Komatsu PC200-8,PC200LC-8,PC220-8,PC220LC-8 Shop Manual SEN00084-03 PDF

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Komatsu PC200-8,PC200LC-8,PC220-8,PC220LC-8 Hydraulic Excavator Shop Manual SEN00084-03 – PDF DOWNLOAD

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Komatsu PC200-8,PC200LC-8,PC220-8,PC220LC-8 Hydraulic Excavator Shop Manual SEN00084-03 – PDF DOWNLOAD

Language : English
Pages : 1040
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200-8,PC200LC-8,PC220-8,PC220LC-8 Hydraulic Excavator Shop Manual SEN00084-03 – PDF DOWNLOAD

SERIAL NUMBERS   

• PC200- 300001          and up
•  PC200LC-300001    and up
• PC220- 70001           and up
• PC220LC- 70001      and up

Table of contents 1
00 Index and foreword
Index SEN00093-03
Organization list of the shop manual . 2
Table of contents 4
Foreword and general information SEN00094-01
Foreword and general information 2
Safety notice 2
How to read the shop manual 6
Explanation of terms for maintenance standard 8
Handling electric equipment and hydraulic component . 10
Handling electric equipment and hydraulic component . 10
How to read electric wire code . 18
Method of disassembling and connecting push-pull type coupler . 21
Standard tightening torque table 24
Conversion table 28
01 Specification
Specification and technical data SEN00095-00
Specification and technical data 2
Specification dimension 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 and cooling system SEN00096-00
Engine and cooling system . 2
Engine related parts . 2
Radiator, oil cooler, aftercooler and fuel cooler 3
Power train SEN00097-00
Power train 2
Power train . 2
Final drive 4
Swing machinery . 6
Swing circle 10
Undercarriage and frame SEN00098-00
Undercarriage and frame 2
Track frame and recoil spring 2
Idler 4
Carrier roller . 6
Track roller . 7
Track shoe . 8
Hydraulic system, Part 1 SEN00099-00
Hydraulic system, Part 1 . 2
Hydraulic equipment layout drawing 2
Hydraulic tank and filter . 4
Hydraulic pump 6
Pilot oil filter . 28
Hydraulic system, Part 2 SEN00100-00
Hydraulic system, Part 2 . 2
Control valve 2
00 Index and foreword SEN00093-03
PC200, 220-8 5
CLSS . 15
Functions and operation by valve 20
Hydraulic system, Part 3 SEN00160-00
Hydraulic system, Part 3 . 3
Swing motor . 3
Center swivel joint . 13
Travel motor . 15
PPC valve 26
Work equipment and swing PPC valve . 26
Travel PPC valve . 30
Service PPC valve (with EPC valve) . 39
Service PPC valve . 45
Valve control 47
Solenoid valve . 49
PPC Accumulator 51
Return oil filter . 52
Attachment circuit selector valve . 53
Hydraulic cylinder 55
Work equipment SEN00101-00
Work equipment 2
Dimensions of components . 2
Cab and its attachments SEN00102-00
Cab and its attachments 2
Air conditioner piping . 2
Electrical system SEN00103-00
Electrical system . 2
Engine control 2
Electrical control system 10
Monitor system 30
Sensor . 57
KOMTRAX terminal system . 60
20 Standard value table
Standard service value table SEN00227-01
Standard service value table . 2
Standard value table for engine related parts 2
Standard value table for chassis related parts . 4
30 Testing and adjusting
Testing and adjusting, Part 1 SEN00228-01
Testing and adjusting, Part 1 . 3
Tools for testing, adjusting, and troubleshooting . 3
Measuring engine speed . 6
Measuring intake air pressure (boost pressure) 7
Checking exhaust gas color 8
Adjusting valve clearance 9
Measuring compression pressure . 11
Measuring blow-by pressure . 13
Measuring engine oil pressure 14
Handling fuel system parts 15
Releasing residual pressure from fuel system . 15
Measuring fuel pressure 16
Measuring fuel return rate and leakage . 18
Bleeding air from fuel circuit 20
Checking fuel circuit for leakage 22
Checking and adjusting air conditioner compressor belt tension 23
SEN00093-03 00 Index and foreword
6 PC200, 220-8
