Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Excavator Shop Manual PDF

Description

Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Excavator Shop Manual SEN06765-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Excavator Shop Manual SEN06765-00 – PDF DOWNLOAD 

Language : English
Pages : 1498
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Excavator Shop Manual SEN06765-00 – PDF DOWNLOAD 

SERIAL NUMBERS
PC200- 401217 and up
PC200LC- 401217 and up
PC220- 101052 and up
PC220LC- 101052 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword and general information 14
Foreword, safety and general information 14
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling equipment of fuel system devices 25
Handling of intake system parts 26
Handling of hydraulic equipment 27
Method of disconnecting and connecting of push-pull type coupler 29
Handling of electrical equipment 32
How to read electric wire code 41
Precautions when performing operation 44
Practical use of KOMTRAX 47
Standard tightening torque table 48
List of abbreviation 52
Conversion table 57
01 Specification 63
Specification and technical data 65
Specification dimension drawings 65
Working range diagram 66
Specifications 67
Weight table 71
Table of fuel, coolant and lubricants 75
10 Structure, function and maintenance standard 77
Contents 78
Engine and cooling system 79
Engine related parts 79
Radiator, oil cooler, aftercooler and fuel cooler 80
Power train 81
Power train 81
Final drive 82
Swing machinery 86
Swing circle 90
Undercarriage and frame 92
Track frame and recoil spring 92
Idler 94
Carrier roller 96
Track roller 97
Track shoe 98
Hydraulic system 104
Hydraulic equipment layout drawing 104
Hydraulic tank and filter 106
Hydraulic pump 108
Pilot oil filter 130
Control valve 132
CLSS 143
Functions and operation by valve 147
Swing motor 188
Center swivel joint 196
Travel motor 198
PPC valve 208
Valve control 228
Solenoid valve 230
PPC accumulator 232
Return oil filter 233
Return oil filter with clogging sensor 234
Attachment circuit selector valve 236
Hydraulic cylinder 238
Work equipment 242
Work equipment 242
Dimensions of arm 250
Dimensions of bucket 252
Electrical system 254
Engine control 254
Electrical control system 264
Machine monitor system 287
Sensor 306
KOMTRAX system 310
Clogging detection system of additional filter for breaker 313
20 Standard value table 315
Contents 316
Standard service value table 317
Standard value table for engine related parts 317
Standard value table for chassis related parts 319
30 Testing and adjusting 337
Contents 338
Related information on testing and adjusting 339
Tools for testing, adjusting, and troubleshooting 339
Sketch of special tool 343
Engine and cooling system 344
Testing engine speed 344
Testing intake air pressure (boost pressure) 345
Testing exhaust gas color 346
Adjusting valve clearance 347
Testing compression pressure 349
Testing blowby pressure 352
Testing engine oil pressure 353
Handling fuel system parts 354
Releasing residual pressure from fuel system 354
Testing fuel pressure 355
Handling reduced cylinder mode operation 358
Handling no-injection cranking operation 358
Testing fuel discharge, return and leak amount 359
Bleeding air from fuel circuit 362
Testing fuel circuit for leakage 363
Handling controller high voltage circuit 364
Testing and adjusting air conditioner compressor belt tension 365
Replacing alternator belt 366
Power train 367
Testing swing circle bearing clearance 367
Undercarriage and frame 368
Testing and adjusting track tension 368
Hydraulic system 370
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 370
Testing control circuit source pressure 373
Testing and adjusting oil pressure in pump PC control circuit 374
Testing and adjusting oil pressure in pump LS control circuit 377
Testing solenoid valve output pressure 382
Testing PPC valve output pressure 385
Adjusting play of work equipment and swing PPC valves 387
Testing parts which cause hydraulic drift of work equipment 388
Releasing remaining pressure from hydraulic circuit 390
Testing oil leakage 391
