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KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM001505
- SERIAL NUMBERS:PC200LL-8 A87001 and up
PC220LL-8 A87001 and up
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Description
KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
Screenshot of the Manual:
KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
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.
01 GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
10 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.
20 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.
30 TESTING AND ADJUSTING
This section explains checks to be made before and after perfomiing repairs, as well as adjustments to be made at completion of the checks and repairs.
40 TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
50 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.
60 AIR CONDITIONER
This section explains the structure and function of each air conditioning component. In addition it has the testing and adjusting, troubleshooting, disassembly, assembly and corrections of the air conditioning system.
90 DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.
Table of Contents:
KOMATSU PC200LL-8 PC220LL-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
COVER PC200LL/220LL-8......................................................................................... 0 CONTENTS.................................................................................................. 2 00 FOREWORD............................................................................................... 15 SAFETY................................................................................................ 15 Safety Notice..................................................................................... 15 Important Safety Notice....................................................................... 15 General Precautions........................................................................... 15 Preparations For Work......................................................................... 15 Precautions During Work....................................................................... 15 GENERAL............................................................................................... 18 HOW TO READ THE SHOP MANUAL........................................................................... 19 Volumes........................................................................................... 19 Distribution And Updating......................................................................... 19 Filing Method..................................................................................... 19 Revised Edition Mark.............................................................................. 19 Revisions......................................................................................... 19 Symbols........................................................................................... 19 HOISTING INSTRUCTIONS................................................................................. 20 Hoisting.......................................................................................... 20 Wire Ropes........................................................................................ 20 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.................................................. 21 Points To Remember When Handling Electric Equipment............................................... 21 Points To Remember When Handling Hydraulic Equipment.............................................. 27 PUSH PULL COUPLER..................................................................................... 29 Type 1............................................................................................ 29 Disconnection................................................................................. 29 Connection.................................................................................... 29 Type 2............................................................................................ 30 Disconnection................................................................................. 30 Connection.................................................................................... 30 Type 3............................................................................................ 31 Disconnection................................................................................. 31 Connection.................................................................................... 31 EXPLANATION OF MAINTENANCE STANDARD TERMS............................................................. 32 STANDARD TIGHTENING TORQUE............................................................................ 34 Bolts And Nuts.................................................................................... 34 Tightening Torque Of Hose Nuts.................................................................... 35 Tightening Torque Of Split Flange Bolts........................................................... 35 Tightening Torque For Flared Nuts................................................................. 35 Tightening Torques For O-ring Boss Piping Joints.................................................. 36 Table Of Tightening Torques For O-ring Boss Plugs................................................. 36 Torque Table For Hoses (Taper Seal Type And Face Seal Type)....................................... 36 ELECTRIC WIRE CODE.................................................................................... 37 Classification By Thickness....................................................................... 37 Classification By Color And Code.................................................................. 37 How To Read Electric Wire Code.................................................................... 38 CONVERSION TABLES..................................................................................... 41 Method Of Using The Conversion Table.............................................................. 41 COATING MATERIALS..................................................................................... 47 01 GENERAL................................................................................................ 49 SPECIFICATIONS........................................................................................ 50 Dimensions PC200LL-8.............................................................................. 50 Road Builder.................................................................................. 50 Log Loader - 36 Ft Komatsu Forest Front....................................................... 50 Dimensions PC220LL-8.............................................................................. 52 Road Builder.................................................................................. 52 Log Loader - 38 Ft Komatsu Forest Front....................................................... 52 Working Ranges.................................................................................... 54 Road Builder.................................................................................. 54 PC200LL-8 Log Loader - 36 Ft Komatsu Forest Front............................................. 55 PC220LL-8 Log Loader - 38 Ft Komatsu Forest Front............................................. 55 Specifications PC200LL-8.......................................................................... 56 Specifications PC220LL-8.......................................................................... 58 WEIGHT TABLE.......................................................................................... 61 PC200LL-8......................................................................................... 61 PC220LL-8......................................................................................... 63 FUEL, COOLANT, AND LUBRICANTS......................................................................... 65 Recommended Brands, Recommended Quality for Products Other Than Komatsu Genuine Oil............... 67 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD........................................................... 69 ENGINE AND COOLING SYSTEM............................................................................. 74 Engine Related Parts.............................................................................. 74 Radiator, Oil Cooler, Aftercooler, and Fuel Cooler................................................ 75 Specifications................................................................................ 75 POWER TRAIN........................................................................................... 76 Power Train....................................................................................... 76 FINAL DRIVE........................................................................................... 78 PC200LL-8......................................................................................... 78 Specifications................................................................................ 79 PC220LL-8......................................................................................... 80 Specification................................................................................. 81 SWING MACHINERY....................................................................................... 82 PC200LL-8......................................................................................... 82 Specifications................................................................................ 83 PC220LL-8......................................................................................... 84 Specifications................................................................................ 85 SWING CIRCLE.......................................................................................... 86 PC200LL-8......................................................................................... 