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Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual CEBM000903 – PDF DOWNLOAD
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Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS:
PC200LC-8 A88001 and up
PC220LC-8 A88001 and up
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Description
Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200LC-8, PC220LC-8
Serial Number: A88001 and up
Book Code: CEBM000903
Language: English
Pages: 1195
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
AIR CONDITIONING:
This section explains the air conditioning system. The structure, function, maintenance standard, testing, adjusting, troubleshooting, servicing and some disassembly and assembly.
DIAGRAMS AND DRAWINGS:
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC200LC-8, PC220LC-8 Hydraulic Excavator Shop Manual
CEMB000903 PC200/220LC-8................................................................................. 1 CONTENTS............................................................................................. 2 REVISED PAGES........................................................................................ 3 SAFETY............................................................................................... 13 SAFETY NOTICE.................................................................................... 13 IMPORTANT SAFETY NOTICE...................................................................... 13 GENERAL PRECAUTIONS.......................................................................... 13 PREPARATIONS FOR WORK........................................................................ 13 PRECAUTIONS DURING WORK...................................................................... 13 GENERAL.............................................................................................. 15 HOW TO READ THE SHOP MANUAL.......................................................................... 16 VOLUMES.......................................................................................... 16 DISTRIBUTION AND UPDATING........................................................................ 16 FILING METHOD.................................................................................... 16 REVISED EDITION MARK............................................................................. 16 REVISIONS........................................................................................ 16 SYMBOLS.......................................................................................... 16 HOISTING INSTRUCTIONS................................................................................ 17 HOISTING......................................................................................... 17 WIRE ROPES....................................................................................... 17 PUSH PULL COUPLER.................................................................................... 18 TYPE 1........................................................................................... 18 DISCONNECTION................................................................................ 18 CONNECTION................................................................................... 18 TYPE 2........................................................................................... 19 DISCONNECTION................................................................................ 19 CONNECTION................................................................................... 19 TYPE 3........................................................................................... 20 DISCONNECTION................................................................................ 20 CONNECTION................................................................................... 20 COATING MATERIALS.................................................................................... 21 STANDARD TIGHTENING TORQUE........................................................................... 24 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS..................................................... 24 TIGHTENING TORQUE OF HOSE NUTS................................................................... 25 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......................................................... 25 TIGHTENING TORQUE FOR FLARED NUTS................................................................ 25 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS........................................ 26 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS................................................ 26 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)........................... 26 ELECTRIC WIRE CODE................................................................................... 27 CLASSIFICATION BY THICKNESS...................................................................... 27 CLASSIFICATION BY COLOR AND CODE................................................................. 27 CONVERSION TABLES.................................................................................... 28 METHOD OF USING THE CONVERSION TABLE............................................................. 28 01 GENERAL............................................................................................... 35 SPECIFICATION AND TECHNICAL DATA..................................................................... 36 Specification Dimension Drawings................................................................. 36 Working Range Diagram............................................................................ 37 Specifications................................................................................... 38 PC200LC-8.................................................................................... 38 PC220LC-8.................................................................................... 40 Weight Table..................................................................................... 42 PC200LC-8.................................................................................... 42 PC220LC-8.................................................................................... 44 Table Of Fuel, Coolant And Lubricants............................................................ 46 Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil.............. 47 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......................................................... 49 ENGINE AND COOLING SYSTEM............................................................................ 53 Engine Related Parts............................................................................. 53 Radiator, Oil Cooler, Aftercooler and Fuel Cooler................................................ 54 POWER TRAIN.......................................................................................... 55 Power Train...................................................................................... 55 Final Drive...................................................................................... 56 Swing Machinery.................................................................................. 58 PC200LC-8.................................................................................... 58 PC220LC-8.................................................................................... 60 Swing Circle..................................................................................... 62 PC200LC-8.................................................................................... 62 PC220LC-8.................................................................................... 64 UNDERCARRIAGE AND FRAME.............................................................................. 66 Track Frame And Recoil Spring.................................................................... 66 Standard Shoe................................................................................ 67 Idler............................................................................................ 68 Carrier Roller................................................................................... 70 Track Roller..................................................................................... 72 Track Shoe....................................................................................... 74 Triple Grouser Shoe.......................................................................... 77 HYDRAULIC SYSTEM..................................................................................... 78 Hydraulic Equipment Layout Drawing............................................................... 78 Hydraulic Tank And Filter........................................................................ 80 Hydraulic Pump................................................................................... 82 Type: HPV95+95............................................................................... 82 Operation of pump............................................................................ 87 Control of delivery.......................................................................... 88 LS Valve..................................................................................... 89 PC Valve..................................................................................... 95 LS (PC)-EPC Valve............................................................................ 102 Pilot Oil Filter................................................................................. 105 For breaker.................................................................................. 105 Control Valve.................................................................................... 107 Outline...................................................................................... 