Komatsu PC200-8M0 Install guide

HYDRAULIC
EXCAVATOR
SEN06109-03
PC200
-8M0
PC200LC
-8M0
PC220
-8M0
PC220LC
-8M0
SERIAL NUMBERS
PC200- 400001
PC200LC- 400001
PC220- 100001
PC220LC- 100001
and up

PC200, 200LC, 220, 220LC-8M0 00-100 1
SEN06111-03
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC200-8M0
PC200LC-8M0
PC220-8M0
PC220LC-8M0
Machine model Serial number
PC200-8M0 400001 and up
PC200LC-8M0 400001 and up
PC220-8M0 100001 and up
PC220LC-8M0 100001 and up
00 Index and foreword 1
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4

SEN06111-03
00-100 2 PC200, 200LC, 220, 220LC-8M0
100 Index
Composition of shop manual
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 accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN06109-03
00 Index and foreword SEN06110-03
100 Index SEN06111-03 q
200 Foreword and general information SEN06112-00
01 Specification SEN06113-00
100 Specification and technical data SEN06114-00
10 Structure, function and maintenance standard SEN06115-00
100 Engine and cooling system SEN06116-00
200 Power train SEN06117-00
300 Undercarriage and frame SEN06118-00
401 Hydraulic system, Part 1 SEN06119-00
402 Hydraulic system, Part 2 SEN06120-00
403 Hydraulic system, Part 3 SEN06121-00
500 Work equipment SEN06122-00
600 Electrical system SEN06123-00
20 Standard value table SEN06124-00
100 Standard service value table SEN06125-00
30 Testing and adjusting SEN06126-01
101 Testing and adjusting, Part 1 SEN06127-00
102 Testing and adjusting, Part 2 SEN06128-00
103 Testing and adjusting, Part 3 SEN06129-01 q

SEN06111-03
PC200, 200LC, 220, 220LC-8M0 00-100 3
100 Index
Composition of shop manual
40 Troubleshooting SEN06130-01
100 Failure code table and fuse locations SEN06131-00
200 General Information on troubleshooting SEN06132-01
301 Troubleshooting by failure code, Part 1 SEN06133-00
302 Troubleshooting by failure code, Part 2 SEN06134-00
303 Troubleshooting by failure code, Part 3 SEN06135-00
304 Troubleshooting by failure code, Part 4 SEN06136-00
305 Troubleshooting by failure code, Part 5 SEN06137-00
400 Troubleshooting of electrical system (E-mode) SEN06138-00
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06139-00
600 Troubleshooting of engine (S-mode) SEN06140-00
50 Disassembly and assembly SEN06141-01
100 General information on disassembly and assembly SEN06142-00
200 Engine and cooling system SEN06143-00
300 Power train SEN06144-00
400 Undercarriage and frame SEN06145-00
500 Hydraulic system SEN06146-00
600 Work equipment SEN06147-00
700 Cab and its attachments SEN06148-01
800 Electrical system SEN06149-00
80 Appendix SEN06150-00
100 Air conditioner SEN06151-00
90 Diagrams and drawings SEN06152-00
100 Hydraulic diagrams and drawings SEN06153-00
200 Electrical diagrams and drawings SEN06154-00

SEN06111-03
00-100 4 PC200, 200LC, 220, 220LC-8M0
100 Index
Table of contents
Table of contents 1
00 Index and foreword
100 Index SEN06111-03
Composition of shop manual................................................................................................... 2
Table of contents...................................................................................................................... 4
200 Foreword and general information SEN06112-00
Foreword, safety and general information............................................................................... 2
How to read the shop manual.................................................................................................. 9
Explanation of terms for maintenance standard...................................................................... 11
Handling equipment of fuel system devices ............................................................................ 13
Handling of intake system parts............................................................................................... 14
Handling of hydraulic equipment ............................................................................................. 15
Method of disconnecting and connectingof push-pull type coupler......................................... 17
Handling of electrical equipment.............................................................................................. 20
How to read electric wire code................................................................................................. 29
Precautions when performing operation.................................................................................. 32
Practical use of KOMTRAX ..................................................................................................... 35
Standard tightening torque table.............................................................................................. 36
List of abbreviation................................................................................................................... 40
Conversion table...................................................................................................................... 45
01 Specification
100 Specification and technical data SEN06114-00
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
100 Engine and cooling system SEN06116-00
Engine related parts................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler........................................................................ 3
200 Power train SEN06117-00
Power train............................................................................................................................... 2
Final drive................................................................................................................................ 4
Swing machinery ..................................................................................................................... 8
Swing circle.............................................................................................................................. 12
300 Undercarriage and frame SEN06118-00
Track frame and recoil spring .................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller............................................................................................................................... 7
Track shoe............................................................................................................................... 8
401 Hydraulic system, Part 1 SEN06119-00
Hydraulic equipment layout drawing........................................................................................ 2
Hydraulic tank and filter ........................................................................................................... 4
Hydraulic pump........................................................................................................................ 6
Pilot oil filter ............................................................................................................................. 28
402 Hydraulic system, Part 2 SEN06120-00
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 13
Functions and operation by valve............................................................................................ 17
403 Hydraulic system, Part 3 SEN06121-00
Swing motor............................................................................................................................. 2

