Komatsu PC220-8 Hydraulic Excavator Service & Repair Manual

PC200, 220-8 1 SEN00093-07 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 300001 and up PC200LC-8 300001 and up PC220-8 70001 and up PC220LC-8 70001 and up 00 Index and foreword 1 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

SEN00093-07 00 Index and foreword 2 PC200, 220-8 Composition of shop manual 1 The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs SEN00084-07 00 Index and foreword SEN00085-07 Index SEN00093-07 q Foreword and general information SEN00094-04 q 01 Specification SEN00086-01 Specification and technical data SEN00095-01 q 10 Structure, function and maintenance standard SEN00087-01 Engine and cooling system SEN00096-00 Power train SEN00097-00 Undercarriage and frame SEN00098-00 Hydraulic system, Part 1 SEN00099-01 Hydraulic system, Part 2 SEN00100-01 Hydraulic system, Part 3 SEN00160-01 Work equipment SEN00101-00 Cab and its attachments SEN00102-00 Electrical system SEN00103-01 20 Standard value table SEN00088-01 Standard service value table SEN00227-01 30 Testing and adjusting SEN00089-03 Testing and adjusting, Part 1 SEN00228-02 q Testing and adjusting, Part 2 SEN00229-03 q Testing and adjusting, Part 3 SEN00230-01

00 Index and foreword SEN00093-07 PC200, 220-8 3 40 Troubleshooting SEN00090-03 Failure code table and fuse locations SEN03308-00 Q General information on troubleshooting SEN00231-03 q Troubleshooting by failure code (Display of code), Part 1 SEN00240-03 q Troubleshooting by failure code (Display of code), Part 2 SEN00241-01 Troubleshooting by failure code (Display of code), Part 3 SEN00242-03 q Troubleshooting by failure code (Display of code), Part 4 SEN00243-01 Troubleshooting of electrical system (E-mode) SEN00244-01 Troubleshooting of hydraulic and mechanical system (H-mode) SEN00245-01 q Troubleshooting of engine (S-mode) SEN00246-01 50 Disassembly and assembly SEN00658-02 General information on disassembly and assembly SEN00659-02 q Engine and cooling system SEN00660-02 q Power train SEN00661-00 Undercarriage and frame SEN00662-02 q Hydraulic system SEN00663-02 q Work equipment SEN00664-02 q Cab and its attachments SEN00665-02 q Electrical system SEN00666-02 q 90 Diagrams and drawings SEN00092-05 Hydraulic diagrams and drawings SEN00112-02 q Electrical diagrams and drawings SEN00113-05 q

SEN00093-07 00 Index and foreword 4 PC200, 220-8 Table of contents 1 00 Index and foreword Index SEN00093-07 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information SEN00094-04 Safety notice ............................................................................................................................ 2 How to read the shop manual .................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table .............................................................................................. 32 Conversion table ...................................................................................................................... 36 01 Specification Specification and technical data SEN00095-01 Specification dimension drawings ............................................................................................ 2 Working range diagram ........................................................................................................... 3 Specifications ........................................................................................................................... 4 Weight table ............................................................................................................................. 8 Table of fuel, coolant and lubricants ........................................................................................ 12 10 Structure, function and maintenance standard Engine and cooling system SEN00096-00 Engine and cooling system ......................................................................................................... 2 Engine related parts................................................................................................................. 2 Radiator, oil cooler, aftercooler and fuel cooler ........................................................................ 3 Power train SEN00097-00 Power train .................................................................................................................................. 2 Power train............................................................................................................................... 2 Final drive ................................................................................................................................ 4 Swing machinery ..................................................................................................................... 6 Swing circle.............................................................................................................................. 10 Undercarriage and frame SEN00098-00 Undercarriage and frame ............................................................................................................ 2 Track frame and recoil spring .................................................................................................. 2 Idler .......................................................................................................................................... 4 Carrier roller ............................................................................................................................. 6 Track roller ............................................................................................................................... 7 Track shoe ............................................................................................................................... 8 Hydraulic system, Part 1 SEN00099-01 Hydraulic system, Part 1 ............................................................................................................. 2 Hydraulic equipment layout drawing ........................................................................................ 2 Hydraulic tank and filter ........................................................................................................... 4 Hydraulic pump ........................................................................................................................ 6 Pilot oil filter ............................................................................................................................. 28 Hydraulic system, Part 2 SEN00100-01 Hydraulic system, Part 2 ............................................................................................................. 2 Control valve ............................................................................................................................ 2 CLSS ....................................................................................................................................... 15 Functions and operation by valve ............................................................................................ 20