107 General View................................................................................. 108 Sectional View............................................................................... 112 CLSS............................................................................................. 122 Outline of CLSS.............................................................................. 122 LS Differential Pressure and Pump Swash Plate Angle.......................................... 123 Functions and Operation by Valve................................................................. 126 Hydraulic Circuit Diagram and the Name of Valves............................................. 126 Unload Valve................................................................................. 128 Introduction Of LS Pressure.................................................................. 130 LS Bypass Plug............................................................................... 131 Pressure Compensation Valve.................................................................. 132 Integrated Pressure Compensation Valve....................................................... 133 Pressure Compensation Valve Inner Shuttle Valve.............................................. 135 Boom Regeneration Circuit.................................................................... 137 Arm Regeneration Circuit..................................................................... 139 Merge-divider Valve.......................................................................... 141 LS Select Valve.............................................................................. 144 Self Pressure Reducing Valve................................................................. 145 Travel Junction Valve........................................................................ 148 Travel PPC Shuttle Valve..................................................................... 150 Boom Drift Prevention Valve.................................................................. 153 Arm Drift Prevention Valve (if equipped)..................................................... 156 Quick Return Valve........................................................................... 160 Lift Check Valve............................................................................. 163 Main Relief Valve............................................................................ 164 2-stage Safety-suction Valve................................................................. 165 Swing Motor...................................................................................... 168 Torque Values................................................................................ 169 Specifications............................................................................... 169 Swing Holding Brake.......................................................................... 172 Relief Valve Portion......................................................................... 173 Outline...................................................................................... 173 Reverse Prevention Valve..................................................................... 174 Center Swivel Joint.......................................................................... 178 Travel Motor................................................................................. 180 Operation Of Motor........................................................................... 184 Operation of Parking Brake................................................................... 186 Brake Valve.................................................................................. 188 Operation When Pressurized Oil is Supplied................................................... 188 Operation of Brake During Traveling Downhill................................................. 189 PPC Valve........................................................................................ 192 Work Equipment and Swing PPC Valve........................................................... 192 Travel PPC Valve............................................................................. 198 Pressure reducing valve function............................................................. 202 Travel Signal/steering Function.............................................................. 204 Service PPC Valve (With EPC Valve)........................................................... 210 EPC valve.................................................................................... 212 When Signal Current Is 0..................................................................... 214 When Signal Current is Very Small............................................................ 214 When Signal Current Is Maximum............................................................... 215 Service PPC Valve................................................................................ 216 Valve Control.................................................................................... 218 Lever Positions.............................................................................. 219 Solenoid Valve................................................................................... 220 When Solenoid is De-energized................................................................ 221 When Solenoid is Energized................................................................... 222 PPC Accumulator.................................................................................. 223 Specifications............................................................................... 223 CRN (Canadian certified) PPC Accumulator......................................................... 223 Return Oil Filter................................................................................ 224 Attachment Circuit Selector Valve................................................................ 225 When Attachment Other Than Breaker is Installed.............................................. 226 When Breaker is Installed.................................................................... 226 Hydraulic Cylinder............................................................................... 228 PC200LC-8.................................................................................... 228 PC220LC-8.................................................................................... 230 WORK EQUIPMENT....................................................................................... 232 Dimensions of Components......................................................................... 232 PC200LC-8.................................................................................... 233 PC220LC-8.................................................................................... 234 CAB AND ITS ATTACHMENTS.............................................................................. 240 Air Conditioner Piping........................................................................... 240 ELECTRICAL SYSTEM.................................................................................... 241 Engine Control................................................................................... 241 Operation of system.......................................................................... 241 Component........................................................................................ 242 Fuel Control Dial............................................................................ 242 Engine Controller............................................................................ 243 Coolant Temperature Sensor................................................................... 246 Oil Pressure Switch.......................................................................... 246 Rotation Sensor.............................................................................. 247 Boost Pressure and Temperature Sensor........................................................ 247 WIF (Water-in-fuel Detection) Sensor......................................................... 248 Engine Oil Level Sensor...................................................................... 248 Electrical Control System........................................................................ 250 Machine Control System Diagram............................................................... 250 Function..................................................................................... 263 MONITOR SYSTEM....................................................................................... 274 Machine Monitor.................................................................................. 275 Input And Output Signals..................................................................... 276 Monitor Control, Display Portion................................................................. 278 Precautions on the Machine Monitor Display................................................... 279 Monitor Items and Display.................................................................... 280 Switches......................................................................................... 284 Buzzer Cancel Switch......................................................................... 284 Auto-deceleration Switch..................................................................... 284 Guidance Icon And Function Switch............................................................ 284 Working Mode Selector Switch................................................................. 286 Travel Speed Selector Switch................................................................. 286 Window Washer Switch......................................................................... 287 Wiper Switch................................................................................. 287 Air Conditioner Control Switch............................................................... 287 Camera Screen Display Function............................................................... 