86 Specifications................................................................................ 86 PC220LL-8......................................................................................... 88 Specifications................................................................................ 88 UNDERCARRIAGE AND FRAME............................................................................... 90 Track Frame and Recoil Spring..................................................................... 90 Standard Shoe................................................................................. 91 PC200LL-8..................................................................................... 91 PC220LL-8..................................................................................... 91 Idler............................................................................................. 92 PC200LL-8..................................................................................... 92 PC220LL-8..................................................................................... 94 TRACK AND CARRIER ROLLER.............................................................................. 96 PC200LL-8......................................................................................... 96 PC220LL-8......................................................................................... 97 TRACK SHOES........................................................................................... 98 PC200LL-8......................................................................................... 98 PC220LL-8......................................................................................... 102 Double Grouser Shoe............................................................................... 104 PC200LL-8..................................................................................... 104 PC220LL-8..................................................................................... 104 Triple Grouser Shoe............................................................................... 105 PC200LL-8..................................................................................... 105 PC220LL-8..................................................................................... 105 HYDRAULIC SYSTEM...................................................................................... 106 Hydraulic Equipment Layout........................................................................ 106 Hydraulic Tank and Filter......................................................................... 108 Specifications................................................................................ 108 Hydraulic Pump.................................................................................... 110 Type: HPV95+95................................................................................ 110 LS valve...................................................................................... 116 PC valve...................................................................................... 121 LS (PC)-EPC valve............................................................................. 129 Pilot Oil Filter.............................................................................. 132 Control Valve..................................................................................... 134 General View.................................................................................. 135 Sectional View (1/5).......................................................................... 138 Sectional View (2/5).......................................................................... 140 Sectional View (3/5).......................................................................... 142 Sectional View (4/5).......................................................................... 144 Sectional View (5/5).......................................................................... 146 CLSS.............................................................................................. 148 Outline Of CLSS............................................................................... 148 Functions and Operation by Valve.................................................................. 152 Hydraulic Circuit Diagram and the Name of Valves.............................................. 152 Unload Valve.................................................................................. 154 Introduction of LS Pressure................................................................... 156 LS By-pass Plug............................................................................... 157 Pressure Compensation Valve................................................................... 158 Pressure Compensation Valve Inner Shuttle Valve............................................... 161 Boom Regeneration Circuit..................................................................... 163 Arm Regeneration Circuit...................................................................... 165 Merge-Divider Valve........................................................................... 167 LS Select Valve............................................................................... 169 Self Pressure Reducing Valve.................................................................. 170 Travel Junction Valve......................................................................... 174 Travel PPC Shuttle Valve...................................................................... 177 Boom Drift Prevention Valve................................................................... 179 Arm Drift Prevention Valve.................................................................... 182 Quick Return Valve............................................................................ 186 Lift Check Valve.............................................................................. 188 Main Relief Valve............................................................................. 189 Swing Motor....................................................................................... 191 PC200LL-8 Type: KMF125ABE-6................................................................... 191 PC220LL-8 Type: KMF230ABE-5................................................................... 195 Swing Holding Brake........................................................................... 198 Relief Valve Portion.......................................................................... 199 Reverse Prevention Valve.......................................................................... 200 Center Swivel Joint............................................................................... 204 Travel Motor PC200LL-8 Type: HMV110ADT-3.......................................................... 206 Operation of motor............................................................................ 210 Operation of Parking Brake.................................................................... 212 Brake Valve................................................................................... 214 Travel Motor PC220LL-8 Type: HMV160ADT-3.......................................................... 217 Operation of Motor............................................................................ 220 Operation of Parking Brake.................................................................... 222 Brake Valve................................................................................... 224 PPC Valve......................................................................................... 229 Work Equipment and Swing PPC Valve............................................................ 229 Travel PPC Valve.................................................................................. 235 Service PPC Valve (with EPC Valve)............................................................ 244 Service Valve (Straight Travel Option)........................................................ 250 Valve Control..................................................................................... 252 Solenoid Valve.................................................................................... 254 Attachment Solenoid Valve......................................................................... 256 PPC Accumulator................................................................................... 258 CRN (Canadian certified) PPC Accumulator.......................................................... 258 Return Oil Filter................................................................................. 259 Hydraulic Cylinder - Road Builder PC200LL-8....................................................... 260 Boom Cylinder................................................................................. 260 Arm Cylinder.................................................................................. 260 Bucket Cylinder............................................................................... 260 Hydraulic Cylinders - Log Loader PC200LL-8........................................................ 262 Boom Cylinder................................................................................. 262 Arm Cylinder.................................................................................. 262 Heel Cylinder................................................................................. 262 Hydraulic Cylinder - Road Builder PC220LL-8....................................................... 264 Boom Cylinder................................................................................. 264 Arm Cylinder.................................................................................. 264 Bucket Cylinder............................................................................... 264 Hydraulic Cylinders - Log Loader PC220LL-8........................................................ 266 Boom Cylinder................................................................................. 