SEN06111-03
PC200, 200LC, 220, 220LC-8M0 00-100 5
100 Index
Table of contents
Center swivel joint ................................................................................................................... 10
Travel motor............................................................................................................................. 12
PPC valve................................................................................................................................ 22
Valve control............................................................................................................................ 42
Solenoid valve......................................................................................................................... 44
PPC accumulator..................................................................................................................... 46
Return oil filter ......................................................................................................................... 47
Attachment circuit selector valve............................................................................................. 48
Hydraulic cylinder.................................................................................................................... 50
500 Work equipment SEN06122-00
Work equipment ...................................................................................................................... 2
Dimensions of arm................................................................................................................... 10
Dimensions of bucket .............................................................................................................. 12
600 Electrical system SEN06123-00
Engine control.......................................................................................................................... 2
Electrical control system.......................................................................................................... 12
Machine monitor system..........................................................................................................35
Sensor ..................................................................................................................................... 56
KOMTRAX system ..................................................................................................................60
20 Standard value table
100 Standard service value table SEN06125-00
Standard value table for engine related parts.......................................................................... 2
Standard value table for chassis related parts......................................................................... 4
30 Testing and adjusting
101 Testing and adjusting, Part 1 SEN06127-00
Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Sketch of special tool............................................................................................................... 7
Testing engine speed............................................................................................................... 8
Testing intake air pressure (boost pressure) ........................................................................... 9
Testing exhaust gas color........................................................................................................ 10
Adjusting valve clearance........................................................................................................ 11
Testing compression pressure................................................................................................. 13
Testing blowby pressure.......................................................................................................... 16
Testing engine oil pressure...................................................................................................... 17
Handling fuel system parts ......................................................................................................18
Releasing residual pressure from fuel system......................................................................... 18
Testing fuel pressure ............................................................................................................... 19
Handling reduced cylinder mode operation............................................................................. 22
Handling no-injection cranking operation ................................................................................ 22
Testing fuel discharge, return and leak amount....................................................................... 23
Bleeding air from fuel circuit.................................................................................................... 26
Testing fuel circuit for leakage ................................................................................................. 27
Handling controller high voltage circuit.................................................................................... 28
Testing and adjusting air conditioner compressor belt tension................................................ 29
Replacing alternator belt.......................................................................................................... 30
Testing swing circle bearing clearance.................................................................................... 31
Testing and adjusting track tension ......................................................................................... 32
Testing and adjusting oil pressure in work equipment, swing, and travel circuits.................... 34
Testing control circuit source pressure.................................................................................... 37
Testing and adjusting oil pressure in pump PC control circuit ................................................. 38
Testing and adjusting oil pressure in pump LS control circuit.................................................. 41
Testing solenoid valve output pressure ................................................................................... 46
Testing PPC valve output pressure ......................................................................................... 49
Adjusting play of work equipment and swing PPC valves....................................................... 51
Testing parts which cause hydraulic drift of work equipment................................................... 52

