Komatsu PC200-8M0 Page 355 Shop Manual Download

Page: 355 / 1254

SEN06127-00

PC200, 200LC, 220, 220LC-8M0

30-101

101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting

Tools for testing, adjusting, and troubleshooting

Testing/Adjusting item

Sym-

bol

Part No.

Part name

Remarks

Testing intake air pressure
(boost pressure)

799-201-2202 Boost gauge kit

–101 to 200 kPa
{–760 to 1,500 mmHg}

Testing exhaust gas color

799-201-9001 Handy smoke checker

Bosch index: 0 to 9

Commercially

available

Smoke meter

Adjusting valve clearance

795-799-1131

Gear

Commercially

available

Thickness gauge

1 Intake: 0.25 mm, Exhaust: 0.51 mm

Testing compression
pressure

795-799-6700 Puller

795-502-1590 Compression gauge

1 0 to 7.0 MPa {0 to 70 kg/cm

}

795-790-4410 Adapter

1 For 107E-1 engine

6754-11-3130

Gasket

1 For 107E-1 engine

Commercially

available

Hose

1 Inside diameter: Approx. 15 mm

Testing blow-by pressure

799-201-1504 Blowby checker

1 0 to 5 kPa {0 to 500 mmH

795-790-3300 Blowby tool

1 For 107E-1 engine

Testing engine oil pres-
sure

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm

}

790-261-1204 Digital hydraulic tester

1 Pressure gauge: 60 MPa {600 kg/cm

}

799-401-2320 Hydraulic tester

1 Pressure gauge: 1 MPa {10 kg/cm

}

Testing fuel pressure

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm

}

790-261-1204 Digital hydraulic tester

1 Pressure gauge: 60 MPa {600 kg/cm

}

795-790-4430 Adapter

10 × 1.0 mm

R1/8

6215-81-9710 O-ring

799-401-2320 Gauge

1 Pressure gauge: 1 MPa {10 kg/cm

}

795-790-5110

Screw

799-201-2202 Boost gauge kit

07005-01212

Gasket

Testing fuel return rate
and leakage

795-790-4700 Tester kit

6164-81-5790 Joint

07005-01212

Washer

6754-71-5340 Connector

6754-71-5350 Washer

Commercially

available

Measuring cylinder

Commercially

available

Stopwatch

Commercially

available

Hose

1 Inside diameter:

14 mm

Commercially

available

Hose

1 Inside diameter:

7 mm

Commercially

available

Hose

1 Inside diameter:

12 mm

Testing swing circle bear-
ing clearance

Commercially

available

Dial gauge

Testing and adjusting
oil pressure in work
equipment, swing, and
travel circuits

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm

}

790-261-1204 Digital hydraulic tester

1 Pressure gauge: 60 MPa {600 kg/cm

}

799-101-5220 Nipple

Size: 10 × 1.25 mm

07002-11023

O-ring

Summary of Contents for PC200-8M0

Page 1: ...HYDRAULIC EXCAVATOR SEN06109 03 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 SERIAL NUMBERS PC200 400001 PC200LC 400001 PC220 100001 PC220LC 100001 and up...

Page 2: ......

Page 3: ...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 fo...

Page 4: ...aterials 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 10...

Page 5: ...ooting 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 SE...

Page 6: ...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...

Page 7: ...usting 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 Testin...

Page 8: ...ng 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...

Page 9: ...e 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 CA4...

Page 10: ...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 Trave...

Page 11: ...unding 45 E 24 Horn does not sound or does not stop 46 E 25 Windshield wiper and window washer do not operate 48 E 26 BOOM DOWN indicator is not displayed properly with monitoring function 50 E 27 ARM...

Page 12: ...e lacks power 13 S 7 Exhaust smoke is black incomplete combustion 14 S 8 Oil consumption is excessive or exhaust smoke is blue 15 S 9 Oil becomes contaminated early 16 S 10 Fuel consumption is excessi...

Page 13: ...mbly 24 Disassembly and assembly of travel PPC valve 26 Disassembly and assembly of work equipment cylinder 28 600 Work equipment SEN06147 00 Removal and installation of work equipment assembly 2 700...

Page 14: ...lating Damper Abnormality 54 Failure code 879FMC Air Mix Damper Abnormality 55 Failure code 879GKX Refrigerant Abnormality 56 Troubleshooting for power supply and CAN communication system Air conditio...

Page 15: ...SEN06111 03 PC200 200LC 220 220LC 8M0 00 100 13 100 Index Table of contents...

Page 17: ...ord 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 Hand...

Page 18: ...parts with a grinder etc q When performing any work with two or more workers always agree on the working proce dure before starting While working always keep conversations of the work between your fe...