266 Arm Cylinder.................................................................................. 266 Heel Cylinder................................................................................. 266 WORK EQUIPMENT........................................................................................ 268 Dimensions of Components.......................................................................... 268 PC200LL-8..................................................................................... 269 PC220LL-8..................................................................................... 270 Arm........................................................................................... 272 Bucket........................................................................................ 274 CAB AND ITS ATTACHMENTS............................................................................... 276 Air Conditioner Piping............................................................................ 276 ELECTRICAL SYSTEM..................................................................................... 277 Engine Control.................................................................................... 277 Fuel Control Dial................................................................................. 278 Engine Controller................................................................................. 279 CN-CE01....................................................................................... 280 CN-CE02....................................................................................... 281 CN-CE03....................................................................................... 282 Coolant Temperature Sensor........................................................................ 283 Oil Pressure Switch............................................................................... 283 Rotation Sensor................................................................................... 284 Boost Pressure and Temperature Sensor............................................................. 284 WIF (Water-In-Fuel Detection) Sensor.............................................................. 285 Engine Oil Level Sensor........................................................................... 285 ELECTRICAL CONTROL SYSTEM............................................................................. 286 Machine Control System Diagram.................................................................... 286 Engine and Pump Composite Control Function.................................................... 288 Pump and Valve Control Function............................................................... 292 Power Maximizing Function..................................................................... 294 Auto-deceleration Function.................................................................... 295 Auto-warm-up and Overheat Prevention Function................................................. 296 Swing Control Function........................................................................ 299 Swing Control Function with Soft Swing (Option)............................................... 301 Travel Control Function....................................................................... 303 System Component Parts........................................................................ 305 MONITOR SYSTEM........................................................................................ 311 Machine Monitor................................................................................... 312 Input And Output Signals...................................................................... 313 Monitor Control, Display Portion.............................................................. 317 Monitor Items and Display..................................................................... 319 Switches.......................................................................................... 323 Buzzer Cancel Switch.......................................................................... 323 Auto-deceleration Switch...................................................................... 323 Guidance Icon and Function Switch............................................................. 324 Working Mode Selector Switch.................................................................. 325 Travel Speed Selector Switch.................................................................. 326 Window Washer Switch.......................................................................... 326 Wiper Switch.................................................................................. 326 Air Conditioner Control Switch................................................................ 327 Camera Screen Display Function................................................................ 328 Service Meter/Time Selector Function.......................................................... 329 Maintenance Function.......................................................................... 330 User Mode..................................................................................... 332 Breaker/Attachment Setting.................................................................... 332 Changing Breaker Mode Setting................................................................. 333 Changing Attachment Mode Setting.............................................................. 335 Message Display............................................................................... 337 Screen Adjustment............................................................................. 337 Clock Adjustment.............................................................................. 338 Language Setting.............................................................................. 339 Economy Mode Adjustment....................................................................... 339 Idle Stop Guidance Function................................................................... 340 Service Meter Check Function.................................................................. 340 Display LCD Check Function.................................................................... 341 User Code/Failure Code Display Function....................................................... 342 SENSORS............................................................................................... 343 Fuel Level Sensor................................................................................. 343 Air Cleaner Clogging Sensor....................................................................... 344 Coolant Level Sensor.............................................................................. 344 KOMTRAX TERMINAL SYSTEM............................................................................... 345 Komtrax Communication Orbcomm..................................................................... 346 20 STANDARD VALUE TABLES.................................................................................. 349 STANDARD SERVICE VALUE TABLE.......................................................................... 350 Engine Related Parts.............................................................................. 350 PC200LL-8..................................................................................... 350 PC220LL-8..................................................................................... 351 Chassis Related Parts............................................................................. 352 PC200LL-8..................................................................................... 352 PC220LL-8..................................................................................... 359 MACHINE POSTURE....................................................................................... 367 Measuring Performance And Measurement Procedure................................................... 367 Control Valve: Spool Stroke................................................................... 367 Swing 1: Swing Brake Angle, Time Taken To Start Swing, Time Taken To Swing.................... 367 Swing 2: Hydraulic Drift Of Swing............................................................. 367 Travel 1: Travel Speed (Without Load)......................................................... 367 Travel 2: Travel Speed (Actual Run), Travel Deviation......................................... 368 Travel 3: Travel Deviation.................................................................... 368 Travel 4: Hydraulic Drift Of Travel........................................................... 368 Work Equipment 1: Hydraulic Drift Of Work Equipment........................................... 368 Work Equipment 2: Boom Speed.................................................................. 369 Work Equipment 3: Arm Speed................................................................... 369 Work Equipment 4: Bucket Speed................................................................ 369 Work Equipment 5: Boom Time Lag............................................................... 369 Work Equipment 6: Arm Time Lag................................................................ 370 Work Equipment 7: Bucket Time Lag............................................................. 370 30 TESTING AND ADJUSTING.................................................................................. 371 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................... 374 Sketch of Special Tool............................................................................ 377 ENGINE COMPONENTS..................................................................................... 378 Determining a Defective Cylinder.................................................................. 378 Procedures.................................................................................... 378 Determining Cylinder Group.................................................................... 