Bleeding air from each part 394
Testing cab tipping stopper 396
Adjusting mirrors 397
Installation and adjustment of mirrors 398
Angle adjustment of rear view camera 401
Electrical system 404
Special functions of machine monitor 404
Handling voltage circuit of engine controller 455
Preparation work for troubleshooting of electrical system 456
Procedure for testing diodes 461
Handling battery disconnect switch 462
Pm Clinic service 463
Pm Clinic service 463
40 Troubleshooting 473
Contents 474
Failure code table and fuse locations 479
Failure codes table 479
Fuse locations 486
General Information on troubleshooting 488
Symptom and troubleshooting numbers 488
Sequence of events in troubleshooting 490
Checks before troubleshooting 492
Classification and procedures for troubleshooting 494
Symptom and troubleshooting numbers 496
Information in troubleshooting table 498
Connector/electrical wiring connection table 500
Connector arrangement diagram 530
Connection table for connector pin numbers 536
T- branch box and T- branch adapter table 572
Troubleshooting method for open circuit in wiring harness of pressure sensor system 575
Troubleshooting by failure code 577
Failure code [879AKA] 577
Failure code [879AKB] 577
Failure code [879BKA] 577
Failure code [879BKB] 577
Failure code [879CKA] 577
Failure code [879CKB] 577
Failure code [879DKZ] 578
Failure code [879EMC] 578
Failure code [879FMC] 578
Failure code [879GKX] 578
Failure code [989L00] 579
Failure code [989M00] 580
Failure code [989N00] 581
Failure code [AA10NX] 582
Failure code [AB00KE] 584
Failure code [B@BAZG] 587
Failure code [B@BAZK] 588
Failure code [B@BCNS] 590
Failure code [B@BCZK] 591
Failure code [B@HANS] 593
Failure code [CA111] 594
Failure code [CA115] 595
Failure code [CA122] 596
Failure code [CA123] 599
Failure code [CA131] 602
Failure code [CA132] 605
Failure code [CA144] 608
Failure code [CA145] 611
Failure code [CA153] 614
Failure code [CA154] 617
Failure code [CA155] 620
Failure code [CA187] 621
Failure code [CA221] 623
Failure code [CA222] 626
Failure code [CA227] 629
Failure code [CA234] 630
Failure code [CA238] 631
Failure code [CA271] 633
Failure code [CA272] 635
Failure code [CA322] 637
Failure code [CA323] 640
Failure code [CA324] 643
Failure code [CA325] 646
Failure code [CA331] 649
Failure code [CA332] 652
Failure code [CA342] 655
Failure code [CA351] 656
Failure code [CA352] 657
Failure code [CA386] 659
Failure code [CA428] 660
Failure code [CA429] 662
Failure code [CA435] 664
Failure code [CA441] 666
Failure code [CA442] 669
Failure code [CA449] 670
Failure code [CA451] 672
Failure code [CA452] 675
Failure code [CA488] 678
Failure code [CA553] 679
Failure code [CA559] 680
Failure code [CA689] 682
Failure code [CA731] 685
Failure code [CA757] 688
Failure code [CA778] 689
Failure code [CA2185] 694
Failure code [CA2186] 697
Failure code [CA2249] 699
Failure code [CA2311] 700
Failure code [CA2555] 701
Failure code [CA2556] 704
Failure code [D110KB] 708
Failure code [D19JKZ] 710
Failure code [D811MC] 713
Failure code [D862KA] 714
Failure code [D8AQKR] 715
Failure code [DA22KK] 718
Failure code [DA25KP] 721
Failure code [DA26KP] 724
Failure code [DA29KQ] 727
Failure code [DA29KQ] 730
Failure code [DA2QKR] 732
Failure code [DAF0MB] 735
Failure code [DAF0MC] 735
Failure code [DAF8KB] 736
Failure code [DAF9KQ] 738
Failure code [DAFGMC] 739
Failure code [DAFQKR] 740
Failure code [DAZ9KQ] 741
Failure code [DAZQKR] 742
Failure code [DB2QKR] 743
Failure code [DGH2KB] 749
Failure code [DHA4KA] 751
Failure code [DHPAMA] 752
Failure code [DHPBMA] 755
Failure code [DHS3MA] 758
Failure code [DHS4MA] 761
Failure code [DHS8MA] 764
Failure code [DHS9MA] 767
Failure code [DHSAMA] 770
Failure code [DHSBMA] 773
Failure code [DHSCMA] 776
Failure code [DHSDMA] 779
Failure code [DHSFMA] 782
Failure code [DHSGMA] 785
Failure code [DHSHMA] 788
Failure code [DHSJMA] 791
Failure code [DHX1MA] 794
Failure code [DR21KX] 795
Failure code [DR31KX] 797
Failure code [DV20KB] 798
Failure code [DW43KA] 800
Failure code [DW43KB] 802
Failure code [DW45KA] 804
Failure code [DW45KB] 807
Failure code [DW91KA] 810