288 Service Meter/Time Selector Function......................................................... 289 Maintenance Function......................................................................... 289 User Mode.................................................................................... 291 Breaker/Attachment Setting................................................................... 291 Changing Breaker Mode Setting................................................................ 292 Changing Attachment Mode Setting............................................................. 294 Message Display.............................................................................. 295 Screen Adjustment............................................................................ 296 Clock Adjustment............................................................................. 296 Language Setting............................................................................. 297 Economy Mode Adjustment...................................................................... 297 Idle Stop Guidance Function.................................................................. 298 Service Meter Check Function................................................................. 298 Display LCD Check Function................................................................... 298 User Code/Failure Code Display Function...................................................... 299 SENSOR............................................................................................... 300 Fuel Level Sensor................................................................................ 300 Air Cleaner Clogging Sensor...................................................................... 301 Coolant Level Sensor............................................................................. 301 KOMTRAX TERMINAL SYSTEM.............................................................................. 302 KOMTRAX Communication ORBCOMM.................................................................... 303 TH300........................................................................................ 303 Input And Output Signals..................................................................... 303 20 STANDARD VALUE TABLES................................................................................. 305 STANDARD SERVICE VALUE TABLE......................................................................... 307 Standard Service Value Table for Engine.......................................................... 307 PC200LC-8.................................................................................... 307 PC220LC-8.................................................................................... 308 Standard Value Table for Chassis Related Parts................................................... 309 PC200LC-8.................................................................................... 309 PC220LC-8.................................................................................... 316 Machine Position for Measurement (For Both Models)............................................... 323 Control Valve: Spool Stroke.................................................................. 323 Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing................... 323 Swing 2: Hydraulic Drift Of Swing............................................................ 323 Travel 1: Travel Speed (Without Load)........................................................ 323 Travel 2: Travel Speed (Actual Run), Travel Deviation........................................ 324 Travel 3: Travel Deviation................................................................... 324 Travel 4: Hydraulic Drift Of Travel.......................................................... 324 Work Equipment 1: Hydraulic Drift Of Work Equipment.......................................... 324 Work Equipment 2: Boom Speed................................................................. 325 Work Equipment 3: Arm Speed.................................................................. 325 Work Equipment 4: Bucket Speed............................................................... 325 Work Equipment 5: Boom Time Lag.............................................................. 325 Work Equipment 6: Arm Time Lag............................................................... 326 Work Equipment 7: Bucket Time Lag............................................................ 326 Work Equipment 8: Characteristics Of PC Flow Control Valve................................... 326 30 TESTING AND ADJUSTING................................................................................. 327 SPECIAL TOOL LIST.................................................................................... 330 Sketch Of Special Tool........................................................................... 333 ENGINE COMPONENTS.................................................................................... 334 Determining A Defective Cylinder................................................................. 334 Procedures................................................................................... 334 Determining Cylinder Group................................................................... 334 Isolating the Defective Cylinder............................................................. 334 Water Pump Leakage............................................................................... 335 Engine Speed..................................................................................... 340 Intake Air Pressure (Boost Pressure)............................................................. 342 Exhaust Gas Color................................................................................ 343 Valve Clearance.................................................................................. 345 Compression Pressure............................................................................. 347 Blow-by Pressure................................................................................. 349 Engine Oil Pressure.............................................................................. 350 Handling Fuel System Parts....................................................................... 351 Releasing Residual Pressure From Fuel System................................................. 351 Fuel Pressure.................................................................................... 352 Fuel Return Rate And Leakage..................................................................... 355 Bleeding Air From Fuel Circuit................................................................... 360 Fuel Circuit - Checking For Leakage.............................................................. 361 AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................. 362 Checking......................................................................................... 362 Adjusting........................................................................................ 362 FAN BELT............................................................................................. 363 SWING CIRCLE BEARING CLEARANCE....................................................................... 364 TRACK SHOE TENSION................................................................................... 366 Checking......................................................................................... 366 Adjusting........................................................................................ 366 OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS........................................... 368 Measuring........................................................................................ 368 Adjusting........................................................................................ 371 CONTROL CIRCUIT BASIC PRESSURE....................................................................... 373 OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.............................................................. 375 Measuring........................................................................................ 375 Adjusting........................................................................................ 377 Pump PC Valve................................................................................ 377 OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.............................................................. 378 Measuring........................................................................................ 378 Adjusting........................................................................................ 382 LS valve..................................................................................... 382 SOLENOID VALVE OUTPUT PRESSURE....................................................................... 383 PPC VALVE OUTPUT PRESSURE............................................................................ 386 Connecting Points Of PPC Piping.................................................................. 386 Adjusting Play of Work Equipment and Swing PPC Valves............................................ 388 WORK EQUIPMENT HYDRAULIC DRIFT....................................................................... 389 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT................................................... 391 OIL LEAKAGE.......................................................................................... 392 BLEEDING AIR FROM EACH PART.......................................................................... 395 CAB TIPPING STOPPER.................................................................................. 397 MIRRORS.............................................................................................. 398 REAR VIEW CAMERA..................................................................................... 