378 Isolating the Defective Cylinder.............................................................. 378 Water Pump Leakage................................................................................ 379 Engine Speed...................................................................................... 384 Intake Air Pressure (Boost Pressure).............................................................. 386 Exhaust Gas Color................................................................................. 387 Valve Clearance................................................................................... 389 Compression Pressure.............................................................................. 391 Blow-by Pressure.................................................................................. 393 Engine Oil Pressure............................................................................... 394 Handling Fuel System Parts........................................................................ 395 Releasing Residual Pressure from Fuel System.................................................. 395 Fuel Pressure..................................................................................... 396 Fuel Return Rate and Leakage...................................................................... 399 Bleeding Air from Fuel Circuit.................................................................... 403 Checking Fuel Circuit for Leakage................................................................. 404 AIR CONDITIONER COMPRESSOR BELT TENSION............................................................... 405 FAN BELT.............................................................................................. 406 SWING CIRCLE BEARING CLEARANCE........................................................................ 407 TRACK CHAIN TENSION................................................................................... 408 OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................ 409 CONTROL CIRCUIT BASIC PRESSURE........................................................................ 414 OIL PRESSURE IN PUMP PC CONTROL CIRCUIT............................................................... 416 Measuring......................................................................................... 416 Adjusting......................................................................................... 418 OIL PRESSURE IN PUMP LS CONTROL CIRCUIT............................................................... 419 Measuring......................................................................................... 419 Adjusting......................................................................................... 423 SOLENOID VALVE OUTPUT PRESSURE........................................................................ 424 Measuring......................................................................................... 424 Operation Table of PPC Lock Solenoid Valve........................................................ 426 Operation Table of 2-stage Relief Solenoid Valve.................................................. 426 Operation Table of Swing Holding Brake Solenoid Valve............................................. 426 Operation Table of Travel Speed Shifting Solenoid Valve........................................... 426 Operation Table of Travel Junction Solenoid Valve................................................. 427 Operation Table of Att Return Selector Solenoid Valve (Attachment Installation Specification)..... 427 ATTACHMENT SOLENOID VALVE OUTPUT PRESSURE............................................................. 428 Measuring......................................................................................... 428 Table for Functioning Conditions.............................................................. 429 PPC VALVE OUTPUT PRESSURE............................................................................. 430 SOFT SWING ADJUSTMENTS (IF EQUIPPED).................................................................. 433 Overview.......................................................................................... 433 Testing........................................................................................... 433 Adjustments....................................................................................... 433 PLAY OF WORK EQUIPMENT AND SWING PPC VALVES........................................................... 434 HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................... 435 RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.............................................................. 437 OIL LEAKAGE........................................................................................... 438 BLEEDING AIR FROM EACH PART........................................................................... 441 ADJUSTING MIRRORS..................................................................................... 445 SPECIAL FUNCTIONS OF MACHINE MONITOR.................................................................. 447 Operator Mode..................................................................................... 451 Service Mode...................................................................................... 465 Failure Codes Table............................................................................... 477 Long Distance Transport Mode...................................................................... 513 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER......................................................... 515 PREPARATION FOR ELECTRICAL SYSTEM TROUBLESHOOTING..................................................... 516 PROCEDURE FOR TESTING DIODES.......................................................................... 521 PM CLINIC SERVICE..................................................................................... 524 PC200LL-8 Check sheet............................................................................. 527 PC220LL-8 Check sheet............................................................................. 531 40 TROUBLESHOOTING........................................................................................ 535 GENERAL INFORMATION................................................................................... 539 Points to Remember................................................................................ 539 Sequence of Events................................................................................ 541 Handling Electric Equipment and Hydraulic Components.............................................. 542 Connectors for Tier 3 Engines..................................................................... 550 Checks Before Troubleshooting..................................................................... 554 Classification and Procedures for Troubleshooting................................................. 555 Procedure for Troubleshooting................................................................. 555 Information in Troubleshooting Table.......................................................... 556 Related Circuit Diagram....................................................................... 557 Possible Problems and Troubleshooting No.......................................................... 558 ELECTRIC WIRE CODE.................................................................................... 561 Classification by Thickness....................................................................... 561 Classification by Color and Code.................................................................. 561 HOW TO READ ELECTRIC WIRE CODE........................................................................ 562 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................ 565 T-ADAPTER TABLE....................................................................................... 598 FAILURE CODES (DISPLAY CODES)......................................................................... 601 Failure Code Tables............................................................................... 601 Before Performing Troubleshooting when Failure Code is Displayed.................................. 607 Connection Table of Fuse Box.................................................................. 607 Locations of Fusible Links.................................................................... 609 Location of Fuse Box and Fuse Nos............................................................. 609 Troubles That Occur When Power Supply of Pump Controller is Defective......................... 610 Troubles That Occur When Power Supply of Pump Controller is Defective......................... 611 989L00 - Engine Controller Lock Caution 1......................................................... 612 989M00 - Engine Controller Lock Caution 2......................................................... 612 989N00 - Engine Controller Lock Caution 3......................................................... 613 AA10NX - Air Cleaner Clogging..................................................................... 613 AB00KE - Charge Voltage Low....................................................................... 614 B@BAZG - Eng Oil Press. Low....................................................................... 616 B@BAZK - Eng Oil Level Low........................................................................ 616 B@BCNS - Eng Coolant Overheat..................................................................... 617 B@BCZK - Eng Coolant Level Low.................................................................... 618 B@HANS - Hyd Oil Overheat......................................................................... 619 CA111 - EMC Critical Internal Failure............................................................. 619 CA115 - Eng Ne and Bkup Speed Sens Error.......................................................... 620 CA122 - Chg Air Press Sensor High Error........................................................... 