
Disassembly and assembly of track roller assembly1195
Removal and installation of idler and idler cushion assembly1197
Disassembly and assembly of idler1198
Disassembly and assembly of idler cushion1201
Removal and installation of sprocket1203
Separation and connection of track shoe assembly1204
Removal and installation of revolving frame assembly1208
Removal and installation of counterweight assembly1210
500 Hydraulic system1213
Removal and installation of center swivel joint assembly1214
Disassembly and assembly of center swivel joint assembly1216
Removal and installation of hydraulic tank assembly1217
Removal and installation of control valve assembly1221
Disassembly and assembly of control valve1226
Removal and installation of hydraulic pump assembly1231
Removal and installation of oil seal in hydraulic pump input shaft1235
Disassembly and assembly of work equipment PPC valve assembly1236
Disassembly and assembly of travel PPC valve1238
Disassembly and assembly of work equipment cylinder1240
600 Work equipment1249
Removal and installation of work equipment assembly1250
700 Cab and its attachments1255
Removal and installation of operator’s cab assembly1256
Removal and installation of operator cab glass (stuck glass)1259
Removal and installation of front window assembly1269
Removal and installation of floor frame assembly1276
Removal and installation of air conditioner unit assembly1280
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY1285
800 Electrical system1299
Removal and installation of machine monitor assembly1300
Removal and installation of engine controller assembly1302
Removal and installation of pump controller assembly1304
Removal and installation of KOMTRAX terminal assembly1306
Removal and installation of clogging caution lamp for breaker1307
80 Appendix1309
100 Air conditioner1309
Precautions for refrigerant1311
Air conditioner component1312
Configuration and function of refrigeration cycle1314
Outline of refrigeration cycle1315
Air conditioner unit1317
Air conditioner controller1323
Compressor1324
Condenser and Modulator1325
Sensor1326
Procedure for testing and troubleshooting1328
Circuit diagram and arrangement of connector pins1330
System diagram1332
Parts and connectors layout1334
Testing air leakage (duct)1337
Testing with self-diagnosis function1339
Testing vent (mode) changeover1341
Testing FRESH/RECIRC air changeover1342
Testing sunlight sensor1343
Testing (dual) pressure switch for refrigerant1344
Testing relays1345
Troubleshooting chart 11346
Troubleshooting chart 21348
Information in troubleshooting table1350
Failure code list related to air conditioner1351
Failure code [879AKA] A/C Inner sensor Open Circuit1352
Failure code [879AKB] A/C Inner sensor Short Circuit1353
Failure code [879BKA] A/C Outer sensor Open Circuit1354
Failure code [879BKB] A/C Outer sensor Short Circuit1356
Failure code [879CKA] Ventilating sensor Open Circuit1358
Failure code [879CKB] Ventilating sensor Short Circuit1359
Failure code [879DKZ] Sunlight sensor Open or Short Circuit1360
Failure code [879EMC] Ventilating Damper Abnormality1362
Failure code [879FMC] Air Mix Damper Abnormality1363
Failure code [879GKX] Refrigerant Abnormality1364
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)1366
Troubleshooting for compressor and refrigerant system (Air is not cooled)1368
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1372
Troubleshooting for FRESH/RECIRC air changeover1374
Troubleshooting with gauge pressure1376
Connection of service tool1378
Precautions for disconnecting and connecting air conditioner piping1380
Handling of compressor oil1382
Desiccant replacement procedure1384
90 Diagrams and drawings1387
100 Hydraulic diagrams and drawings1387
Symbols in hydraulic circuit diagram1388
Hydraulic circuit diagram1391
Hydraulic circuit diagram (Arm crane specification)1399
200 Electrical diagrams and drawings1405
Symbols in electric circuit diagram1406
Electrical circuit diagram1409
Wiring harness diagram1429

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24