Measuring swing circle bearing clearance . 24
Checking and adjusting track shoe tension . 25
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits . 27
Measuring control circuit basic pressure . 30
Measuring and adjusting oil pressure in pump PC control circuit 31
Measuring and adjusting oil pressure in pump LS control circuit . 34
Measuring solenoid valve output pressure 38
Measuring PPC valve output pressure 41
Adjusting play of work equipment and swing PPC valves . 43
Checking parts which cause hydraulic drift of work equipment . 44
Releasing residual pressure from hydraulic circuit 46
Measuring oil leakage 47
Bleeding air from each part 50
Checking cab tipping stopper 53
Adjusting mirrors 54
Testing and adjusting, Part 2 SEN00229-01
Testing and adjusting, Part 2 . 2
Special functions of machine monitor 2
Testing and adjusting, Part 3 SEN00230-01
Testing and adjusting, Part 3 . 2
Handling voltage circuit of engine controller 2
Preparation work for troubleshooting of electrical system . 3
Procedure for testing diodes 8
Pm Clinic service . 9
40 Troubleshooting
General information on troubleshooting SEN00231-01
General information on troubleshooting 2
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Check before troubleshooting 4
Classification and procedures for troubleshooting . 5
How to read electric wire code . 9
Connection table for connector pin numbers . 12
T-boxes and T-adapters table 35
Troubleshooting by failure code (Display of code), Part 1 SEN00240-01
Troubleshooting by failure code (Display of code), Part 1 . 3
Failure codes table 3
Before carrying out troubleshooting when failure code is displayed 8
Information in troubleshooting table . 12
Failure code [989L00] Engine Controller Lock Caution 1 14
Failure code [989M00] Engine Controller Lock Caution 2 . 14
Failure code [989N00] Engine Controller Lock Caution 3 15
Failure code [AA10NX] Air Cleaner Clogging 15
Failure code [AB00KE] Charge Voltage Low . 16
Failure code [B@BAZG] Eng Oil Press. Low . 18
Failure code [B@BAZK] Eng Oil Level Low . 18
Failure code [B@BCNS] Eng Water Overheat 19
Failure code [B@BCZK] Eng Water Level Low . 19
Failure code [B@HANS] Hydr Oil Overheat 20
Failure code [CA111] EMC Critical Internal Failure 20
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 21
Failure code [CA122] Chg Air Press Sensor High Error 22
Failure code [CA123] Chg Air Press Sensor Low Error . 24
Failure code [CA131] Throttle Sensor High Error 26
Failure code [CA132] Throttle Sensor Low Error . 28
00 Index and foreword SEN00093-03
PC200, 220-8 7
Failure code [CA144] Coolant Temp Sens High Error . 30
Failure code [CA145] Coolant Temp Sens Low Error 32
Failure code [CA153] Chg Air Temp Sensor High Error 34
Failure code [CA154] Chg Air Temp Sensor Low Error . 36
Failure code [CA155] Chg Air Temp High Speed Derate . 38
Failure code [CA187] Sens Supply 2 Volt Low Error . 40
Failure code [CA221] Ambient Press Sens High Error 42
Failure code [CA222] Ambient Press Sens Low Error . 44
Failure code [CA227] Sens Supply 2 Volt High Error 46
Failure code [CA234] Eng Overspeed . 47
Failure code [CA238] Ne Speed Sens Supply Volt Error . 48
Failure code [CA271] IMV/PCV1 Short Error 49
Failure code [CA272] IMV/PCV1 Open Error 50
Failure code [CA322] Inj #1 (L#1) Open/Short Error . 52
Failure code [CA323] Inj #5 (L#5) Open/Short Error . 54
Failure code [CA324] Inj #3 (L#3) Open/Short Error . 56
Failure code [CA325] Inj #6 (L#6) Open/Short Error . 58
Failure code [CA331] Inj #2 (L#2) Open/Short Error . 60
Failure code [CA332] Inj #4 (L#4) Open/Short Error . 62
Troubleshooting by failure code (Display of code), Part 2 SEN00241-01
Troubleshooting by failure code (Display of code), Part 2 . 3
Failure code [CA342] Calibration Code Incompatibility . 3
Failure code [CA351] Injectors Drive Circuit Error . 4
Failure code [CA352] Sens Supply 1 Volt Low Error . 6