SEN06111-03
00-100 6 PC200, 200LC, 220, 220LC-8M0
100 Index
Table of contents
Releasing remaining pressure from hydraulic circuit............................................................... 54
Testing oil leakage................................................................................................................... 55
Bleeding air from each part...................................................................................................... 58
Testing cab tipping stopper...................................................................................................... 60
Adjusting mirrors...................................................................................................................... 61
Installation and adjustment of mirrors...................................................................................... 62
Angle adjustment of rear view camera .................................................................................... 65
102 Testing and adjusting, Part 2 SEN06128-00
Special functions of machine monitor...................................................................................... 2
103 Testing and adjusting, Part 3 SEN06129-01
Handling voltage circuit of engine controller............................................................................ 2
Preparation work for troubleshooting of electrical system....................................................... 3
Procedure for testing diodes....................................................................................................8
Handling battery disconnect switch ......................................................................................... 9
Pm Clinic service..................................................................................................................... 10
40 Troubleshooting
100 Failure code table and fuse locations SEN06131-00
Failure codes table .................................................................................................................. 2
Fuse locations.......................................................................................................................... 9
200 General Information on troubleshooting SEN06132-01
Symptom and troubleshooting numbers.................................................................................. 2
Sequence of events in troubleshooting.................................................................................... 4
Checks before troubleshooting................................................................................................ 6
Classification and procedures for troubleshooting................................................................... 8
Symptom and troubleshooting numbers.................................................................................. 10
Information in troubleshooting table......................................................................................... 12
Connector list and layout......................................................................................................... 14
Connection table for connector pin numbers........................................................................... 24
T- branch box and T- branch adapter table.............................................................................. 60
Troubleshooting method for open circuit in wiring harness of pressure sensor system .......... 63
301 Troubleshooting by failure code, Part 1 SEN06133-00
Failure code [879AKA] A/C Inner Sensor Open Circuit........................................................... 3
Failure code [879AKB] A/C Inner Sensor Short Circuit ........................................................... 3
Failure code [879BKA] A/C Outer Sensor Open Circuit .......................................................... 3
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................... 3
Failure code [879CKA] Ventilating Sensor Open Circuit.......................................................... 3
Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................... 4
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit............................................... 4
Failure code [879EMC] Ventilation Damper Abnormality......................................................... 4
Failure code [879FMC] Air Mix Damper Abnormality .............................................................. 4
Failure code [879GKX] Refrigerant Abnormality...................................................................... 4
Failure code [989L00] Engine Controller Lock Caution1 ......................................................... 5
Failure code [989M00] Engine Controller Lock Caution2 ........................................................ 6
Failure code [989N00] Engine Controller Lock Caution3......................................................... 7
Failure code [AA10NX] Air Cleaner Clogging.......................................................................... 8
Failure code [AB00KE] Charge Voltage Low........................................................................... 10
Failure code [B@BAZG] Eng Oil Press Low............................................................................ 12
Failure code [B@BAZK] Engine Oil Level Low........................................................................ 13
Failure code [B@BCNS] Eng Water Overheat ........................................................................ 14
Failure code [B@BCZK] Radiator Coolant Level Low............................................................. 16
Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 18
Failure code [CA111] ECM Critical Internal Failure.................................................................. 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 19
Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 20
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 22
Failure code [CA131] Throttle Sensor High Error.................................................................... 24

SEN06111-03
PC200, 200LC, 220, 220LC-8M0 00-100 7
100 Index
Table of contents
Failure code [CA132] Throttle Sensor Low Error..................................................................... 26
Failure code [CA144] Coolant Temp Sens High Error............................................................. 28
Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 30
Failure code [CA153] Chg Air Temp Sensor High Error.......................................................... 32
Failure code [CA154] Chg Air Temp Sensor Low Error........................................................... 34
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 36
Failure code [CA187] Sens Supply 2 Volt Low Error............................................................... 38
Failure code [CA221] Ambient Press Sens High Error............................................................ 40
Failure code [CA222] Ambient Press Sens Low Error............................................................. 42
Failure code [CA227] Sens 2 Supply Volt High Error .............................................................. 44
Failure code [CA234] Eng Overspeed..................................................................................... 44
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 45
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 46
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 48
302 Troubleshooting by failure code, Part 2 SEN06134-00
Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................ 4
Failure code [CA323] Inj #5(L#5) Open/Short Error................................................................ 6
Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................ 8
Failure code [CA325] Inj #6(L#6) Open/Short Error................................................................ 10
Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................ 12
Failure code [CA332] Inj #4(L#4) Open/Short Error................................................................ 14
Failure code [CA342] Calibration Code Incompatibility ........................................................... 16
Failure code [CA351] Injectors Drive Circuit Error................................................................... 17
Failure code [CA352] Sens Supply 1 Volt Low Error............................................................... 18
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 20
Failure code [CA428] Water in Fuel Sensor High Error........................................................... 22
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 24
Failure code [CA435] Eng Oil Press Sw Error......................................................................... 26
Failure code [CA441] Battery Voltage Low Error..................................................................... 28
Failure code [CA442] Battery Voltage High Error.................................................................... 30
Failure code [CA449] Rail Press Very High Error.................................................................... 31
Failure code [CA451] Rail Press Sensor High Error................................................................ 32
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 34
Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 36
Failure code [CA553] Rail Press High Error............................................................................ 37
Failure code [CA559] Rail Press Low Error............................................................................. 38
Failure code [CA689] Eng Ne Speed Sensor Error................................................................. 40
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 42
Failure code [CA757] All Continuous Data Lost Error ............................................................. 43
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 44
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 48
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 50
Failure code [CA2249] Rail Press Very Low Error................................................................... 51
Failure code [CA2311] lMV Solenoid Error.............................................................................. 51
Failure code [CA2555] Grid Htr Relay Open Circuit Error....................................................... 52
Failure code [CA2556] Grid Htr Relay Short Circuit Error ....................................................... 54
303 Troubleshooting by failure code, Part 3 SEN06135-00
Failure code [D110KB] Battery Relay Drive Short Circuit........................................................ 4
Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 6
Failure code [D811MC] KOMTRAX Error................................................................................ 8
Failure code [D862KA] GPS Antenna Open Circuit ................................................................ 9
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)............................................................... 10
Failure code [DA22KK] Pump Solenoid Power Low Error....................................................... 12
Failure code [DA25KP] 5V Sensor 1 Power Abnormality........................................................ 14
Failure code [DA26KP] 5V Sensor 2 Power Abnormality........................................................ 16
Failure code [DA29KQ] Model Selection Abnormality............................................................. 18
Failure code [DA2QKR] CAN2 Discon (Pump Con)................................................................ 23
Failure code [DAF0MB] Monitor ROM Abnormality................................................................. 26