00 Index and foreword SEN00093-07 PC200, 220-8 5 Hydraulic system, Part 3 SEN00160-01 Hydraulic system, Part 3 ............................................................................................................. 3 Swing motor............................................................................................................................. 3 Center swivel joint ................................................................................................................... 12 Travel motor............................................................................................................................. 14 PPC valve ................................................................................................................................ 25 Work equipment and swing PPC valve ................................................................................... 25 Travel PPC valve ..................................................................................................................... 31 Service PPC valve (with EPC valve) ....................................................................................... 40 Service PPC valve ................................................................................................................... 46 Valve control ............................................................................................................................ 48 Solenoid valve ......................................................................................................................... 50 PPC accumulator..................................................................................................................... 52 Return oil filter ......................................................................................................................... 53 Attachment circuit selector valve ............................................................................................. 54 Hydraulic cylinder .................................................................................................................... 56 Work equipment SEN00101-00 Work equipment .......................................................................................................................... 2 Dimensions of components ..................................................................................................... 2 Cab and its attachments SEN00102-00 Cab and its attachments.............................................................................................................. 2 Air conditioner piping ............................................................................................................... 2 Electrical system SEN00103-01 Electrical system ......................................................................................................................... 1 Engine control.......................................................................................................................... 2 Electrical control system .......................................................................................................... 10 Monitor system ........................................................................................................................ 33 Sensor ..................................................................................................................................... 60 KOMTRAX terminal system..................................................................................................... 63 20 Standard value table Standard service value table SEN00227-01 Standard service value table ....................................................................................................... 2 Standard value table for engine related parts .......................................................................... 2 Standard value table for chassis related parts ......................................................................... 4 30 Testing and adjusting Testing and adjusting, Part 1 SEN00228-02 Testing and adjusting, Part 1 ....................................................................................................... 3 Tools for testing, adjusting, and troubleshooting ..................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 7 Checking exhaust gas color .................................................................................................... 8 Adjusting valve clearance ........................................................................................................ 9 Measuring compression pressure ........................................................................................... 11 Measuring blow-by pressure ................................................................................................... 13 Measuring engine oil pressure ................................................................................................ 14 Handling fuel system parts ...................................................................................................... 15 Releasing residual pressure from fuel system......................................................................... 15 Measuring fuel pressure .......................................................................................................... 16 Measuring fuel return rate and leakage ................................................................................... 18 Bleeding air from fuel circuit .................................................................................................... 20 Checking fuel circuit for leakage.............................................................................................. 22 Checking and adjusting air conditioner compressor belt tension ............................................ 23 Replacing fan belt .................................................................................................................... 24 Measuring swing circle bearing clearance............................................................................... 25