Page 19: ...sling chain and hook for damage before the work Use the slings with ample capacity and install them to the proper places Operate the hoist or crane slowly to prevent the component from hitting any ot...

Page 20: ...that of the hook a When slinging a load with two ropes or more the larger the hanging angle is the larger the tension of each rope The figure bellow shows the variation of allowable load in kN kg whe...

Page 21: ...ol switch q Remember the position of the main switch so that you can turn off the power immediately in an emergency q Shut down the main switch when the hoist stops because of a blackout When turning...

Page 22: ...se it q When removing the O rings use a soft tool so that the piping is not damaged q Check that the O ring is not damaged or deteri orated q Apply compressor oil for refrigerant R134a to the O ring a...

Page 23: ...o spill fuel on overheated surfaces or on parts of the electrical sys tem q After adding fuel or oil wipe up any spilled fuel or oil q Put greasy rags and other flammable materials into a safe contain...

Page 24: ...g operation to prevent fire hazard of highly heated exhaust gas caused by KDPF regeneration See the operation and maintenance man ual for the setting procedure q Explosion caused by lighting equipment...

Page 25: ...le 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 Disasse...

Page 26: ...is used to be used is indicated in parentheses of Symbol Item Remarks k Safety The special safety precautions required for performing work are described a Caution The special technical precautions or...

Page 27: ...and shaft The tightness of fit is decided by the tolerance q Indication of dimension of rotating shaft and hole and their related drawing Standard clearance and standard value q The clearance made whe...

Page 28: ...A product whose dimension is out of the allow able value must be repaired However since the allowable values are generally estimated through various tests or experiences in most cases the judgement m...

Page 29: ...m entering Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked D...

Page 30: ...cause a failure Use special care to prevent entry of the foreign material when servicing the air intake system Be careful of working environment q Avoid the repair work of the machine in rain or stro...

Page 31: ...nd the openings of the compo nents which are removed with the caps tapes vinyl bags etc to prevent foreign material from entering Never leave the openings of the pipes and hoses without being covered...

Page 32: ...lushing is performed twice Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil Cleaning operations q After repairing...

Page 33: ...sh hose joint 2 into mating adapter 3 Fig 1 a It can be pushed in by approximately 3 5mm a Do not hold rubber cap portion 4 2 While pushing hose joint 2 into adapter 3 push rubber cap 4 against adapte...

Page 34: ...ention ring 6 hits contact surface a at the hexagonal part on the male side Fig 6 2 While keeping the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While keeping the conditions of St...

Page 35: ...at the hexagonal portion on the male side Fig 10 2 While keeping the condition of Step 1 push cover 10 straight until it hits contact surface b of the hexagonal portion on the male side Fig 11 3 While...

Page 36: ...d installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful when handling the wiring harnesses Main failures occurring in wiring harnes...

Page 37: ...ry cloth or blow it with compressed air Oil mud or dirt stuck to connector q If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins...

Page 38: ...ntact to occur so always cover the connector Connecting connectors 1 Check the connector visually q Check that there is no oil dirt or water stick to the connector pins joint portion q Check that the...

Page 39: ...ale connector 2 horizontally until the lock clicks Arrow x 2 Since locks a and b may not be set com pletely push in female connector 2 with curv ing movement until the locks are set normally Arrow x y...

Page 40: ...and perform a continuity test to check for any short circuits between pins caused by water a After the connector is completely dried blow the contact restorer and reassemble them Handling of connector...

Page 41: ...nnect the connector 2 by pulling lock B on the wiring harness side of connector 2 outward Connection 1 Insert the connector securely until a click is heard Push lock type 1 BOSCH 3 Disconnection 1 Whi...

Page 42: ...irection of the arrow Connection 1 Insert the connector securely until a click is heard Push lock type 3 AMP 3 Disconnection 1 While pressing lock E pull out connector 5 in the direction of the arrow...

Page 43: ...circuits for control including the microcomputers are assembled in the control ler These electronic circuits in the controller must be handled with care as they control the machine q Do not place obj...

Page 44: ...disconnecting and connect ing them several times q Be sure to connect all the disconnected con nectors before proceeding to the next step a If the starting switch is turned to the ON position with th...

Page 45: ...AVS in material of the coating AEX Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since the use of AV and AVS wires depends on size nominal No their symbols are...

Page 46: ...6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diam eter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0...

Page 47: ...lack LR Blue Red BrR Brown Red LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green B...

Page 48: ...hen dis connecting the connectors Do not pull the wires q Attach the tags to wires and hoses to show their installing positions to prevent any mistake when install ing q Check the number and thickness...

Page 49: ...LM P q After installing the snap ring check that the snap ring is settled in the ring groove completely q When connecting wiring harness connectors clean the connectors to remove oil dirt or water the...