Failure code [CA386] Sens Supply 1 Volt High Error 8
Failure code [CA428] Water in Fuel Sensor High Error . 10
Failure code [CA429] Water in Fuel Sensor Low Error 12
Failure code [CA435] Eng Oil Press Sw Error . 14
Failure code [CA441] Battery Voltage Low Error . 15
Failure code [CA442] Battery Voltage High Error 18
Failure code [CA449] Rail Press Very High Error 20
Failure code [CA451] Rail Press Sensor High Error 22
Failure code [CA452] Rail Press Sensor Low Error 24
Failure code [CA488] Chg Air Temp High Torque Derate 26
Failure code [CA553] Rail Press High Error 26
Failure code [CA559] Rail Press Low Error . 27
Failure code [CA689] Eng Ne Speed Sensor Error . 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error 30
Failure code [CA757] All Continuous Data Lost Error . 32
Failure code [CA778] Eng Bkup Speed Sensor Error 34
Failure code [CA1633] KOMNET Datalink Timeout Error 36
Failure code [CA2185] Throt Sens Sup Volt High Error 38
Failure code [CA2186] Throt Sens Sup Volt Low Error . 39
Failure code [CA2249] Rail Press Very Low Error . 40
Failure code [CA2311] IMV Solenoid Error 42
Failure code [CA2555] Grid Htr Relay Volt High Error . 44
Failure code [CA2556] Grid Htr Relay Volt Low Error . 46
Failure code [D19JKZ] Personal Code Relay Abnormality 48
Failure code [D862KA] GPS Antenna Discon . 50
Failure code [DA22KK] Pump Solenoid Power Low Error . 51
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 53
Failure code [DA29KQ] Model Selection Abnormality . 60
Troubleshooting by failure code (Display of code), Part 3 SEN00242-01
Troubleshooting by failure code (Display of code), Part 3 . 4
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 4
Failure code [DAFGMC] GPS Module Error 6
Failure code [DAFRMC] CAN Discon (Monitor Detected) . 8
SEN00093-03 00 Index and foreword
8 PC200, 220-8
Failure code [DGH2KB] Hydr Oil Sensor Short . 10
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 12
Failure code [DHPBMA] R Pump Press Sensor Abnormality 14
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality . 16
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 18
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality . 20
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality . 22
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality . 24
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality . 26
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 29
Failure code [DW43KA] Travel Speed Sol Discon . 32
Failure code [DW43KB] Travel Speed Sol Short . 34
Failure code [DW45KA] Swing Brake Sol Discon 36
Failure code [DW45KB] Swing Brake Sol Short 38
Failure code [DW91KA] Travel Junction Sol Discon 40
Failure code [DW91KB] Travel Junction Sol Short 42
Failure code [DWA2KA] Service Sol Discon 44
Failure code [DWA2KB] Service Sol Short 45
Failure code [DWK0KA] 2-stage Relief Sol Discon . 46
Failure code [DWK0KB] 2-stage Relief Sol Short 48
Troubleshooting by failure code (Display of code), Part 4 SEN00243-01
Troubleshooting by failure code (Display of code), Part 4 . 4
Failure code [DXA8KA] PC-EPC (F) Sol Discon . 4
Failure code [DXA8KB] PC-EPC (F) Sol Short 6
Failure code [DXA9KA] PC-EPC (R) Sol Discon . 8
Failure code [DXA9KB] PC-EPC (R) Sol Short . 10
Failure code [DXE0KA] LS-EPC Sol Discon 12
Failure code [DXE0KB] LS-EPC Sol Short 14
Failure code [DXE4KA] Service Current EPC Discon . 16
Failure code [DXE4KB] Service Current EPC Short 18
Failure code [DXE5KA] Merge-divider Main Sol Discon 20
Failure code [DXE5KB] Merge-divider Main Sol Short 22
Failure code [DXE6KA] Merge-divider LS Sol Discon . 24
Failure code [DXE6KB] Merge-divider LS Sol Short 26
Failure code [DY20KA] Wiper Working Abnormality 28
Failure code [DY20MA] Wiper Parking Abnormality 30
Failure code [DY2CKA] Washer Drive Discon . 32
Failure code [DY2CKB] Washer Drive Short . 34