622 CA123 - Chg Air Press Sensor Low Error............................................................ 624 CA131 - Throttle Sensor High Error................................................................ 626 CA132 - Throttle Sensor Low Error................................................................. 628 CA144 - Coolant Temp Sens High Error.............................................................. 630 CA145 - Coolant Temp Sens Low Error............................................................... 632 CA153 - Chg Air Temp Sensor High Error............................................................ 634 CA154 - Chg Air Temp Sensor Low Error............................................................. 636 CA155 - Chg Air Temp High Speed Derate............................................................ 638 CA187 - Sens Supply 2 Volt Low Error.............................................................. 640 CA221 - Ambient Press Sens High Error............................................................. 642 CA222 - Ambient Press Sens Low Error.............................................................. 644 CA227 - Sens Supply 2 Volt High Error............................................................. 646 CA234 - Eng Overspeed............................................................................. 647 CA238 - Ne Speed Sens Supply Volt Error........................................................... 648 CA271 - IMV/PCV1 Short Error...................................................................... 650 CA272 - IMV/PCV1 Open Error....................................................................... 652 CA322 - Inj #1 Open/short Error................................................................... 654 CA323 - Inj #5 Open/short Error................................................................... 656 CA324 - Inj #3 Open/short Error................................................................... 658 CA325 - Inj #6 Open/short Error................................................................... 660 CA331 - Inj #2 Open/short Error................................................................... 662 CA332 - Inj #4 Open/short Error................................................................... 664 CA342 - Calibration Code Incompatibility.......................................................... 667 CA351 - Injectors Drive Circuit Error............................................................. 668 CA352 - Sens Supply 1 Volt Low Error.............................................................. 670 CA386 - Sens Supply 1 Volt High Error............................................................. 672 CA428 - Water in Fuel Sensor High Error........................................................... 674 CA429 - Water in Fuel Sensor Low Error............................................................ 676 CA435 - Eng Oil Press Sw Error.................................................................... 678 CA441 - Battery Voltage Low Error................................................................. 680 CA442 - Battery Voltage High Error................................................................ 684 CA449 - Rail Press Very High Error................................................................ 686 CA451 - Rail Press Sensor High Error.............................................................. 688 CA452 - Rail Press Sensor Low Error............................................................... 690 CA488 - Chg Air Temp High Torque Derate........................................................... 692 CA553 - Rail Press High Error..................................................................... 693 CA559 - Rail Press Low Error...................................................................... 694 CA689 - Eng NE Speed Sensor Error................................................................. 696 CA731 - Eng Bkup Speed Sens Phase Error........................................................... 698 CA757 - All Continuous Data Lost Error............................................................ 699 CA778 - Eng Bkup Speed Sensor Error............................................................... 702 CA1633 - KOMNET Datalink Timeout Error............................................................ 706 CA2185 - Throt Sens Sup Volt High Error........................................................... 708 CA2186 - Throt Sens Sup Volt Low Error............................................................ 710 CA2249 - Rail Press Very Low Error................................................................ 711 CA2311 - IMV Solenoid Error....................................................................... 712 CA2555 - Grid Htr Relay Volt High Error........................................................... 714 CA2556 - Grid Htr Relay Volt Low Error............................................................ 717 D19JKZ - Personal Code Relay Abnormality.......................................................... 720 D862KA - GPS Antenna Discon....................................................................... 723 DA22KK - Pump Solenoid Power Low Error............................................................ 724 DA25KP - 5 V Sensor 1 Power Abnormality........................................................... 727 Overload Alarm Monitor Non-display Specification.............................................. 727 Overload Alarm Monitor Display Specification.................................................. 732 DA29KQ - Model Selection Abnormality.............................................................. 736 PC200LL-8..................................................................................... 736 PC220LL-8..................................................................................... 738 DA2RMC - CAN Discon (Pump Con Detected)........................................................... 740 DAF8KB Short Circuit In Camera Power Supply....................................................... 748 DAFGMC - GPS Module Error......................................................................... 750 DAFRMC CAN Discon (Monitor Detected).............................................................. 751 DGH2KB - Hyd Oil Sensor Short..................................................................... 758 DHPAMA - F Pump Press Sensor Abnormality.......................................................... 760 DHPBMA - R Pump Press Sensor Abnormality.......................................................... 762 DHS3MA - Arm Curl PPC Press Sensor Abnormality.................................................... 764 DHS4MA - Bucket Curl PPC Press Sensor Abnormality................................................. 766 DHS8MA - Boom Raise PPC Press Sensor Abnormality.................................................. 768 DHSAMA - Swing RH PPC Press Sensor Abnormality.................................................... 770 DHSBMA - Swing LH PPC Press Sensor Abnormality.................................................... 772 DHSDMA - Bucket Dump PPC Press Sensor Abnormality................................................. 774 DHX1MA - Overload Sensor Abnormality (Analog)..................................................... 777 Overload Alarm Monitor Non-display Specification.............................................. 777 Overload Alarm Monitor Display Specification.................................................. 778 DW43KA - Travel Speed Sol Discon.................................................................. 780 DW43KB - Travel Speed Sol Short................................................................... 782 DW45KA - Swing Brake Sol Discon................................................................... 784 DW45KB - Swing Brake Sol Short.................................................................... 786 DW91KA - Travel Junction Sol Discon............................................................... 788 DW91KB - Travel Junction Sol Discon............................................................... 790 DWA2KA - Service Sol Discon....................................................................... 792 DWA2KB - Service Sol Short........................................................................ 794 DWK0KA - 2-Stage Relief Sol Discon................................................................ 796 DWK0KB - 2-Stage Relief Sol Short................................................................. 798 DXA8KA - PC-EPC (F) Sol Discon.................................................................... 800 DXA8KB - PC-EPC (F) Sol Short..................................................................... 802 DXA9KA - PC-EPC (R) Sol Discon.................................................................... 804 DXA9KB - PC-EPC (R) Sol Short..................................................................... 806 DXE0KA - LS-EPC Sol Discon........................................................................ 808 DXE0KB - LS-EPC Sol Short......................................................................... 810 DXE4KA - Service Current EPC Discon............................................................... 812 DXE4KB - Service Current EPC Short................................................................ 814 DXE5KA - Merge-divider Main Sol Discon............................................................ 816 DXE5KB - Merge-divider Main Sol Short............................................................. 818 DXE6KA - Merge-divider LS Sol Discon.............................................................. 820 DXE6KB - Merge-divider LS Sol Short............................................................... 822 DY20KA - Wiper Working Abnormality................................................................ 824 DY20MA - Wiper Parking Abnormality................................................................ 826 DY2CKA - Washer Drive Discon...................................................................... 