401 Angle Adjustment................................................................................. 401 MACHINE MONITOR SPECIAL FUNCTIONS.................................................................... 403 Air Conditioner Specification.................................................................... 403 Upper Section of Machine Monitor................................................................. 404 Display Section.............................................................................. 404 Switch Section............................................................................... 404 Lower Section Of Machine Monitor................................................................. 404 Switch Section............................................................................... 404 Ordinary Functions and Special Functions of Machine Monitor...................................... 405 Operator Mode (Outline).......................................................................... 407 Display of KOMATSU Logo...................................................................... 408 Display of Inputting Password................................................................ 408 Display of Check of Breaker Mode............................................................. 408 Display of Check Before Starting............................................................. 409 Display of Warning After Check Before Starting............................................... 409 Display of Ending of Maintenance Interval.................................................... 409 Display of Check of Working Mode and Travel Speed............................................ 409 Display of Ordinary Screen................................................................... 410 Display of End Screen........................................................................ 410 Selection of Auto-Deceleration............................................................... 410 Selection of Working Mode.................................................................... 410 Selection of Travel Speed.................................................................... 412 Operation to Stop Alarm Buzzer............................................................... 412 Operation of Windshield Wiper................................................................ 412 Operation of Window Washer................................................................... 412 Operation of Air Conditioner/heater.......................................................... 412 Operation to Display Camera Mode (If Camera is Installed).................................... 413 Operation to Display Clock and Service Meter................................................. 414 Check of Maintenance Information............................................................. 414 Setting and Display of User Mode (Including KOMTRAX Messages for User)....................... 415 KOMTRAX Message.............................................................................. 416 Display of Energy-Saving Guidance............................................................ 416 Display of Caution Monitor................................................................... 416 Display of Automatic Judgment of Breaker..................................................... 416 Display of User Code and Failure Code........................................................ 417 Function of Checking Display of LCD (Liquid Crystal Display)................................. 418 Function of Checking Service Meter........................................................... 418 Function of Changing Attachment/Maintenance Password......................................... 418 Service Mode..................................................................................... 420 Monitoring................................................................................... 421 Monitoring Items Table....................................................................... 424 Abnormality Record (Mechanical Systems)...................................................... 427 Abnormality Record (Electrical Systems)...................................................... 428 Failure Codes Table.......................................................................... 430 Abnormality Record (Air-Conditioning System/ Heater System).................................. 434 Maintenance Record........................................................................... 435 Maintenance Mode Change...................................................................... 436 Phone Number Entry........................................................................... 438 Default (Key-on Mode)........................................................................ 439 Default (Unit)............................................................................... 440 Default (With/Without Attachment)............................................................ 441 Default (Attachment/Maintenance Password).................................................... 442 Default (Camera)............................................................................. 443 Default (ECO Display)........................................................................ 444 Default (Breaker Detect)..................................................................... 446 Adjustment (Pump Absorption Torque (F))...................................................... 447 Adjustment (Pump Absorption Torque (R))...................................................... 448 Adjustment (Low Speed)....................................................................... 449 Adjustment (Attachment Flow Adjustment)...................................................... 450 Cylinder Cut-Out............................................................................. 451 No Injection................................................................................. 452 Fuel Consumption............................................................................. 454 KOMTRAX Settings (Terminal Status)........................................................... 455 KOMTRAX Settings (GPS & Communication Status)................................................ 456 KOMTRAX Setting (MODEM S/N: TH300)........................................................... 457 Display of KOMTRAX message................................................................... 458 Long Distance Transport Mode..................................................................... 459 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER........................................................ 461 PREPARING FOR ELECTRICAL SYSTEM TROUBLESHOOTING...................................................... 461 PROCEDURE FOR TESTING DIODES......................................................................... 466 PM CLINIC SERVICE.................................................................................... 468 40 TROUBLESHOOTING....................................................................................... 479 GENERAL INFORMATION.................................................................................. 483 Points To Remember............................................................................... 483 Sequence Of Events In Troubleshooting............................................................ 485 Handling Electric Equipment and Hydraulic Components............................................. 486 New Connectors for Tier 3 Engines................................................................ 494 Check Before Troubleshooting..................................................................... 498 Classification And Troubleshooting Steps......................................................... 499 Troubleshooting Classification............................................................... 499 Troubleshooting steps........................................................................ 499 Information In Troubleshooting Table......................................................... 500 Related Circuit Diagram...................................................................... 501 Possible Problems and Troubleshooting No......................................................... 502 How To Read Electric Wire Code................................................................... 505 Connection Table For Connector Pin Numbers....................................................... 508 T-boxes and T-adapters Table..................................................................... 541 FAILURE CODE (DISPLAY OF CODE)....................................................................... 544 Failure Codes Table.............................................................................. 544 Before Troubleshooting With Failure Code Displayed............................................... 549 Fuse Box Connection Table.................................................................... 549 Locations Of Fusible Links................................................................... 550 Location Of Fuse Box And Fuse Nos............................................................ 550 Trouble That Occurs When Power Supply Of Pump Controller Is Defective........................ 551 989L00 Engine Controller Lock Caution 1.......................................................... 553 989M00 Engine Controller Lock Caution 2.......................................................... 553 989N00 Engine Controller Lock Caution 3.......................................................... 554 AA10NX Air Cleaner Clogging...................................................................... 554 AB00KE Charge Voltage Low........................................................................ 556 B@BAZG Eng Oil Press. Low........................................................................ 558 B@BAZK Eng Oil Level Low......................................................................... 558 B@BCNS Eng Water Overheat........................................................................ 