Page 50: ...nder head and intake and exhaust manifold mountings for looseness q If any bolt is loose retighten it a For the tightening torques see the Disassembly and assembly Check of engine piping for damage an...

Page 51: ...tion etc can be generated and utilized as an advice tool for the user and operator How to use KOMTRAX practically With KOMTRAX following support activities will be available 1 Quick response to sudden...

Page 52: ...the width across flats of marked bolts flanged bolts Thread diameter Width across flats Tightening torque mm mm Nm kgm 6 10 10 11 8 to 14 7 1 2 to 1 5 8 13 12 27 to 34 2 8 to 3 5 10 17 14 59 to 74 6...

Page 53: ...lats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 to 63 3 5 to 6 5 44 4 5 18 59 to 98 6 0 to10 0 78 8 0 03 04 20 84 to 132 8 5 to13 5 103 10 5 05 06 24 1...

Page 54: ...Target Thread size mm Nominal No threads per inch type of thread Thread root diameter reference 02 19 34 to 54 3 5 to 5 5 44 4 5 9 16 18UN 14 3 34 to 63 3 5 to 6 5 44 4 5 14 03 22 54 to 93 5 5 to 9 5...

Page 55: ...que table for tapered screws on 102 107 and 114 series engines a Unless otherwise specified tighten the tapered inch thread screws used on the 102 107 and 114 series engines to the torques shown in th...

Page 56: ...Function that the retarder works automatically with a certain braking force when the accelerator pedal is released while the machine travels downhill ARSC Automatic Retarder Speed Control Travel and b...

Page 57: ...ectromagnetic proportional control Mechanism that actuator works in proportion to current FOPS Falling Object Protective Structure Cab and canopy Structure that protects operator s head from falling o...

Page 58: ...etwork on the machine LS Load Sensing Oil pressure Function that detects differential pressure of pump and controls discharge amount according to load LVDS Low Voltage Differential Signaling Communica...

Page 59: ...elt from being crushed when machine tips over Structure to protect operator when machine tips over Performance standardized in ISO 3471 SI International unit system Unit Abbreviation for International...

Page 60: ...200 Foreword and general information List of abbreviation SOL Solenoid STD Standard OPT Option if equipped OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Tra...

Page 61: ...1 The number 550 does not appear in the table so divide it by 10 move the decimal point one place to the left to get 55 mm 2 Then convert 55 mm to 2 165 in by the same procedure as above 3 The origin...

Page 62: ...8 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132...

Page 63: ...44 7 151 9 159 1 166 4 173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9...

Page 64: ...394 1 408 100 1 422 1 437 1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 8...

Page 65: ...26 7 16 3 2 7 2 19 66 2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 9...

Page 67: ...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 01 Specification 1 100 Specification and technical data Specificati...

Page 68: ...200LC 8M0 PC220 8M0 PC220LC 8M0 A Overall length mm 9 425 9 425 9 885 9 885 B Overall height mm 3 040 3 040 3 185 3 185 C Overall width mm 2 800 3 080 2 980 3 280 D Shoe width mm 600 700 600 700 E Cab...

Page 69: ...200LC 8M0 PC220 8M0 PC220LC 8M0 A Max digging reach mm 9 875 9 875 10 180 10 180 B Max digging depth mm 6 620 6 620 6 920 6 920 C Max digging height mm 10 000 10 000 10 000 10 000 D Max vertical wall...

Page 70: ...00 Swing speed min 1 rpm 12 4 12 4 12 4 12 4 Swing operation max slope angle degree 25 25 Travel speed km h Lo 3 0 Mi 4 1 Hi 5 5 Lo 3 0 Mi 4 1 Hi 5 5 Gradability degree 35 35 Ground pressure Standard...

Page 71: ...ulic pump Type and numbers HPV95 95 Variable displacement piston type 2 Discharge l min Piston 219 5 x 2 Set pressure MPa kg cm2 Piston 37 2 380 Control valve Type and number 6 spool type 1 Operating...

Page 72: ...ng speed min 1 rpm 11 7 11 7 11 7 11 7 Swing operation max slope angle degree 25 25 Travel speed km h Lo 3 1 Mi 4 2 Hi 5 5 Lo 3 1 Mi 4 2 Hi 5 5 Gradability degree 35 35 Ground pressure Standard shoe k...

Page 73: ...draulic pump Type and numbers HPV95 95 Variable displacement piston type 2 Discharge l min Piston 219 5 x 2 Set pressure MPa kg cm2 Piston 37 2 380 Control valve Type and number 6 spool type 1 Operati...

Page 74: ...t including fuel 141 141 Revolving frame 1 721 1 721 Cab 480 480 Operator s seat 35 35 Counterweight 3 735 3 735 Swing machinery 174 174 Control valve 235 235 Swing motor 51 5 51 5 Travel motor 93 x 2...