Failure code [DY2DKB] Wiper Drive (For) Short . 36
Failure code [DY2EKB] Wiper Drive (Rev) Short . 38
Troubleshooting of electrical system (E-mode) SEN00244-01
Troubleshooting of electrical system (E-mode) . 3
Before carrying out troubleshooting of electrical system . 3
Information in troubleshooting table . 5
E-1 When starting switch turned ON, machine monitor displays nothing 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up 8
E-3 Engine does not start (Engine does not turn) 11
E-4 Preheater does not operate 14
E-5 Automatic warm-up system does not operate (in cold season) 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 18
E-7 Precaution lights up while engine is running . 20
E-8 Emergency stop item lights up while engine is running 25
E-9 Engine coolant temperature gauge does not indicate normally 26
E-10 Hydraulic oil temperature gauge does not indicate normally 27
E-11 Fuel level gauge does not indicate normally . 29
E-12 Contents of display by machine monitor are different from applicable machine . 31
E-13 Machine monitor does not display some items . 31
00 Index and foreword SEN00093-03
PC200, 220-8 9
E-14 Function switch does not work 31
E-15 Auto-decelerator does not operate normally . 32
E-16 Working mode does not change . 33
E-17 Travel speed does not change 34
E-18 Alarm buzzer cannot be stopped 35
E-19 Windshield wiper and window washer do not operate 36
E-20 Power maximizing function does not operate normally . 38
E-21 Swing holding brake does not operate normally . 40
E-22 Travel alarm does not sound or does not stop sounding 42
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 44
E-24 While starting switch is in OFF position, service meter is not displayed . 56
E-25 Machine monitor cannot be set in service mode . 56
E-26 Monitoring function does not display lever control signal normally . 57
E-27 KOMTRAX system does not operate normally . 65
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00245-00
Troubleshooting of hydraulic and mechanical system (H-mode) 4
System diagram of hydraulic and mechanical system . 4
Information in troubleshooting table 6
H-1 Speed or power of whole work equipment, swing, and travel is low . 7
H-2 Engine speed lowers extremely or engine stalls . 9
H-3 Work equipment, swing, and travel systems do not work . 10
H-4 Abnormal sound comes out from around hydraulic pump 10
H-5 Auto-decelerator does not operate . 11
H-6 Fine control performance or response is low 11
H-7 Speed or power of boom is low . 12
H-8 Speed or power of arm is low . 13
H-9 Speed or power of bucket is low . 14
H-10 Work equipment does not move singly . 14
H-11 Hydraulic drift of work equipment is large . 15
H-12 Time lag of work equipment is large . 17
H-13 When part of work equipment is relieved singly, other parts of work equipment move 17
H-14 Power maximizing function does not work 18
H-15 In compound operation of work equipment, speed of part loaded more is low . 18
H-16 When machine swings and raises boom simultaneously, boom rising speed is low 19
H-17 When machine swings and travels simultaneously, travel speed lowers largely 19
H-18 Machine deviates during travel . 20
H-19 Travel speed is low . 21
H-20 Machine is not steered well or steering power is low 22
H-21 Travel speed does not change or travel speed is low/high . 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 swinging 28
H-26 Large shock is made when upper structure stops swinging . 29
H-27 Large sound is made when upper structure stops swinging . 29
H-28 Hydraulic drift of swing is large . 30
H-29 Attachment circuit is not changed . 31
H-30 Oil flow in attachment circuit cannot be controlled 31
Troubleshooting of engine (S-mode) SEN00246-01
Troubleshooting of engine (S-mode) . 4
Method of using troubleshooting chart 4
S-1 Starting performance is poor . 8
S-2 Engine does not start 9