559 B@BCZK Eng Water Level Low....................................................................... 559 B@HANS Hydr Oil Overheat......................................................................... 560 CA111 EMC Critical Internal Failure.............................................................. 560 CA115 Eng Ne and Bkup Speed Sens Error........................................................... 561 CA122 Chg Air Press Sensor High Error............................................................ 562 CA123 Chg Air Press Sensor Low Error............................................................. 564 CA131 Throttle Sensor High Error................................................................. 566 CA132 Throttle Sensor Low Error.................................................................. 568 CA144 Coolant Temp Sens High Error............................................................... 570 CA145 Coolant Temp Sens Low Error................................................................ 572 CA153 Chg Air Temp Sensor High Error............................................................. 574 CA154 Chg Air Temp Sensor Low Error.............................................................. 576 CA155 Chg Air Temp High Speed Derate............................................................. 578 CA187 Sens Supply 2 Volt Low Error............................................................... 580 CA221 Ambient Press Sens High Error.............................................................. 582 CA222 Ambient Press Sens Low Error............................................................... 584 CA227 Sens Supply 2 Volt High Error.............................................................. 586 CA234 Eng Overspeed.............................................................................. 587 CA238 Ne Speed Sens Supply Volt Error............................................................ 588 CA271 IMV/PCV1 Short Error....................................................................... 589 CA272 IMV/PCV1 Open Error........................................................................ 590 CA322 Inj #1 Open/Short Error.................................................................... 592 CA323 Inj #5 Open/Short Error.................................................................... 594 CA324 Inj #3 Open/Short Error.................................................................... 596 CA325 Inj #6 Open/Short Error.................................................................... 598 CA331 Inj #2 Open/Short Error.................................................................... 600 CA332 Inj #4 Open/Short Error.................................................................... 602 CA342 Calibration Code Incompatibility........................................................... 604 CA351 Injectors Drive Circuit Error.............................................................. 606 CA352 Sens Supply 1 Volt Low Error............................................................... 608 CA386 Sens Supply 1 Volt High Error.............................................................. 610 CA428 Water in Fuel Sensor High Error............................................................ 612 CA429 Water in Fuel Sensor Low Error............................................................. 614 CA435 Eng Oil Press Sw Error..................................................................... 616 CA441 Battery Voltage Low Error.................................................................. 617 CA442 Battery Voltage High Error................................................................. 620 CA449 Rail Press Very High Error................................................................. 622 CA451 Rail Press Sensor High Error............................................................... 624 CA452 Rail Press Sensor Low Error................................................................ 626 CA488 Chg Air Temp High Torque Derate............................................................ 628 CA553 Rail Press High Error...................................................................... 629 CA559 Rail Press Low Error....................................................................... 630 CA689 Eng Ne Speed Sensor Error.................................................................. 632 CA731 Eng Bkup Speed Sens Phase Error............................................................ 634 CA757 All Continuous Data Lost Error............................................................. 636 CA778 Eng Bkup Speed Sensor Error................................................................ 638 CA2185 Throt Sens Sup Volt High Error............................................................ 641 CA2186 Throt Sens Sup Volt Low Error............................................................. 642 CA2249 Rail Press Very Low Error................................................................. 643 CA2311 IMV Solenoid Error........................................................................ 644 CA2555 Grid Htr Relay Volt High Error............................................................ 646 CA2556 Grid Htr Relay Volt Low Error............................................................. 648 D19JKZ Personal Code Relay Abnormality........................................................... 650 D862KA GPS Antenna Discon........................................................................ 652 DA22KK Pump Solenoid Power Low Error............................................................. 654 DA25KP 5V Sensor 1 Power Abnormality............................................................. 656 DA29KQ Model Selection Abnormality............................................................... 662 PC200LC-8.................................................................................... 662 PC220LC-8.................................................................................... 664 DA2RMC CAN Discon (Pump Con Detected)............................................................ 666 DAF8KB Short Circuit In Camera Power Supply...................................................... 674 DAFGMC GPS Module Error.......................................................................... 676 DAFRMC CAN Discon (Monitor Detected)............................................................. 677 DGH2KB Hyd Oil Sensor Short...................................................................... 684 DHPAMA F Pump Press Sensor Abnormality........................................................... 686 DHPBMA R Pump Press Sensor Abnormality........................................................... 688 DHS3MA Arm Curl PPC Press Sensor Abnormality..................................................... 690 DHS4MA Bucket Curl PPC Press Sensor Abnormality.................................................. 692 DHS8MA Boom Raise PPC Press Sensor Abnormality................................................... 694 DHSAMA Swing RH PPC Press Sensor Abnormality..................................................... 696 DHSBMA Swing LH PPC Press Sensor Abnormality..................................................... 698 DHSDMA Bucket Dump PPC Press Sensor Abnormality.................................................. 700 DHX1MA Overload Sensor Abnormality (Analog)...................................................... 702 DW43KA Travel Speed Sol Discon................................................................... 706 DW43KB Travel Speed Sol Short.................................................................... 708 DW45KA Swing Brake Sol Discon.................................................................... 710 DW45KB Swing Brake Sol Short..................................................................... 712 DW91KA Travel Junction Sol Discon................................................................ 714 DW91KB Travel Junction Sol Short................................................................. 716 DWA2KA Service Sol Discon........................................................................ 718 DWA2KB Service Sol Short......................................................................... 719 DWK0KA 2-Stage Relief Sol Discon................................................................. 720 DWK0KB 2-Stage Relief Sol Short.................................................................. 722 DXA8KA PC-EPC (F) Sol Discon..................................................................... 724 DXA8KB PC-EPC (F) Sol Short...................................................................... 726 DXA9KA PC-EPC (R) Sol Discon..................................................................... 728 DXA9KB PC-EPC (R) Sol Short...................................................................... 730 DXE0KA LS-EPC Sol Discon......................................................................... 732 DXE0KB LS-EPC Sol Short.......................................................................... 734 DXE4KA Service Current EPC Discon................................................................ 736 DXE4KB Service Current EPC Short................................................................. 738 DXE5KA Merge-divider Main Sol Discon............................................................. 740 DXE5KB Merge-divider Main Sol Short.............................................................. 742 DXE6KA Merge-divider LS Sol Discon............................................................... 744 DXE6KB Merge-divider LS Sol Short................................................................ 746 DY20KA Wiper Working Abnormality................................................................. 748 DY20MA Wiper Parking Abnormality................................................................. 750 DY2CKA Washer Drive Discon....................................................................... 752 DY2CKB Washer Drive Short........................................................................ 