828 DY2CKB - Washer Drive Short....................................................................... 830 DY2DKB - Wiper Drive Forward Short................................................................ 832 DY2EKB - Wiper Drive Reverse Short................................................................ 834 ELECTRICAL SYSTEM (E-MODE)............................................................................ 836 Troubleshooting Additional Information for Two-piece Harness...................................... 836 E-1 When starting Switch Turned On, Machine Monitor Displays Nothing.............................. 837 E-2 When starting Switch Turned on (Before Starting Engine), Basic Check Item Lights Up........... 840 E-3 Engine Does Not Start......................................................................... 844 E-4 Preheater Does Not Operate.................................................................... 850 E-5 Automatic Warm-up System Does Not Operate (In Cold Season).................................... 854 E-6 All Work Equipment, Swing, and Travel Mechanism Does Not Move or Cannot Be Locked............. 855 E-7 Precaution Lights Up While Engine is Running.................................................. 858 E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally................................... 866 E-11 Fuel Level Gauge Does Not Indicate Normally.................................................. 870 E-12 Contents of Display by Machine Monitor are Different from Applicable Machine................. 872 E-13 Machine Monitor Does Not Display Some Items.................................................. 872 E-14 Function Switch Does Not Work................................................................ 872 E-15 Auto-decelerator Does Not Operate Normally................................................... 873 E-16 Working Mode Does Not Change................................................................. 874 E-17 Travel Speed Does Not Change................................................................. 876 E-18 Alarm Buzzer Cannot be Stopped............................................................... 878 E-19 Windshield Wiper and Window Washer Do Not Operate............................................ 879 E-20 Power Maximizing Function Does Not Operate Normally.......................................... 882 E-21 Swing Holding Brake Does Not Operate Normally................................................ 886 E-22 Travel Alarm Does Not Sound or Does Not Stop Sounding........................................ 888 E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)..... 890 E-25 Machine Monitor Cannot be set in Service Mode................................................ 903 E-26 Monitoring Function Does Not Display Lever Control Signal Normally........................... 905 E-27 KOMTRAX System Does Not Operate Normally..................................................... 916 NONE - Failure Code Soft Swing System............................................................. 918 No Code........................................................................................... 920 Short or Open in Attachment Solenoid System................................................... 920 Open in Cab Tilt System....................................................................... 924 HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).............................................................. 926 System Diagram Of Hydraulic And Mechanical System................................................. 926 Information in Troubleshooting Table.............................................................. 928 H-1 Speed or Power of Whole Work Equipment, Swing, and Travel is Low.............................. 930 H-2 Engine Speed Lowers Extremely or Engine Stalls................................................ 932 H-3 Work Equipment, Swing, and Travel Systems Do Not Work......................................... 934 H-4 Abnormal Sound Comes Out From Around Hydraulic Pump........................................... 934 H-5 Auto-decelerator Does Not Operate............................................................. 935 H-6 Fine Control Performance or Response is Low................................................... 936 H-7 Speed or Power of Boom is Low................................................................. 937 H-8 Speed or Power of Arm is Low.................................................................. 938 H-9 Speed or Power of Bucket is Low............................................................... 939 H-10 Work Equipment Does Not Move Independently................................................... 940 H-11 Hydraulic Drift of Work Equipment is Large................................................... 940 H-12 Time Lag of Work Equipment is Large.......................................................... 942 H-13 When Part of Work Equipment is Relieved Independently, Other Parts of Work Equipment Move.... 942 H-14 Power Maximizing Function Does Not Work...................................................... 943 H-15 In Compound Operation of Work Equipment, Speed of Part Loaded More is Low.................... 943 H-16 When Machine Swings and Raises Boom Simultaneously, Boom Rising Speed is Low................. 944 H-17 When Machine Swings and Travels Simultaneously, Travel Speed Lowers Largely.................. 944 H-18 Machine Deviates During Travel............................................................... 946 H-19 Travel Speed is Low.......................................................................... 948 H-20 Machine is Not Steered Well or Steering Power is Low......................................... 950 H-21 Travel Speed Does Not Change or Travel Speed is Low/high..................................... 952 H-22 Travel System Does Not Move (Only One Side).................................................. 953 H-23 Upper Structure Does Not Swing............................................................... 954 H-24 Swing Acceleration or Swing Speed is Low..................................................... 956 H-26 Large Shock is Made When Upper Structure Stops Swinging...................................... 960 H-27 Large Sound is Made When Upper Structure Stops Swinging...................................... 960 H-28 Hydraulic Drift of Swing is Large............................................................ 961 H-29 Attachment Circuit is Not Changed............................................................ 962 H-30 Oil Flow in Attachment Circuit Cannot Be Controlled.......................................... 962 50 DISASSEMBLY AND ASSEMBLY............................................................................... 963 HOW TO READ THIS MANUAL............................................................................... 967 Removal and Installation of Assemblies............................................................ 967 Special Tools................................................................................. 967 Removal....................................................................................... 967 Installation.................................................................................. 967 Disassembly and Assembly of Assemblies............................................................ 968 Special Tools................................................................................. 968 Disassembly................................................................................... 968 Assembly...................................................................................... 969 SPECIAL TOOLS LIST.................................................................................... 970 SKETCHES OF SPECIAL TOOLS............................................................................. 976 CONNECTOR REPAIR PROCEDURES........................................................................... 982 Stripping Insulation.............................................................................. 982 Wire Inspection................................................................................... 982 Contact Terminal Removal (HD30 Type).............................................................. 983 Crimping Contact Terminal (HD30 Type)............................................................. 984 Insertion of Contact Terminal (HD30 Type)......................................................... 985 Contact Terminal Removal (DT Type)................................................................ 986 Crimping Contact Terminal (DT Type)............................................................... 987 Insertion of Contact Terminal (DT Type)........................................................... 988 PRECAUTIONS DURING OPERATION.......................................................................... 989 Precautions when Performing Removal Work.......................................................... 989 Precautions when Performing Installation Work..................................................... 990 Precautions when Completing The Operations........................................................ 991 Other Precautions................................................................................. 991 LIST OF ADHESIVES..................................................................................... 992 ENGINE AND COOLING SYSTEM............................................................................. 995 Fuel Supply Pump.................................................................................. 995 Removal....................................................................................... 995 Installation.................................................................................. 