S-3 Engine does not pick up smoothly 12
S-4 Engine stops during operations 13
S-5 Engine does not rotate smoothly 14
S-6 Engine lack output (or lacks power) 15
SEN00093-03 00 Index and foreword
10 PC200, 220-8
S-7 Exhaust smoke is black (incomplete combustion) 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 17
S-9 Oil becomes contaminated quickly 18
S-10 Fuel consumption is excessive . 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 20
S-12 Oil pressure drops . 21
S-13 Oil level rises (Entry of coolant/fuel) 22
S-14 Coolant temperature becomes too high (overheating) 23
S-15 Abnormal noise is made 24
S-16 Vibration is excessive 25
50 Disassembly and assembly
Disassembly and assembly related information SEN00659-00
Disassembly and assembly related information 2
How to read this manual 2
List of adhesives 4
Special tool list . 7
Sketches of special tools . 12
Engine cooling related SEN00660-00
Engine cooling related . 2
Removal and installation of fuel supply pump assembly . 2
Removal and installation of fuel injector assembly 4
Removal and installation of engine front seal 11
Removal and installation of engine rear seal . 14
Removal and installation of cylinder head assembly . 17
Removal and installation of radiator assembly 29
Removal and installation of assembly hydraulic oil cooler assembly 32
Removal and installation of aftercooler assembly 34
Removal and installation of fuel cooler assembly. . 36
Removal and installation of engine and hydraulic pump assemblies 37
Power train SEN00661-00
Power train 2
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 20
Disassembly and assembly of swing motor and swing machinery assembly 22
Removal and installation of swing circle assembly 32
Under carriage and frame SEN00662-00
Under carriage and frame . 2
Disassembly and assembly of carrier roller . 2
Disassembly and assembly of track roller assembly . 5
Disassembly and assembly of idler assembly . 7
Disassembly and assembly of recoil spring . 10
Removal and installation of sprocket . 12
Expansion and installation of track shoe assembly . 13
Removal and installation of revolving frame assembly 15
Removal and installation of counterweight assembly 17
Hydraulic system SEN00663-00
Hydraulic system . 2
Removal and installation of center swivel joint assembly 2
Disassembly and assembly of center swivel joint assembly 4
00 Index and foreword SEN00093-03
PC200, 220-8 11
Removal and installation of hydraulic tank assembly 5
Removal and installation of control valve assembly 8
Disassembly and assembly of control valve assembly 13
Removal and installation of hydraulic pump assembly 17
Removal and installation of oil seal in hydraulic pump input shaft . 21
Disassembly and assembly of work equipment PPC valve assembly . 22
Disassembly and assembly of travel PPC valve assembly . 23
Disassembly and assembly of hydraulic cylinder assembly 24
Work equipment SEN00664-00
Work equipment 2
Removal and installation of the work equipment assembly . 2
Cab related SEN00665-00
Cab related 2
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
Electric components SEN00666-00
Electric components 2
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 9
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN00112-00
Hydraulic diagrams and drawings . 3
Hydraulic circuit diagram PC200, 200LC-8 3
Hydraulic circuit diagram PC220, 220LC-8 5
Electrical diagrams and drawings SEN00113-02
Electrical diagrams and drawings . 3
Electrical circuit diagram 3
Connector arrangement diagram . 5
Electrical circuit diagram for air conditioner . 7

DESCRIPTION:

Komatsu PC200-8,PC200LC-8,PC220-8,PC220LC-8 Hydraulic Excavator Shop Manual SEN00084-03 – PDF DOWNLOAD

SERIAL NUMBERS   

• PC200- 300001          and up
•  PC200LC-300001    and up
• PC220- 70001           and up
• PC220LC- 70001      and up

G.B 29/12/24