754 DY2DKB Wiper Drive (For) Short................................................................... 756 DY2EKB Wiper Drive (Rev) Short................................................................... 758 ELECTRICAL SYSTEM (E-MODE)........................................................................... 760 Troubleshooting Table............................................................................ 760 E-1 No Machine Monitor Display When Starting Switch Is Turned On................................. 762 E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)........... 764 E-3 Engine Does Not Start........................................................................ 767 E-4 Preheater Does Not Operate................................................................... 772 E-5 Automatic Warm-up System Does Not Operate (In Cold Season)................................... 776 E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked.............. 778 E-7 Precaution Lights Up While Engine Is Running................................................. 780 E-8 Emergency Stop Item Lights Up While Engine Is Running........................................ 785 E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally.................................. 786 E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally.................................. 787 E-11 Fuel Level Gauge Does Not Indicate Normally................................................. 790 E-12 Machine Monitor Content Displays Are Different From Applicable Machine...................... 792 E-13 Machine Monitor Does Not Display Some Items................................................. 792 E-14 Function Switch Does Not Work............................................................... 792 E-15 Auto-decelerator Does Not Operate Normally.................................................. 793 E-16 Working Mode Does Not Change................................................................ 794 E-17 Travel Speed Does Not Change................................................................ 795 E-18 Alarm Buzzer Cannot be Stopped.............................................................. 796 E-19 Windshield Wiper and Window Washer Do Not Operate........................................... 798 E-20 Power Maximizing Function Does Not Operate Normally......................................... 800 E-21 Swing Holding Brake Does Not Operate Normally............................................... 802 E-22 Travel Alarm Does Not Sound or Does Not Stop................................................ 804 E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record).... 806 E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position....................... 828 E-25 Machine Monitor Cannot Be Set In Service Mode............................................... 828 E-26 Monitoring Function Does Not Display Lever Control Signal Normally.......................... 829 E-27 Komtrax System Does Not Operate Normally.................................................... 838 HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)............................................................. 840 System Diagram of Hydraulic and Mechanical System................................................ 840 Information In Troubleshooting Table............................................................. 842 H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow........................... 843 H-2 Engine Speed Drops Sharply or Engine Stalls.................................................. 845 H-3 Work Equipment, Swing, and Travel Systems Do Not Work........................................ 846 H-4 Abnormal Noise Is Heard Around Hydraulic Pump................................................ 846 H-5 Auto-decelerator Does Not Work............................................................... 847 H-6 Fine Control Mode Does Not Function or Responds Slow......................................... 847 H-7 Boom Moves Slowly or Lacks Power............................................................. 848 H-8 Arm Moves Slowly or Lacks Power.............................................................. 849 H-9 Bucket Moves Slowly or Lacks Power........................................................... 850 H-10 Work Equipment Does Not Move In Its Single Operation........................................ 850 H-11 Work Equipment Hydraulic Drift Is Too Fast.................................................. 851 H-12 Work Equipment Has Big Time Lag............................................................. 853 H-13 Other Work Equipment Moves When Relieving Single Circuit.................................... 853 H-14 Power Maximizing Function Does Not Work..................................................... 854 H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly......................... 854 H-16 In Swing and Boom Raise Operation, Boom Moves Slowly........................................ 855 H-17 In Swing and Travel Operation, Travel Speed Drops Sharply................................... 855 H-18 Machine Swerves In Travel................................................................... 856 H-19 Machine Travels Slowly...................................................................... 857 H-20 Machine Steers With Difficulty or Lacks Power............................................... 858 H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast...................................... 859 H-22 Track Shoe Does Not Turn (On One Side Only)................................................. 860 H-23 Machine Does Not Swing...................................................................... 861 H-24 Swing Acceleration Is Poor or Swing Speed Is Slow........................................... 863 H-25 Excessive Overrun When Stopping Swing....................................................... 865 H-26 There Is a Big Jolt When Stopping Swing..................................................... 866 H-27 Large Sound Is Made When Upper Structure Stops Swinging..................................... 866 H-28 Swing Hydraulic Drift Is Too Big............................................................ 867 H-29 Attachment Circuit Is Not Changed........................................................... 868 H-30 Oil Flow In Attachment Circuit Cannot Be Controlled......................................... 868 50 DISASSEMBLY AND ASSEMBLY.............................................................................. 869 HOW TO READ THIS SECTION............................................................................. 873 Removal And Installation Of Assemblies........................................................... 873 Special Tools................................................................................ 873 Removal...................................................................................... 873 Installation................................................................................. 873 Disassembly And Assembly Of Assemblies........................................................... 874 Special Tools................................................................................ 874 Disassembly.................................................................................. 874 Assembly..................................................................................... 875 SPECIAL TOOLS LIST................................................................................... 876 SKETCHES OF SPECIAL TOOLS............................................................................ 881 CONNECTOR REPAIR PROCEDURES.......................................................................... 886 Stripping Insulation............................................................................. 886 Wire Inspection.................................................................................. 886 Contact Terminal Removal (HD30 Type)............................................................. 887 Crimping Contact Terminal (HD30 Type)............................................................ 888 Insertion Of Contact Terminal (HD30 Type)........................................................ 889 Contact Terminal Removal (DT Type)............................................................... 890 Crimping Contact Terminal (DT Type).............................................................. 891 Insertion Of Contact Terminal (DT Type).......................................................... 892 ENGINE AND COOLING SYSTEM............................................................................ 893 Fuel Supply Pump Assembly........................................................................ 893 Special Tools................................................................................ 893 Removal...................................................................................... 893 Installation................................................................................. 897 Fuel Injector Assembly........................................................................... 899 Special Tools................................................................................ 899 Removal...................................................................................... 899 Installation................................................................................. 903 Engine Front Seal................................................................................ 909 Special Tools................................................................................ 909 Removal...................................................................................... 909 Installation................................................................................. 911 Engine Rear Seal................................................................................. 913 Special Tools................................................................................ 913 Removal...................................................................................... 