Komatsu PC200-8M0 PC220-8M0 Series Excavator Service Manual PDF

Description

Komatsu PC200-8M0,PC200LC-8M0,PC220-8M0,PC220LC-8M0 Hydraulic Excavator Shop Manual SEN06109-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC200-8M0,PC200LC-8M0,PC220-8M0,PC220LC-8M0 Hydraulic Excavator Shop Manual SEN06109-08 – PDF DOWNLOAD

Language : English
Pages : 1558
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC200-8M0,PC200LC-8M0,PC220-8M0,PC220LC-8M0 Hydraulic Excavator Shop Manual SEN06109-08 – PDF DOWNLOAD

SERIAL NUMBERS

• PC200- 400001          and up
• PC200LC- 400001     and up
• PC220- 100001          and up  
• PC220LC- 100001     and up

Cover 1
00 Index and foreword 0
100 Index 3
Composition of shop manual . 4
Table of contents 6
200 Foreword and general information . 17
Foreword, safety and general information . 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler . 33
Handling of electrical equipment . 36
How to read electric wire code . 45
Precautions when performing operation 48
Practical use of KOMTRAX . 51
Standard tightening torque table . 52
List of abbreviation . 56
Conversion table . 61
01 Specification . 0
100 Specification and technical data . 67
Specification dimension drawings . 68
Working range diagram 69
Specifications . 70
Weight table . 74
Table of fuel, coolant and lubricants 78
10 Structure, function and maintenance standard 0
100 Engine and cooling system 81
Engine related parts . 82
Radiator, oil cooler, aftercooler and fuel cooler 83
200 Power train 85
Power train 86
Final drive 88
Swing machinery 92
Swing circle . 96
300 Undercarriage and frame 99
Track frame and recoil spring 100
Idler 102
Carrier roller . 104
Track roller . 105
Track shoe . 106
401 Hydraulic system, Part 1 . 113
Hydraulic equipment layout drawing . 114
Hydraulic tank and filter 116
Hydraulic pump . 118
Pilot oil filter . 140
402 Hydraulic system, Part 2 . 143
Control valve 144
CLSS . 155
Functions and operation by valve . 159
403 Hydraulic system, Part 3 . 201
Swing motor 202
Center swivel joint 210
Travel motor . 212
PPC valve 222
Valve control 242
Solenoid valve . 244
PPC accumulator 246
Return oil filter 247
Return oil filter with clogging sensor . 248
Attachment circuit selector valve 250
Hydraulic cylinder . 252
500 Work equipment . 257
Work equipment . 258
Dimensions of arm 266
Dimensions of bucket . 268
600 Electrical system 271
Engine control . 272
Electrical control system 282
Machine monitor system . 305
Sensor . 326
KOMTRAX system . 330
Clogging detection system of additional filter for breaker . 333
20 Standard value table 0
100 Standard service value table . 335
Standard value table for engine related parts 336
Standard value table for chassis related parts . 338
30 Testing and adjusting . 0
101 Testing and adjusting, Part 1 357
Tools for testing, adjusting, and troubleshooting 359
Sketch of special tool . 363
Testing engine speed . 364
Testing intake air pressure (boost pressure) . 365
Testing exhaust gas color 366
Adjusting valve clearance 367
Testing compression pressure . 369
Testing blowby pressure 372
Testing engine oil pressure 373
Handling fuel system parts . 374
Releasing residual pressure from fuel system . 374
Testing fuel pressure 375
Handling reduced cylinder mode operation . 378
Handling no-injection cranking operation . 378
Testing fuel discharge, return and leak amount . 379
Bleeding air from fuel circuit . 382
Testing fuel circuit for leakage . 383
Handling controller high voltage circuit . 384
Testing and adjusting air conditioner compressor belt tension 385
Replacing alternator belt 386
Testing swing circle bearing clearance . 387
Testing and adjusting track tension 388
Testing and adjusting oil pressure in work equipment, swing, and travel circuits . 390
Testing control circuit source pressure 393
Testing and adjusting oil pressure in pump PC control circuit 394
Testing and adjusting oil pressure in pump LS control circuit 397
Testing solenoid valve output pressure . 402
Testing PPC valve output pressure 405
Adjusting play of work equipment and swing PPC valves 407