SEN00093-07 00 Index and foreword 6 PC200, 220-8 Checking and adjusting track shoe tension ............................................................................. 26 Measuring and adjusting oil pressure in work equipment, swing, and travel circuits ............... 28 Measuring control circuit basic pressure ................................................................................. 31 Measuring and adjusting oil pressure in pump PC control circuit ............................................ 32 Measuring and adjusting oil pressure in pump LS control circuit............................................. 35 Measuring solenoid valve output pressure .............................................................................. 39 Measuring PPC valve output pressure .................................................................................... 42 Adjusting play of work equipment and swing PPC valves ....................................................... 44 Checking parts which cause hydraulic drift of work equipment ............................................... 45 Releasing residual pressure from hydraulic circuit .................................................................. 47 Measuring oil leakage .............................................................................................................. 48 Bleeding air from each part ...................................................................................................... 51 Checking cab tipping stopper .................................................................................................. 53 Adjusting mirrors ...................................................................................................................... 54 Testing and adjusting, Part 2 SEN00229-03 Testing and adjusting, Part 2 ....................................................................................................... 2 Special functions of machine monitor ...................................................................................... 2 Testing and adjusting, Part 3 SEN00230-01 Testing and adjusting, Part 3 ....................................................................................................... 2 Handling voltage circuit of engine controller ............................................................................ 2 Preparation work for troubleshooting of electrical system ....................................................... 3 Procedure for testing diodes .................................................................................................... 8 Pm Clinic service ..................................................................................................................... 9 40 Troubleshooting Failure code table and fuse locations SEN03308-00 Failure codes table .................................................................................................................. 2 Fuse locations.......................................................................................................................... 7 General information on troubleshooting SEN00231-03 General information on troubleshooting ...................................................................................... 2 Points to remember when troubleshooting .............................................................................. 2 Sequence of events in troubleshooting.................................................................................... 3 Check before troubleshooting .................................................................................................. 4 Classification and procedures for troubleshooting ................................................................... 5 How to read electric wire code................................................................................................. 9 Connection table for connector pin numbers ........................................................................... 12 T- branch box and T- branch adapter table.............................................................................. 46 Troubleshooting by failure code (Display of code), Part 1 SEN00240-03 Failure code [989L00] Engine Controller Lock Caution 1 ........................................................ 4 Failure code [989M00] Engine Controller Lock Caution 2 ....................................................... 4 Failure code [989N00] Engine Controller Lock Caution 3........................................................ 5 Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 5 Failure code [AB00KE] Charge Voltage Low ........................................................................... 6 Failure code [B@BAZG] Eng Oil Press. Low........................................................................... 8 Failure code [B@BAZK] Eng Oil Level Low............................................................................. 8 Failure code [B@BCNS] Eng Water Overheat ........................................................................ 9 Failure code [B@BCZK] Eng Water Level Low ....................................................................... 9 Failure code [B@HANS] Hydr Oil Overheat ............................................................................ 10 Failure code [CA111] EMC Critical Internal Failure.................................................................. 10 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..................................................... 11 Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 12 Failure code [CA123] Chg Air Press Sensor Low Error ........................................................... 14 Failure code [CA131] Throttle Sensor High Error .................................................................... 16 Failure code [CA132] Throttle Sensor Low Error ..................................................................... 18 Failure code [CA144] Coolant Temp Sens High Error ............................................................. 20 Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 22

00 Index and foreword SEN00093-07 PC200, 220-8 7 Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 24 Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 26 Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 28 Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 30 Failure code [CA221] Ambient Press Sens High Error ............................................................ 32 Failure code [CA222] Ambient Press Sens Low Error ............................................................. 34 Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 36 Failure code [CA234] Eng Overspeed ..................................................................................... 37 Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 38 Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 39 Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 40 Failure code [CA322] Inj #1 Open/Short Error......................................................................... 42 Failure code [CA323] Inj #5 Open/Short Error......................................................................... 44 Failure code [CA324] Inj #3 Open/Short Error......................................................................... 46 Failure code [CA325] Inj #6 Open/Short Error......................................................................... 48 Failure code [CA331] Inj #2 Open/Short Error......................................................................... 50 Failure code [CA332] Inj #4 Open/Short Error......................................................................... 52 Troubleshooting by failure code (Display of code), Part 2 SEN00241-01 Troubleshooting by failure code (Display of code), Part 2........................................................... 3 Failure code [CA342] Calibration Code Incompatibility ........................................................... 3 Failure code [CA351] Injectors Drive Circuit Error ................................................................... 4 Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 6 Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 8 Failure code [CA428] Water in Fuel Sensor High Error ........................................................... 10 Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 12 Failure code [CA435] Eng Oil Press Sw Error ......................................................................... 14 Failure code [CA441] Battery Voltage Low Error ..................................................................... 15 Failure code [CA442] Battery Voltage High Error .................................................................... 18 Failure code [CA449] Rail Press Very High Error .................................................................... 20 Failure code [CA451] Rail Press Sensor High Error................................................................ 22 Failure code [CA452] Rail Press Sensor Low Error ................................................................ 24 Failure code [CA488] Chg Air Temp High Torque Derate ........................................................ 26 Failure code [CA553] Rail Press High Error ............................................................................ 26 Failure code [CA559] Rail Press Low Error ............................................................................. 27 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 30 Failure code [CA757] All Continuous Data Lost Error ............................................................. 32 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 34 Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................ 36 Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38 Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 39 Failure code [CA2249] Rail Press Very Low Error ................................................................... 40 Failure code [CA2311] IMV Solenoid Error .............................................................................. 42 Failure code [CA2555] Grid Htr Relay Volt High Error ............................................................. 44 Failure code [CA2556] Grid Htr Relay Volt Low Error ............................................................. 46 Failure code [D19JKZ] Personal Code Relay Abnormality ...................................................... 48 Failure code [D862KA] GPS Antenna Discon ......................................................................... 50 Failure code [DA22KK] Pump Solenoid Power Low Error ....................................................... 51 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 53 Failure code [DA29KQ] Model Selection Abnormality ............................................................. 60 Troubleshooting by failure code (Display of code), Part 3 SEN00242-03 Troubleshooting by failure code (Display of code), Part 3........................................................... 4 Failure code [DA2RMC] CAN Discon (Pump Con Detected) .................................................. 4 Failure code [DAF8KB] Short circuit in camera power supply ................................................. 6 Failure code [DAFGMC] GPS Module Error ............................................................................ 8 Failure code [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 10 Failure code [DGH2KB] Hydr Oil Sensor Short ....................................................................... 12