913 Installation................................................................................. 914 Cylinder Head.................................................................................... 917 Special Tools................................................................................ 917 Removal...................................................................................... 917 Installation................................................................................. 925 Radiator......................................................................................... 935 Removal...................................................................................... 935 Installation................................................................................. 937 Hydraulic Oil Cooler............................................................................. 939 Removal...................................................................................... 939 Installation................................................................................. 941 Aftercooler Assembly............................................................................. 942 Removal...................................................................................... 942 Installation................................................................................. 944 Fuel Cooler...................................................................................... 945 Removal...................................................................................... 945 Installation................................................................................. 945 Engine And Hydraulic Pump........................................................................ 946 Special Tools................................................................................ 946 Removal...................................................................................... 946 Installation................................................................................. 955 POWER TRAIN.......................................................................................... 958 Final Drive...................................................................................... 958 Removal...................................................................................... 958 Installation................................................................................. 959 PC200LC-8 Final Drive............................................................................ 960 Special Tools................................................................................ 960 Disassembly.................................................................................. 960 Assembly..................................................................................... 963 PC220LC-8 Final Drive............................................................................ 970 Special Tools................................................................................ 970 Disassembly.................................................................................. 970 Assembly..................................................................................... 973 Swing Motor and Swing Machinery.................................................................. 979 Removal...................................................................................... 979 Installation................................................................................. 981 Swing Motor and Swing Machinery.................................................................. 982 Special Tools................................................................................ 982 Disassembly.................................................................................. 982 Assembly..................................................................................... 988 Swing Circle Assembly............................................................................ 995 Removal...................................................................................... 995 Installation................................................................................. 995 UNDERCARRIAGE AND FRAME.............................................................................. 996 Carrier Roller................................................................................... 996 Special Tools................................................................................ 996 Disassembly.................................................................................. 996 Assembly..................................................................................... 997 Track Roller.....................................................................................1000 Special Tools................................................................................1000 Disassembly..................................................................................1000 Assembly.....................................................................................1000 Idler, Recoil Spring.............................................................................1002 Removal......................................................................................1002 Installation.................................................................................1002 Idler............................................................................................1003 Special Tools................................................................................1003 Disassembly..................................................................................1003 Assembly.....................................................................................1004 Recoil Spring....................................................................................1007 Special Tools................................................................................1007 Disassembly..................................................................................1007 Assembly.....................................................................................1008 Sprocket.........................................................................................1010 Removal......................................................................................1010 Installation.................................................................................1010 Track Shoe.......................................................................................1011 Special Tools................................................................................1011 Expanding Track Shoe.........................................................................1011 Installation of Track Shoe...................................................................1013 Revolving Frame..................................................................................1014 Removal......................................................................................1014 Installation.................................................................................1016 Counterweight....................................................................................1017 Special Tools................................................................................1017 Removal......................................................................................1017 Installation.................................................................................1019 HYDRAULIC SYSTEM.....................................................................................1020 Center Swivel Joint..............................................................................1020 Removal......................................................................................1020 Installation.................................................................................1021 Special Tools................................................................................1022 Disassembly..................................................................................1022 Assembly.....................................................................................1023 Hydraulic Tank...................................................................................1024 Removal......................................................................................1024 Installation.................................................................................1027 Control Valve....................................................................................1028 Removal......................................................................................1028 Installation.................................................................................1033 Special Tools................................................................................1034 Precautions for Replacing Pressure Compensation Valve Seal...................................1035 Precautions for Assembling Control Valve.....................................................1037 Hydraulic Pump...................................................................................1040 Special Tools................................................................................1040 Removal......................................................................................1040 Installation.................................................................................1044 Oil Seal In Hydraulic Pump Input Shaft...........................................................1045 Special Tools................................................................................1045 Removal......................................................................................1045 Installation.................................................................................1045 Work Equipment PPC Valve.........................................................................1046 