Testing parts which cause hydraulic drift of work equipment 408
Releasing remaining pressure from hydraulic circuit 410
Testing oil leakage 411
Bleeding air from each part 414
Testing cab tipping stopper 416
Adjusting mirrors 417
Installation and adjustment of mirrors . 418
Angle adjustment of rear view camera . 421
102 Testing and adjusting, Part 2 425
Special functions of machine monitor . 426
103 Testing and adjusting, Part 3 477
Handling voltage circuit of engine controller 478
Preparation work for troubleshooting of electrical system 479
Procedure for testing diodes . 484
Handling battery disconnect switch . 485
Pm Clinic service 486
40 Troubleshooting . 0
100 Failure code table and fuse locations 497
Failure codes table 498
Fuse locations . 505
200 General Information on troubleshooting . 509
Symptom and troubleshooting numbers 510
Sequence of events in troubleshooting 512
Checks before troubleshooting 514
Classification and procedures for troubleshooting 516
Symptom and troubleshooting numbers 518
Information in troubleshooting table . 520
Connector/electrical wiring connection table . 522
Connector arrangement diagram 552
Connection table for connector pin numbers . 558
T- branch box and T- branch adapter table 594
Troubleshooting method for open circuit in wiring harness of pressure sensor system 597
301 Troubleshooting by failure code, Part 1 601
Failure code [879AKA] 603
Failure code [879AKB] 603
Failure code [879BKA] 603
Failure code [879BKB] 603
Failure code [879CKA] 603
Failure code [879CKB] 603
Failure code [879DKZ] 604
Failure code [879EMC] 604
Failure code [879FMC] 604
Failure code [879GKX] 604
Failure code [989L00] 605
Failure code [989M00] 606
Failure code [989N00] 607
Failure code [AA10NX] 608
Failure code [AB00KE] 610
Failure code [B@BAZG] 613
Failure code [B@BAZK] 614
Failure code [B@BCNS] 616
Failure code [B@BCZK] 617
Failure code [B@HANS] 619
Failure code [CA111] . 620
Failure code [CA115] . 621
Failure code [CA122] . 622
Failure code [CA123] . 625
Failure code [CA131] . 628
Failure code [CA132] . 631
Failure code [CA144] . 634
Failure code [CA145] . 637
Failure code [CA153] . 640
Failure code [CA154] . 643
Failure code [CA155] . 646
Failure code [CA187] . 647
Failure code [CA221] . 649
Failure code [CA222] . 652
Failure code [CA227] . 655
Failure code [CA234] . 656
Failure code [CA238] . 657
Failure code [CA271] . 659
Failure code [CA272] . 661
302 Troubleshooting by failure code, Part 2 665
Failure code [CA322] . 667
Failure code [CA323] . 670
Failure code [CA324] . 673
Failure code [CA325] . 676
Failure code [CA331] . 679
Failure code [CA332] . 682
Failure code [CA342] . 685
Failure code [CA351] . 686
Failure code [CA352] . 687
Failure code [CA386] . 689
Failure code [CA428] . 690
Failure code [CA429] . 692
Failure code [CA435] . 694
Failure code [CA441] . 696
Failure code [CA442] . 699
Failure code [CA449] . 700
Failure code [CA451] . 702
Failure code [CA452] . 705
Failure code [CA488] . 708
Failure code [CA553] . 709
Failure code [CA559] . 710
Failure code [CA689] . 712
Failure code [CA731] . 715
Failure code [CA757] . 718
Failure code [CA778] . 719
Failure code [CA2185] 724
Failure code [CA2186] 727
Failure code [CA2249] 729
Failure code [CA2311] 730
Failure code [CA2555] 731
Failure code [CA2556] 734
303 Troubleshooting by failure code, Part 3 739
Failure code [D110KB] 740
Failure code [D19JKZ] 742
Failure code [D811MC] 745
Failure code [D862KA] 746
Failure code [D8AQKR] 747
Failure code [DA22KK] 750
Failure code [DA25KP] 753
Failure code [DA26KP] 756
Failure code [DA29KQ] 759
Failure code [DA29KQ] 762
Failure code [DA2QKR] 764
Failure code [DAF0MB] 767
Failure code [DAF0MC] 767
Failure code [DAF8KB] 768
Failure code [DAF9KQ] 770
Failure code [DAFGMC] 771
Failure code [DAFQKR] 772
Failure code [DAZ9KQ] 773
Failure code [DAZQKR] 774
Failure code [DB2QKR] 775
Failure code [DGH2KB] 781
Failure code [DHA4KA] 783
Failure code [DHPAMA] 784
Failure code [DHPBMA] 787
304 Troubleshooting by failure code, Part 4 791
Failure code [DHS3MA] 792
Failure code [DHS4MA] 795
Failure code [DHS8MA] 798