SEN00093-07 00 Index and foreword 8 PC200, 220-8 Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 14 Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 16 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ......................................... 18 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................... 20 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 22 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 24 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 26 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................. 28 Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ............................................ 31 Failure code [DW43KA] Travel Speed Sol Discon ................................................................... 34 Failure code [DW43KB] Travel Speed Sol Short ..................................................................... 36 Failure code [DW45KA] Swing Brake Sol Discon .................................................................... 38 Failure code [DW45KB] Swing Brake Sol Short ...................................................................... 40 Failure code [DW91KA] Travel Junction Sol Discon ................................................................ 42 Failure code [DW91KB] Travel Junction Sol Short .................................................................. 44 Failure code [DWA2KA] Service Sol Discon ............................................................................ 46 Failure code [DWA2KB] Service Sol Short .............................................................................. 47 Failure code [DWK0KA] 2-stage Relief Sol Discon ................................................................. 48 Failure code [DWK0KB] 2-stage Relief Sol Short .................................................................... 50 Troubleshooting by failure code (Display of code), Part 4 SEN00243-01 Troubleshooting by failure code (Display of code), Part 4 ........................................................... 4 Failure code [DXA8KA] PC-EPC (F) Sol Discon ..................................................................... 4 Failure code [DXA8KB] PC-EPC (F) Sol Short ........................................................................ 6 Failure code [DXA9KA] PC-EPC (R) Sol Discon ..................................................................... 8 Failure code [DXA9KB] PC-EPC (R) Sol Short ....................................................................... 10 Failure code [DXE0KA] LS-EPC Sol Discon............................................................................ 12 Failure code [DXE0KB] LS-EPC Sol Short .............................................................................. 14 Failure code [DXE4KA] Service Current EPC Discon ............................................................. 16 Failure code [DXE4KB] Service Current EPC Short ................................................................ 18 Failure code [DXE5KA] Merge-divider Main Sol Discon .......................................................... 20 Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................ 22 Failure code [DXE6KA] Merge-divider LS Sol Discon ............................................................. 24 Failure code [DXE6KB] Merge-divider LS Sol Short................................................................ 26 Failure code [DY20KA] Wiper Working Abnormality................................................................ 28 Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 30 Failure code [DY2CKA] Washer Drive Discon ......................................................................... 32 Failure code [DY2CKB] Washer Drive Short ........................................................................... 34 Failure code [DY2DKB] Wiper Drive (For) Short ..................................................................... 36 Failure code [DY2EKB] Wiper Drive (Rev) Short..................................................................... 38 Troubleshooting of electrical system (E-mode) SEN00244-01 Troubleshooting of electrical system (E-mode) ........................................................................... 3 Before carrying out troubleshooting of electrical system ......................................................... 3 Information in troubleshooting table......................................................................................... 5 E-1 When starting switch turned ON, machine monitor displays nothing ................................ 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 8 E-3 Engine does not start (Engine does not turn).................................................................... 11 E-4 Preheater does not operate .............................................................................................. 14 E-5 Automatic warm-up system does not operate (in cold season) ........................................ 16 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ...... 18 E-7 Precaution lights up while engine is running ..................................................................... 20 E-8 Emergency stop item lights up while engine is running .................................................... 25 E-9 Engine coolant temperature gauge does not indicate normally ........................................ 26 E-10 Hydraulic oil temperature gauge does not indicate normally .......................................... 27 E-11 Fuel level gauge does not indicate normally ................................................................... 29 E-12 Contents of display by machine monitor are different from applicable machine ............. 31 E-13 Machine monitor does not display some items ............................................................... 31 E-14 Function switch does not work ........................................................................................ 31

Komatsu PC220-8 Hydraulic Excavator Service & Repair Manual

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