Disassembly..................................................................................1046 Assembly.....................................................................................1046 Travel PPC Valve.................................................................................1048 Special Tools................................................................................1048 Disassembly..................................................................................1048 Assembly.....................................................................................1049 Hydraulic Cylinder...............................................................................1051 Special Tools................................................................................1051 Disassembly..................................................................................1052 Assembly.....................................................................................1054 WORK EQUIPMENT.......................................................................................1058 Work Equipment Assembly..........................................................................1058 Special Tools................................................................................1058 Removal......................................................................................1058 Installation.................................................................................1060 CAB AND ITS ATTACHMENTS..............................................................................1061 Operator's Cab...................................................................................1061 Removal......................................................................................1061 Installation.................................................................................1064 Operator Cab Glass (Fixed Glass).................................................................1065 Special Tools................................................................................1066 Removal......................................................................................1066 Installation.................................................................................1067 Front Window.....................................................................................1076 Removal......................................................................................1076 Installation.................................................................................1079 Floor Frame Assembly.............................................................................1084 Special Tools................................................................................1084 Removal......................................................................................1084 Installation.................................................................................1088 ELECTRICAL SYSTEM....................................................................................1089 Air Conditioner Unit Assembly....................................................................1089 Special Tools................................................................................1089 Removal......................................................................................1089 Installation.................................................................................1093 KOMTRAX Communication Modem......................................................................1094 Removal......................................................................................1094 Installation.................................................................................1094 Monitor..........................................................................................1095 Removal......................................................................................1095 Installation.................................................................................1096 Pump Controller..................................................................................1097 Removal......................................................................................1097 Installation.................................................................................1098 Engine Controller................................................................................1100 Removal......................................................................................1100 Installation.................................................................................1101 80 AIR CONDITIONER.......................................................................................1103 STRUCTURE AND FUNCTION...............................................................................1106 Air Conditioner Component........................................................................1106 Configuration and Function of Refrigerating Cycle................................................1108 Outline of Refrigerating Cycle...................................................................1109 Air Conditioner Unit.............................................................................1112 Functions of Major Components in the Air Conditioner Unit........................................1114 Control Plate....................................................................................1116 Compressor.......................................................................................1119 Condenser and Receiver Drier.....................................................................1120 TESTING AND ADJUSTING................................................................................1121 Caution About Refrigerant........................................................................1121 Troubleshooting Procedure........................................................................1122 Block Diagram....................................................................................1123 Circuit Diagram and Arrangement of Connector Pins................................................1124 Detail of Air Conditioner Unit...................................................................1126 Part and Connector Locations.....................................................................1128 Testing Air Leakage (Ducts)......................................................................1132 Testing with Self-diagnosis Function.............................................................1134 Testing Temperature Control......................................................................1137 Testing Vent (Mode) Changeover...................................................................1140 Testing Recirc/Fresh Changeover..................................................................1144 Testing Inner Sensor.............................................................................1146 Testing Evaporator Temperature Sensor............................................................1147 Testing Sunlight Sensor..........................................................................1149 Testing (Dual) Pressure Switch for Refrigerant...................................................1150 Testing Relays...................................................................................1152 TROUBLESHOOTING......................................................................................1154 Troubleshooting Chart 1..........................................................................1154 Troubleshooting Chart 2..........................................................................1155 Troubleshooting for Electrical System (E mode)...................................................1158 E-1 Power Supply System (Air Conditioner Does Not Operate)...................................1159 E-2 Compressor System (Air is Not Cooled)....................................................1163 E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)...........................1166 E-4 Temperature Cannot be Controlled.........................................................1170 E-5 Vent (Mode) Cannot be Changed Over.......................................................1173 E-6 Recirc/Fresh Air Cannot be Changed Over..................................................1176 Troubleshooting With Gauge Pressure..............................................................1179 Connection of Service Tool.......................................................................1182 Precautions for Connecting Air Conditioner Piping................................................1184 Handling of Compressor Oil.......................................................................1185 Control of Compressor Oil....................................................................1185 Adding Compressor Oil........................................................................1185 Compressor Replacement.......................................................................1186 Applying Compressor Oil for O-ring...........................................................1186 Desiccant Replacement Procedure..................................................................1187 90 DIAGRAMS AND SCHEMATICS...............................................................................1189 Hydraulic circuit diagram............................................................................1190 Hydraulic circuit diagram............................................................................1191 Electrical circuit diagram...........................................................................1192 Connector arrangement diagram........................................................................1193 Electrical circuit diagram for air conditioner.......................................................1194
KOMATSU PC200LC-8, PC220LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL CEBM000903 – PDF DOWNLOAD:
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