999 Fuel Injector.....................................................................................1001 Removal.......................................................................................1001 Installation..................................................................................1006 Engine Front Seal.................................................................................1011 Removal.......................................................................................1011 Installation..................................................................................1013 Engine Rear Seal..................................................................................1015 Removal.......................................................................................1015 Installation..................................................................................1016 Cylinder Head.....................................................................................1018 Removal.......................................................................................1018 Installation..................................................................................1026 Radiator..........................................................................................1036 Removal.......................................................................................1036 Installation..................................................................................1038 Hydraulic Oil Cooler..............................................................................1040 Removal.......................................................................................1040 Installation..................................................................................1042 After Cooler......................................................................................1043 Removal.......................................................................................1043 Installation..................................................................................1045 Fuel Cooler.......................................................................................1046 Removal.......................................................................................1046 Installation..................................................................................1046 Engine and Hydraulic Pump.........................................................................1047 Removal.......................................................................................1047 Installation..................................................................................1056 POWER TRAIN...........................................................................................1059 Final Drive PC200LL-8.............................................................................1059 Removal.......................................................................................1059 Installation..................................................................................1060 Disassembly...................................................................................1061 Assembly......................................................................................1065 Final Drive PC220LL-8.............................................................................1071 Removal.......................................................................................1071 Installation..................................................................................1072 Disassembly...................................................................................1073 Special Tools.................................................................................1073 Assembly......................................................................................1078 Swing Motor and Swing Machinery PC200LL-8.........................................................1085 Removal.......................................................................................1085 Installation..................................................................................1087 Disassembly...................................................................................1088 Assembly......................................................................................1093 Swing Motor and Swing Machinery PC220LL-8.........................................................1099 Removal.......................................................................................1099 Installation..................................................................................1100 Disassembly...................................................................................1101 Assembly......................................................................................1105 Swing Circle......................................................................................1111 Removal.......................................................................................1111 Installation..................................................................................1111 UNDERCARRIAGE AND FRAME...............................................................................1112 Track and Carrier Roller PC200LL-8................................................................1112 Disassembly...................................................................................1112 Assembly......................................................................................1112 Track and Carrier Roller PC220LL-8................................................................1114 Assembly......................................................................................1114 Idler PC200LL-8...................................................................................1115 Disassembly...................................................................................1115 Assembly......................................................................................1116 Idler PC220LL-8...................................................................................1119 Disassembly...................................................................................1119 Assembly......................................................................................1120 Recoil Spring.....................................................................................1123 Disassembly...................................................................................1124 Assembly......................................................................................1125 Sprocket..........................................................................................1126 Removal.......................................................................................1126 Installation..................................................................................1126 Track Shoe PC200LL-8..............................................................................1127 Expanding track shoe..........................................................................1127 Installation..................................................................................1129 Track Shoe PC220LL-8..............................................................................1130 Expansion.....................................................................................1130 Installation..................................................................................1131 Revolving Frame...................................................................................1132 Removal.......................................................................................1132 Installation..................................................................................1134 Counterweight.....................................................................................1135 Removal.......................................................................................1135 Installation..................................................................................1136 Additional Fuel Tank Counterweight................................................................1137 Removal.......................................................................................1137 Installation..................................................................................1139 HYDRAULIC SYSTEM......................................................................................1140 Center Swivel Joint...............................................................................1140 Removal.......................................................................................1140 Installation..................................................................................1141 Disassembly...................................................................................1142 Assembly......................................................................................1143 Hydraulic Tank....................................................................................1144 Removal.......................................................................................1144 Installation..................................................................................1147 Control Valve.....................................................................................1148 Removal.......................................................................................1148 Installation..................................................................................1153 Disassembly...................................................................................1154 Procedures for Replacing Pressure Compensation Valve Seal.....................................1155 Assembly......................................................................................1157 Hydraulic Pump....................................................................................1159 Removal.......................................................................................1159 Installation..................................................................................1163 Hydraulic Pump Input Shaft Oil Seal...............................................................1164 Removal.......................................................................................1164 