Failure code [DW91KB] 812
Failure code [DWA2KA] 814
Failure code [DWA2KB] 816
Failure code [DWK0KA] 818
Failure code [DWK0KB] 820
Failure code [DWK2KA] 822
Failure code [DWK2KB] 824
Failure code [DXA8KA] 826
Failure code [DXA8KB] 829
Failure code [DXA9KA] 832
Failure code [DXA9KB] 835
Failure code [DXE0KA] 838
Failure code [DXE0KB] 840
Failure code [DXE4KA] 842
Failure code [DXE4KB] 844
Failure code [DXE5KA] 846
Failure code [DXE5KB] 848
Failure code [DXE6KA] 850
Failure code [DXE6KB] 852
Failure code [DY20KA] 854
Failure code [DY20MA] 857
Failure code [DY2CKB] 860
Failure code [DY2DKB] 863
Failure code [DY2EKB] 865
Troubleshooting of electrical system (E-mode) 867
Before troubleshooting for electrical system 867
Information described in troubleshooting table 869
E-1 Engine does not start (engine does not rotate) 871
E-2 Preheating system does not work 880
E-3 Machine monitor displays nothing when starting switch is turned to ON position 886
E-4 When starting switch is turned to ON position (with engine stopped), basic check items light up 889
E-5 Caution item lights up while the engine is running 890
E-6 Caution item lights up while the engine is running 895
E-7 Fuel gauge does not indicate correct level 898
E-8 Engine coolant temperature gauge does not indicate correct temperature 901
E-9 Hydraulic oil temperature gauge does not indicate correct temperature 903
E-10 Contents of display on machine monitor are different from actual machine model 906
E-11 Some areas of machine monitor screen are not displayed 908
E-12 Function switch does not work 908
E-13 Automatic warm-up system does not work (in cold weather) 909
E-14 Auto-deceleration function does not work properly 911
E-15 Working mode does not change 913
E-16 Travel speed does not change 914
E-17 Alarm buzzer does not stop sounding 916
E-18 Service meter is not displayed while starting switch is in OFF position 916
E-19 Service mode cannot be selected 917
E-20 All work equipment, swing and travel do not work, or lock is not available 918
E-21 Swing parking brake does not work properly 921
E-22 One-touch power maximizing function does not work properly 925
E-23 Travel alarm does not sound or does not stop sounding 928
E-24 Horn does not sound or does not stop sounding 930
E-25 Wiper or window washer does not operate 934
E-26 “Boom LOWER” is not displayed correctly via monitoring function 937
E-27 “Arm OUT” is not displayed correctly via monitoring function 937
E-28 “Arm IN” is not displayed correctly via monitoring function 938
E-29 “Boom RAISE” is not displayed correctly via monitoring function 938
E-30 “Bucket CURL” is not displayed correctly via monitoring function 938
E-31 “Bucket DUMP” is not displayed correctly via monitoring function 939
E-32 “Swing” is not displayed correctly via monitoring function 939
E-33 “Travel” is not displayed correctly via monitoring function 939
E-34 “Service” is not displayed correctly via monitoring function 940
E-35 Attachment hydraulic circuit cannot be changed 943
E-36 KOMTRAX system does not operate normally 944
E-37 Breaker clogging caution lamp lights up when breaker is not used 946
Troubleshooting of hydraulic and mechanical system (H-mode) 948
System diagram of hydraulic and mechanical system 948
Failure mode and cause table 950
Information in troubleshooting table 952
H-1 All work equipment, swing and travel speed are all slow, or there is no force 953
H-2 Engine speed drops significantly or engine stalls 956
H-3 All work equipment, swing and travel do not work 958
H-4 Unusual noise is heard from the vicinity of the hydraulic pump 959
H-5 Fine control performance or response is poor 960
H-6 Boom speed is low or power is insufficient 961
H-7 Arm speed is low or power is insufficient 965
H-8 Bucket speed is low or power is insufficient 969
H-9 Work equipment does not move in single operation 971
H-10 Hydraulic drift of work equipment is large 972
H-11 Time lag of work equipment is large 976
H-12 When certain work equipment is relieved hydraulically, other work equipment moves 977
H-13 One-touch power maximization function does not work 978