Failure code [DHS9MA] 801
Failure code [DHSAMA] 804
Failure code [DHSBMA] 807
Failure code [DHSCMA] 810
Failure code [DHSDMA] 813
Failure code [DHSFMA] 816
Failure code [DHSGMA] 819
Failure code [DHSHMA] 822
Failure code [DHSJMA] 825
Failure code [DHX1MA] 828
Failure code [DR21KX] 829
Failure code [DR31KX] 831
Failure code [DV20KB] 832
Failure code [DW43KA] 834
Failure code [DW43KB] 836
Failure code [DW45KA] 838
Failure code [DW45KB] 841
Failure code [DW91KA] 844
Failure code [DW91KB] 846
305 Troubleshooting by failure code, Part 5 849
Failure code [DWA2KA] 850
Failure code [DWA2KB] 852
Failure code [DWK0KA] 854
Failure code [DWK0KB] 856
Failure code [DWK2KA] 858
Failure code [DWK2KB] 860
Failure code [DXA8KA] 862
Failure code [DXA8KB] 865
Failure code [DXA9KA] 868
Failure code [DXA9KB] 871
Failure code [DXE0KA] 874
Failure code [DXE0KB] 876
Failure code [DXE4KA] 878
Failure code [DXE4KB] 880
Failure code [DXE5KA] 882
Failure code [DXE5KB] 884
Failure code [DXE6KA] 886
Failure code [DXE6KB] 888
Failure code [DY20KA] 890
Failure code [DY20MA] 893
Failure code [DY2CKB] 896
Failure code [DY2DKB] 899
Failure code [DY2EKB] 901
400 Troubleshooting of electrical system (E-mode) 905
Before troubleshooting for electrical system . 907
Information described in troubleshooting table . 909
E-1 Engine does not start (engine does not rotate) . 911
E-2 Preheating system does not work 920
E-3 Machine monitor displays nothing when starting switch is turned to ON position . 926
E-4 When starting switch is turned to ON position (with engine stopped), basic check items light up 929
E-5 Caution item lights up while the engine is running . 930
E-6 Caution item lights up while the engine is running . 935
E-7 Fuel gauge does not indicate correct level . 938
E-8 Engine coolant temperature gauge does not indicate correct temperature . 941
E-9 Hydraulic oil temperature gauge does not indicate correct temperature 943
E-10 Contents of display on machine monitor are different from actual machine model 946
E-11 Some areas of machine monitor screen are not displayed 948
E-12 Function switch does not work . 948
E-13 Automatic warm-up system does not work (in cold weather) 949
E-14 Auto-deceleration function does not work properly . 951
E-15 Working mode does not change 953
E-16 Travel speed does not change 954
E-17 Alarm buzzer does not stop sounding . 956
E-18 Service meter is not displayed while starting switch is in OFF position . 956
E-19 Service mode cannot be selected . 957
E-20 All work equipment, swing and travel do not work, or lock is not available 958
E-21 Swing parking brake does not work properly 961
E-22 One-touch power maximizing function does not work properly 965
E-23 Travel alarm does not sound or does not stop sounding . 968
E-24 Horn does not sound or does not stop sounding . 970
E-25 Wiper or window washer does not operate . 974
E-26 “Boom LOWER” is not displayed correctly via monitoring function . 977
E-27 “Arm OUT” is not displayed correctly via monitoring function 977
E-28 “Arm IN” is not displayed correctly via monitoring function . 978
E-29 “Boom RAISE” is not displayed correctly via monitoring function . 978
E-30 “Bucket CURL” is not displayed correctly via monitoring function 978
E-31 “Bucket DUMP” is not displayed correctly via monitoring function 979
E-32 “Swing” is not displayed correctly via monitoring function 979
E-33 “Travel” is not displayed correctly via monitoring function . 979
E-34 “Service” is not displayed correctly via monitoring function 980
E-35 Attachment hydraulic circuit cannot be changed 983
E-36 KOMTRAX system does not operate normally 984
E-37 Breaker clogging caution lamp lights up when breaker is not used 986
500 Troubleshooting of hydraulic and mechanical system (H-mode) 989
System diagram of hydraulic and mechanical system 992
Failure mode and cause table . 994
Information in troubleshooting table . 996
H-1 All work equipment, swing and travel speed are all slow, or there is no force 997
H-2 Engine speed drops significantly or engine stalls 1000
H-3 All work equipment, swing and travel do not work .1002