SEN06111-03
00-100 8 PC200, 200LC, 220, 220LC-8M0
100 Index
Table of contents
Failure code [DAF0MC] Monitor Error..................................................................................... 27
Failure code [DAF8KB] Camera Power Supply Short Circuit.................................................. 28
Failure code [DAF9KQ] Model Selection Abnormality............................................................. 30
Failure code [DAFGMC] GPS Module Error............................................................................ 31
Failure code [DAFQKR] CAN2 Discon .................................................................................... 32
Failure code [DAZ9KQ] A/C Model Selection Abnormality...................................................... 33
Failure code [DAZQKR] CAN2 Discon (Aircon ECU).............................................................. 34
Failure code [DB2QKR] CAN2 Discon (Engine Con) .............................................................. 36
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit............................................................. 40
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit............................................... 42
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 44
Failure code [DHPBMA] R Pump Press Sensor Abnormality.................................................. 46
304 Troubleshooting by failure code, Part 4 SEN06136-00
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 4
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality................................. 6
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 8
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality................................... 10
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 12
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality....................................... 14
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ..................................... 16
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................. 18
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ................................... 20
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality.................................. 22
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality................................... 24
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality................................... 26
Failure code [DHX1MA] Overload Sensor Abnormality........................................................... 28
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ......................................... 30
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ......................................... 32
Failure code [DV20KB] Travel Alarm Short Circuit.................................................................. 34
Failure code [DW43KA] Travel Speed Sol Open Circuit.......................................................... 36
Failure code [DW43KB] Travel Speed Sol Short Circuit.......................................................... 38
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit................................................ 40
Failure code [DW45KB] Swing Brake Sol Short Circuit........................................................... 42
Failure code [DW91KA] Travel Neutral Sol Open Circuit......................................................... 44
Failure code [DW91KB] Travel Neutral Sol Short Circuit......................................................... 46
305 Troubleshooting by failure code, Part 5 SEN06137-00
Failure code [DWA2KA] Attachment Sol Open Circuit............................................................. 4
Failure code [DWA2KB] Attachment Sol Short Circuit............................................................. 6
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ........................................................ 8
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit......................................................... 10
Failure code [DWK2KA] Variable Back Press Sol Open Circuit .............................................. 12
Failure code [DWK2KB] Variable Back Press Sol Short Circuit............................................... 14
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ............................................................ 16
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................. 18
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit............................................................ 20
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit............................................................ 22
Failure code [DXE0KA] LS-EPC Sol Open Circuit................................................................... 24
Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................... 26
Failure code [DXE4KA] Attachment Flow EPC Open Circuit................................................... 28
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................... 30
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit.................................................. 32
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit.................................................. 34
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ..................................................... 36
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit...................................................... 38
Failure code [DY20KA] Wiper Working Abnormality................................................................ 40
Failure code [DY20MA] Wiper Parking Abnormality................................................................ 42
Failure code [DY2CKB] Washer Drive Short Circuit................................................................ 44
Failure code [DY2DKB] Wiper Drive (Fwd) Short.................................................................... 46