H-14 When combining operations of work equipment, equipment subject to heavier loads moves slower 979
H-15 Boom RAISE is slow in Swing + Boom RAISE operation 980
H-16 When combining swing and travel operations, travel speed drops significantly 981
H-17 Travel deviation is detected 982
H-18 Travel speed is slow 984
H-19 Machine does not steer well or steering power is low 987
H-20 Travel speed does not change, or travel speed is too slow or too fast 991
H-21 One track does not move 993
H-22 Machine does not swing 995
H-23 Swing acceleration or swing speed is low 998
H-24 Upper structure overruns excessively when it stops swinging 1001
H-25 Shock is significant when upper structure stops swinging 1004
H-26 An unusual loud noise is heard when the upper structure stops swinging 1005
H-27 Swing drift on a slope is significant 1006
H-28 Attachment circuit cannot be changed 1009
H-29 Oil flow in the attachment circuit cannot be changed 1010
Troubleshooting of engine (S-mode) 1012
Method of using troubleshooting chart 1012
S-1 Startability is poor 1016
S-2 Engine does not start 1017
S-3 Engine does not pick up smoothly 1020
S-4 Engine stops during operation 1021
S-5 Engine runs rough or is unstable 1022
S-6 Engine lacks power 1023
S-7 Exhaust smoke is black (incomplete combustion) 1024
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1025
S-9 Oil becomes contaminated early 1026
S-10 Fuel consumption is excessive 1027
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 1028
S-12 Oil pressure drops 1029
S-13 Oil level rises (coolant or fuel in oil) 1030
S-14 Coolant temperature rises too high (overheating) 1031
S-15 Unusual noise is made 1032
S-16 Vibration is excessive 1033
50 Disassembly and assembly 1035
Contents 1036
General information on disassembly and assembly 1038
How to read this manual 1038
Coating materials list 1040
Special tools list 1043
Sketches of special tools 1048
Engine and cooling system 1052
Removal and installation of fuel supply pump assembly 1052
Removal and installation of fuel injector assembly 1059
Removal and installation of engine front oil seal 1069
Removal and installation of engine rear oil seal 1076
Removal and installation of cylinder head assembly 1081
Removal and installation of radiator assembly 1102
Removal and installation of hydraulic oil cooler assembly 1107
Removal and installation of aftercooler assembly 1112
Removal and installation of fuel cooler assembly 1117
Removal and installation of engine and hydraulic pump assembly 1120
Power train 1142
Removal and installation of final drive assembly 1142
Disassembly and assembly of final drive assembly 1147
Disassembly and assembly of final drive assembly 1157
Removal and installation of swing motor and swing machinery assembly 1167
Disassembly and assembly of swing motor and swing machinery assembly 1173
Removal and installation of swing circle assembly 1185
Undercarriage and frame 1188
Disassembly and assembly of carrier roller assembly 1188
Disassembly and assembly of track roller assembly 1192
Removal and installation of idler and idler cushion assembly 1195
Disassembly and assembly of idler 1198
Disassembly and assembly of idler cushion 1203
Removal and installation of sprocket 1206
Separation and connection of track assembly 1208
Removal and installation of revolving frame assembly 1214
Removal and installation of counterweight assembly 1221
Hydraulic system 1225
Removal and installation of center swivel joint assembly 1225
Disassembly and assembly of center swivel joint assembly 1232
Removal and installation of hydraulic tank assembly 1234
Removal and installation of control valve assembly 1244
Disassembly and assembly of control valve 1261
Removal and installation of hydraulic pump assembly 1267
Removal and installation of hydraulic pump input shaft oil seal 1277
Disassembly and assembly of work equipment PPC valve assembly 1278
Disassembly and assembly of travel PPC valve 1280
Disassembly and assembly of work equipment cylinder 1282
Work equipment 1289
Removal and installation of work equipment assembly 1289
Cab and its attachments 1294