H-4 Unusual noise is heard from the vicinity of the hydraulic pump .1003
H-5 Fine control performance or response is poor .1004
H-6 Boom speed is low or power is insufficient .1005
H-7 Arm speed is low or power is insufficient 1009
H-8 Bucket speed is low or power is insufficient .1013
H-9 Work equipment does not move in single operation .1015
H-10 Hydraulic drift of work equipment is large 1016
H-11 Time lag of work equipment is large .1020
H-12 When certain work equipment is relieved hydraulically, other work equipment moves .1021
H-13 One-touch power maximization function does not work .1022
H-14 When combining operations of work equipment, equipment subject to heavier loads moves slower 1023
H-15 Boom RAISE is slow in Swing + Boom RAISE operation 1024
H-16 When combining swing and travel operations, travel speed drops significantly 1025
H-17 Travel deviation is detected 1026
H-18 Travel speed is slow 1028
H-19 Machine does not steer well or steering power is low 1031
H-20 Travel speed does not change, or travel speed is too slow or too fast .1035
H-21 One track does not move .1037
H-22 Machine does not swing 1039
H-23 Swing acceleration or swing speed is low 1042
H-24 Upper structure overruns excessively when it stops swinging .1045
H-25 Shock is significant when upper structure stops swinging 1048
H-26 An unusual loud noise is heard when the upper structure stops swinging 1049
H-27 Swing drift on a slope is significant .1050
H-28 Attachment circuit cannot be changed 1053
H-29 Oil flow in the attachment circuit cannot be changed 1054
600 Troubleshooting of engine (S-mode) .1057
Method of using troubleshooting chart 1058
S-1 Startability is poor .1062
S-2 Engine does not start 1063
S-3 Engine does not pick up smoothly .1066
S-4 Engine stops during operation 1067
S-5 Engine runs rough or is unstable .1068
S-6 Engine lacks power .1069
S-7 Exhaust smoke is black (incomplete combustion) .1070
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1071
S-9 Oil becomes contaminated early .1072
S-10 Fuel consumption is excessive .1073
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 1074
S-12 Oil pressure drops 1075
S-13 Oil level rises (coolant or fuel in oil) 1076
S-14 Coolant temperature rises too high (overheating) 1077
S-15 Unusual noise is made .1078
S-16 Vibration is excessive 1079
50 Disassembly and assembly 0
100 General information on disassembly and assembly 1081
How to read this manual 1082
Coating materials list .1084
Special tools list .1087
Sketches of special tools 1092
200 Engine and cooling system 1097
Removal and installation of fuel supply pump assembly 1098
Removal and installation of fuel injector assembly .1105
Removal and installation of engine front oil seal 1115
Removal and installation of engine rear oil seal .1122
Removal and installation of cylinder head assembly .1127
Removal and installation of radiator assembly 1148
Removal and installation of hydraulic oil cooler assembly 1153
Removal and installation of aftercooler assembly .1158
Removal and installation of fuel cooler assembly .1163
Removal and installation of engine and hydraulic pump assembly .1166
300 Power train 1189
Removal and installation of final drive assembly .1190
Disassembly and assembly of final drive assembly .1195
Removal and installation of swing motor and swing machinery assembly .1215
Disassembly and assembly of swing motor and swing machinery assembly .1221
Removal and installation of swing circle assembly 1233
400 Undercarriage and frame 1237
Disassembly and assembly of carrier roller assembly 1238
Disassembly and assembly of track roller assembly 1242
Removal and installation of idler and idler cushion assembly .1245
Disassembly and assembly of idler 1248
Disassembly and assembly of idler cushion 1253
Removal and installation of sprocket .1256
Separation and connection of track assembly 1258
Removal and installation of revolving frame assembly .1264
Removal and installation of counterweight assembly .1271
500 Hydraulic system .1277
Removal and installation of center swivel joint assembly .1278