Installation..................................................................................1164 Work Equipment PPC Valve..........................................................................1165 Disassembly...................................................................................1165 Assembly......................................................................................1165 Travel PPC Valve..................................................................................1167 Special Tools.................................................................................1167 Disassembly...................................................................................1167 Assembly......................................................................................1168 Hydraulic Cylinder................................................................................1170 Disassembly...................................................................................1171 Assembly......................................................................................1174 WORK EQUIPMENT........................................................................................1179 Removal...........................................................................................1179 Installation......................................................................................1182 CAB AND ITS ATTACHMENTS...............................................................................1183 Cab...............................................................................................1183 Removal.......................................................................................1183 Installation..................................................................................1186 Cab Glass (Stuck Glass)...........................................................................1187 Removal.......................................................................................1188 Installation..................................................................................1189 Front Window......................................................................................1198 Removal.......................................................................................1198 Installation..................................................................................1202 Floor Frame.......................................................................................1207 Removal.......................................................................................1207 Installation..................................................................................1209 ELECTRICAL SYSTEM.....................................................................................1210 Air Conditioner Unit..............................................................................1210 Removal.......................................................................................1210 Installation..................................................................................1213 Komtrax Communication Modem.......................................................................1214 Removal.......................................................................................1214 Installation..................................................................................1214 Monitor...........................................................................................1215 Removal.......................................................................................1215 Installation..................................................................................1216 Pump Controller...................................................................................1217 Removal.......................................................................................1217 Installation..................................................................................1218 Engine Controller.................................................................................1220 Removal.......................................................................................1220 Installation..................................................................................1221 60 AIR CONDITIONER........................................................................................1223 STRUCTURE AND FUNCTION................................................................................1226 Air Conditioner Component.........................................................................1226 Configuration and Function of Refrigerating Cycle.................................................1228 Outline of Refrigerating Cycle....................................................................1229 Air Conditioner Unit..............................................................................1232 Functions of Major Components in the Air Conditioner Unit.........................................1234 Control Plate.....................................................................................1236 Compressor........................................................................................1239 Condenser and Receiver Drier......................................................................1240 TESTING AND ADJUSTING.................................................................................1241 Caution About Refrigerant.........................................................................1241 Troubleshooting Procedure.........................................................................1242 Block Diagram.....................................................................................1243 Circuit Diagram and Arrangement of Connector Pins.................................................1244 Detail of Air Conditioner Unit....................................................................1246 Part and Connector Locations......................................................................1248 Testing Air Leakage (Ducts).......................................................................1252 Testing with Self-diagnosis Function..............................................................1254 Testing Temperature Control.......................................................................1257 Testing Vent (Mode) Changeover....................................................................1260 Testing Recirc/Fresh Changeover...................................................................1264 Testing Inner Sensor..............................................................................1266 Testing Evaporator Temperature Sensor.............................................................1267 Testing Sunlight Sensor...........................................................................1269 Testing (Dual) Pressure Switch for Refrigerant....................................................1270 Testing Relays....................................................................................1272 TROUBLESHOOTING.......................................................................................1274 Troubleshooting Chart 1...........................................................................1274 Troubleshooting Chart 2...........................................................................1275 Troubleshooting for Electrical System (E mode)....................................................1278 E-1 Power Supply System (Air Conditioner Does Not Operate)....................................1279 E-2 Compressor System (Air is Not Cooled).....................................................1283 E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)............................1286 E-4 Temperature Cannot be Controlled..........................................................1290 E-5 Vent (Mode) Cannot be Changed Over........................................................1293 E-6 Recirc/Fresh Air Cannot be Changed Over...................................................1296 Troubleshooting With Gauge Pressure...............................................................1299 Connection of Service Tool........................................................................1302 Precautions for connecting air conditioner piping.................................................1304 Handling of Compressor Oil........................................................................1305 Control of Compressor Oil.....................................................................1305 Adding of Compressor Oil......................................................................1305 Compressor Replacement........................................................................1306 Applying Compressor Oil for O-ring............................................................1306 Desiccant Replacement Procedure...................................................................1307 90 DIAGRAMS AND DRAWINGS..................................................................................1309 HYDRAULIC DIAGRAMS AND DRAWINGS.......................................................................1310 PC220LL-8 HYDRAULIC CIRCUIT DIAGRAM...............................................................1310 PC200LL-8 HYDRAULIC CIRCUIT DIAGRAM...............................................................1311 ELECTRICAL DIAGRAMS AND DRAWINGS......................................................................1312 ELECTRICAL CIRCUIT DIAGRAM (1/2)..................................................................1312 ELECTRICAL CIRCUIT DIAGRAM (2/2)..................................................................1313 CIRCUIT DIAGRAM RELATED TO SWING HOLDING BRAKE SOLENOID...........................................1314 ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER....................................................1315 CONNECTOR ARRANGEMENT DIAGRAM.....................................................................1316
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