Removal and installation of operator’s cab assembly 1294
Removal and installation of operator’s cab glass (adhered window glass) 1303
Removal and installation of front window assembly 1316
Removal and installation of floor frame assembly 1326
Removal and installation of air conditioner unit assembly 1336
Electrical system 1347
Removal and installation of machine monitor assembly 1347
Removal and installation of engine controller assembly 1354
Removal and installation of pump controller assembly 1358
Removal and installation of KOMTRAX terminal assembly 1363
80 Appendix 1369
Contents 1370
Air conditioner 1371
Precautions for refrigerant 1371
Air conditioner component 1372
Configuration and function of refrigeration cycle 1374
Outline of refrigeration cycle 1375
Air conditioner unit 1377
Air conditioner controller 1383
Compressor 1384
Condenser and Modulator 1385
Sensor 1386
Procedure for testing and troubleshooting 1388
Circuit diagram and arrangement of connector pins 1390
System diagram 1392
Parts and connectors layout 1394
Testing air leakage (duct) 1397
Testing with self-diagnosis function 1399
Testing vent (mode) changeover 1401
Testing FRESH/RECIRC air changeover 1402
Testing sunlight sensor 1403
Testing (dual) pressure switch for refrigerant 1404
Testing relays 1405
Troubleshooting chart 1 1406
Troubleshooting chart 2 1408
Information in troubleshooting table 1410
Failure code list related to air conditioner 1411
Failure code [879AKA] A/C Inner sensor Open Circuit 1412
Failure code [879AKB] A/C Inner sensor Short Circuit 1413
Failure code [879BKA] A/C Outer sensor Open Circuit 1414
Failure code [879BKB] A/C Outer sensor Short Circuit 1416
Failure code [879CKA] Ventilating sensor Open Circuit 1418
Failure code [879CKB] Ventilating sensor Short Circuit 1419
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1420
Failure code [879EMC] Ventilating Damper Abnormality 1422
Failure code [879FMC] Air Mix Damper Abnormality 1423
Failure code [879GKX] Refrigerant Abnormality 1424
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 1426
Troubleshooting for compressor and refrigerant system (Air is not cooled) 1428
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1431
Troubleshooting for FRESH/RECIRC air changeover 1433
Troubleshooting with gauge pressure 1435
Connection of service tool 1437
Precautions for disconnecting and connecting air conditioner piping 1439
Handling of compressor oil 1441
Desiccant replacement procedure 1443
90 Diagrams and drawings 1445
Contents 1446
Hydraulic diagrams and drawings 1447
Symbols in hydraulic circuit diagram 1447
Hydraulic circuit diagram 1451
Electrical diagrams and drawings 1459
Symbols in electric circuit diagram 1459
Electrical circuit diagram 1463
Wiring harness diagram 1473
Index 1493

DESCRIPTION:

Komatsu PC200-8M0 PC200LC-8M0 PC220-8M0 PC220LC-8M0 Excavator Shop Manual SEN06765-00 – PDF DOWNLOAD 

SERIAL NUMBERS
PC200- 401217 and up
PC200LC- 401217 and up
PC220- 101052 and up
PC220LC- 101052 and up

How to read the shop manual 
Composition of shop manual
q This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
q This section includes the index, foreword, safety and basic information.
01. Specification
q This section explains the specifications of the machine.
10. Structure, function and maintenance standard
q This section explains the structure, function, and maintenance standard values of each component. The
structure and function sub-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.
The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
q The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
q This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
q This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
q This section explains the procedures for removing, installing, disassembling, and assembling each part
or component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for
the works are also explained.
80. Appendix
q The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
q This section gives hydraulic circuit diagrams and electrical circuit diagrams.

S.V 30/12/24