Disassembly and assembly of center swivel joint assembly .1285
Removal and installation of hydraulic tank assembly 1287
Removal and installation of control valve assembly .1297
Disassembly and assembly of control valve 1314
Removal and installation of hydraulic pump assembly 1320
Removal and installation of hydraulic pump input shaft oil seal 1330
Disassembly and assembly of work equipment PPC valve assembly 1331
Disassembly and assembly of travel PPC valve .1333
Disassembly and assembly of work equipment cylinder 1335
600 Work equipment .1343
Removal and installation of work equipment assembly 1344
700 Cab and its attachments 1351
Removal and installation of operator’s cab assembly 1352
Removal and installation of operator’s cab glass (adhered window glass) 1361
Removal and installation of front window assembly 1374
Removal and installation of floor frame assembly .1384
Removal and installation of air conditioner unit assembly 1394
800 Electrical system 1407
Removal and installation of machine monitor assembly .1408
Removal and installation of engine controller assembly .1415
Removal and installation of pump controller assembly .1419
Removal and installation of KOMTRAX terminal assembly 1424
80 Appendix 0
100 Air conditioner 1431
Precautions for refrigerant 1433
Air conditioner component 1434
Configuration and function of refrigeration cycle 1436
Outline of refrigeration cycle .1437
Air conditioner unit .1439
Air conditioner controller .1445
Compressor .1446
Condenser and Modulator 1447
Sensor .1448
Procedure for testing and troubleshooting 1450
Circuit diagram and arrangement of connector pins 1452
System diagram .1454
Parts and connectors layout 1456
Testing air leakage (duct) .1459
Testing with self-diagnosis function .1461
Testing vent (mode) changeover .1463
Testing FRESH/RECIRC air changeover 1464
Testing sunlight sensor 1465
Testing (dual) pressure switch for refrigerant .1466
Testing relays .1467
Troubleshooting chart 1 1468
Troubleshooting chart 2 1470
Information in troubleshooting table .1472
Failure code list related to air conditioner .1473
Failure code [879AKA] A/C Inner sensor Open Circuit 1474
Failure code [879AKB] A/C Inner sensor Short Circuit .1475
Failure code [879BKA] A/C Outer sensor Open Circuit 1476
Failure code [879BKB] A/C Outer sensor Short Circuit .1478
Failure code [879CKA] Ventilating sensor Open Circuit 1480
Failure code [879CKB] Ventilating sensor Short Circuit .1481
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1482
Failure code [879EMC] Ventilating Damper Abnormality .1484
Failure code [879FMC] Air Mix Damper Abnormality .1485
Failure code [879GKX] Refrigerant Abnormality 1486
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .1488
Troubleshooting for compressor and refrigerant system (Air is not cooled) 1490
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .1493
Troubleshooting for FRESH/RECIRC air changeover 1495
Troubleshooting with gauge pressure 1497
Connection of service tool .1499
Precautions for disconnecting and connecting air conditioner piping 1501
Handling of compressor oil .1503
Desiccant replacement procedure 1505
90 Diagrams and drawings . 0
100 Hydraulic diagrams and drawings 1509
Symbols in hydraulic circuit diagram .1510
200 Electrical diagrams and drawings .1523
Symbols in electric circuit diagram 1524
Electrical circuit diagram .1527
Wiring harness diagram .1537

DESCRIPTION:

Komatsu PC200 -8M0,PC200LC-8M0,PC220 -8M0,PC220LC-8M0 Hydraulic Excavator Shop Manual SEN06109-08 – PDF DOWNLOAD

SERIAL NUMBERS

• PC200- 400001          and up
• PC200LC- 400001     and up
• PC220- 100001          and up  
• PC220LC- 100001     and up

How to read the shop manual 
Composition of shop manual
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
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
qThis 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.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-
date information before you start any work.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition table.

G.B 29/12/24