Related Manuals for Komatsu PC200 -8
Summary of Contents for Komatsu PC200 -8
- Page 1 SEN00084-20 HYDRAULIC PC200 EXCAVATOR PC200LC PC220 PC220LC PC200- 300001 PC200LC- 300001 SERIAL NUMBERS and up PC220- 70001 PC220LC- 70001...
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Page 3: Table Of Contents
SEN00093-20 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 Index Composition of shop manual .......................... 2 Table of contents ............................. -
Page 4: Foreword And General Information Sen00094-05
SEN00093-20 00 Index and foreword Composition of shop manual 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. - Page 5 00 Index and foreword SEN00093-20 40 Troubleshooting SEN00090-10 Failure code table and fuse locations SEN03308-02 General information on troubleshooting SEN00231-05 Troubleshooting by failure code (Display of code), Part 1 SEN00240-07 Troubleshooting by failure code (Display of code), Part 2 SEN00241-06 Troubleshooting by failure code (Display of code), Part 3 SEN00242-05 Troubleshooting by failure code (Display of code), Part 4...
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Page 6: Table Of Contents
SEN00093-20 00 Index and foreword Table of contents 00 Index and foreword Index SEN00093-20 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00094-05 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............ - Page 7 00 Index and foreword SEN00093-20 Travel PPC valve ........................31 Service PPC valve (with EPC valve) ..................40 Service PPC valve........................46 Valve control ..........................48 Solenoid valve ......................... 50 PPC accumulator........................52 Anti-drop valve for boom ......................54 Anti-drop valve for arm ......................60 Return oil filter .........................
- Page 8 SEN00093-20 00 Index and foreword Adjusting play of work equipment and swing PPC valves ............46 Checking parts which cause hydraulic drift of work equipment ..........47 Releasing residual pressure from hydraulic circuit ..............49 Testing oil leakage ........................50 Bleeding air from each part......................
- Page 9 00 Index and foreword SEN00093-20 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.................
- Page 10 SEN00093-20 00 Index and foreword Failure code [DW91KA] Travel Junction Sol Discon..............48 Failure code [DW91KB] Travel Junction Sol Short ..............50 Failure code [DWA2KA] Service Sol Discon................52 Failure code [DWA2KB] Service Sol Short ................53 Failure code [DWK0KA] 2-stage Relief Sol Discon ..............54 Failure code [DWK0KB] 2-stage Relief Sol Short..............
- Page 11 00 Index and foreword SEN00093-20 Information in troubleshooting table ..................H-1 Speed or power of whole work equipment, swing, and travel is low......... H-2 Engine speed lowers significantly or engine stalls............H-3 Work equipment, swing, and travel systems do not work ..........10 H-4 Abnormal sound comes out from around hydraulic pump ..........
- Page 12 SEN00093-20 00 Index and foreword Engine and cooling system SEN00660-05 Removal and installation of fuel supply pump assembly ............. Removal and installation of fuel injector assembly..............Removal and installation of engine front seal................14 Removal and installation of engine rear seal ................17 Removal and installation of cylinder head assembly..............
- Page 13 00 Index and foreword SEN00093-20 90 Diagrams and drawings Hydraulic diagrams and drawings SEN00112-03 Hydraulic circuit diagram (PC200, 200LC-8)................Hydraulic circuit diagram (PC220, 220LC-8)................Hydraulic circuit diagram (PC200, 200LC-8, PC220, 220LC-8)..........Electrical diagrams and drawings SEN00113-09 Electrical circuit diagram ......................Connector arrangement diagram ....................
- Page 14 SEN00093-20 PC200, 220(LC)-8 Hydraulic excavator Form No. SEN00093-20 © 2017 KOMATSU All Rights Reserved Printed in Japan 02-17 (01)
- Page 15 SEN00094-05 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 Foreword and general information Safety notice ..............................2 How to read the shop manual .........................
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Page 16: Composition Of Shop Manual
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. -
Page 17: Working Range Diagram
00 Index and foreword SEN00094-05 Preparations for work When removing a cover which is under Before adding oil or making any repairs, internal pressure or under pressure from a park the machine on a hard and level spring, always leave 2 bolts in diagonal ground, and apply the parking brake and positions. -
Page 18: Table Of Contents
SEN00094-05 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. - Page 19 00 Index and foreword SEN00094-05 If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
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Page 20: Carrier Roller
SEN00094-05 00 Index and foreword a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection For the environment, the air condi- tioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. -
Page 21: How To Read The Shop Manual
This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC200, 220-8... -
Page 22: Weight Table
SEN00094-05 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. -
Page 23: Explanation Of Terms For Maintenance Standard
00 Index and foreword SEN00094-05 Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. - Page 24 SEN00094-05 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
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Page 25: Handling Of Electric Equipment And Hydraulic Component
00 Index and foreword SEN00094-05 Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. -
Page 26: Table Of Fuel, Coolant And Lubricants
SEN00094-05 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken. - Page 27 00 Index and foreword SEN00094-05 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
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Page 28: Travel Motor
SEN00094-05 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector. -
Page 29: Clss
00 Index and foreword SEN00094-05 Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks. - Page 30 SEN00094-05 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
- Page 31 00 Index and foreword SEN00094-05 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
- Page 32 SEN00094-05 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
- Page 33 00 Index and foreword SEN00094-05 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
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Page 34: Handling Of Connectors Newly Used For Engines
SEN00094-05 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5 intake manifold: TIM 140E-5... - Page 35 00 Index and foreword SEN00094-05 Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
- Page 36 SEN00094-05 00 Index and foreword 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.
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Page 37: How To Read Electric Wire Code
00 Index and foreword SEN00094-05 How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols. - Page 38 SEN00094-05 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
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Page 39: Ppc Valve
00 Index and foreword SEN00094-05 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &... -
Page 40: Precautions When Carrying Out Operation
SEN00094-05 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. - Page 41 00 Index and foreword SEN00094-05 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
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Page 42: Pilot Oil Filter
SEN00094-05 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. -
Page 43: Method Of Disassembling And Connecting Push-Pull Type Coupler
00 Index and foreword SEN00094-05 Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. - Page 44 SEN00094-05 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
- Page 45 00 Index and foreword SEN00094-05 Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end.
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Page 46: Standard Tightening Torque Table
SEN00094-05 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque... - Page 47 00 Index and foreword SEN00094-05 Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
- Page 48 SEN00094-05 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
- Page 49 00 Index and foreword SEN00094-05 Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size Tightening torque 8 ±...
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Page 50: Conversion Table
SEN00094-05 00 Index and foreword Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches. - Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...