Page 75: ...00001 and up Boom assembly 1 541 1 541 Arm assembly 794 794 Bucket assembly 633 633 Boom cylinder assembly 176 x 2 176 x 2 Arm cylinder assembly 228 228 Bucket cylinder assembly 137 137 Link large ass...

Page 76: ...23 Cab 480 480 Operator s seat 35 35 Counterweight 5 056 5 056 Swing machinery 218 218 Control valve 235 235 Swing motor 51 5 51 5 Travel motor 93 x 2 93 x 2 Center swivel joint 36 36 Track frame asse...

Page 77: ...0001 and up Boom assembly 1 947 1 947 Arm assembly 950 950 Bucket assembly 722 722 Boom cylinder assembly 203 x 2 203 x 2 Arm cylinder assembly 269 269 Bucket cylinder assembly 167 167 Link large asse...

Page 78: ...0 200LC 220 220LC 8M0 100 Specification and technical data Table of fuel coolant and lubricants Table of fuel coolant and lubricants 1 a For details of the notes Notes 1 Note 2 in the table see Operat...

Page 79: ...00 200LC 8M0 PC220 220LC 8M0 Specified capacity Refill capacity Specified capacity Refill capacity Engine oil pan 25 4 23 1 25 4 23 1 Swing machinery case 7 1 6 5 8 2 7 2 Final drive case each of righ...

Page 81: ...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 10 Structure function and maintenance standard 1 1...

Page 82: ...ne and cooling system Engine related parts Engine related parts 1 1 Drive plate 2 Torsion spring 3 Stopper pin 4 Friction plate 5 Muffler 6 Rear engine mount 7 Front engine mount 8 Damper assembly Out...

Page 83: ...cooler Radiator oil cooler aftercooler and fuel cooler 1 1 Radiator 2 Oil cooler 3 Aftercooler 4 Fuel cooler 5 Reservoir tank 6 Fan 7 Shroud 8 Radiator cap 9 Radiator inlet hose 10 Net 11 Radiator ou...

Page 85: ...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 10 Structure function and maintenance...

Page 86: ...train Power train 1 1 Idler 2 Center swivel joint 3 Control valve 4 Final drive 5 Travel motor HMV120 6 Hydraulic pump HPV95 95 7 Engine SAA6D107E 1 8 Travel speed solenoid valve 9 Swing brake solenoi...

Page 87: ...SEN06117 00 PC200 200LC 220 220LC 8M0 10 200 3 200 Power train Power train...

Page 88: ...SEN06117 00 10 200 4 PC200 200LC 220 220LC 8M0 200 Power train Final drive Final drive 1 PC200 8M0 PC200LC 8M0...

Page 89: ...riteria Remedy 16 Backlash between travel motor and No 2 planetary carrier Standard clearance Allowable clearance Replace 0 06 to 0 25 1 00 17 Backlash between No 2 plane tary gear and ring gear 0 17...

Page 90: ...SEN06117 00 10 200 6 PC200 200LC 220 220LC 8M0 200 Power train Final drive PC220 8M0 PC220LC 8M0...

Page 91: ...medy 14 Backlash between travel motor and No 2 planetary carrier Standard clearance Allowable clearance Replace 0 13 to 0 47 1 00 15 Backlash between No 2 plane tary gear and ring gear 0 17 to 0 57 1...

Page 92: ...SEN06117 00 10 200 8 PC200 200LC 220 220LC 8M0 200 Power train Swing machinery Swing machinery 1 PC200 8M0 PC200LC 8M0...

Page 93: ...and No 1 planetary gear 0 16 to 0 50 1 00 15 Backlash between No 1 plane tary gear and ring gear 0 18 to 0 59 1 10 16 Backlash between No 1 plane tary carrier and No 2 sun gear 0 39 to 0 71 1 20 17 Ba...

Page 94: ...SEN06117 00 10 200 10 PC200 200LC 220 220LC 8M0 200 Power train Swing machinery PC220 8M0 PC220LC 8M0...

Page 95: ...and No 1 planetary gear 0 16 to 0 50 1 00 15 Backlash between No 1 plane tary gear and ring gear 0 18 to 0 59 1 10 16 Backlash between No 1 plane tary carrier and No 2 sun gear 0 35 to 0 64 1 20 17 Ba...

Page 96: ...f teeth 96 2 Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone S position Specifications Reduction ratio 96 13 7 385 Amount of filled grease 14 6 l G2 LI Unit mm...

Page 97: ...92 2 Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone S position Specifications Reduction ratio 92 13 7 077 Amount of filled grease 15 8 l G2 LI Unit mm No Check...

Page 99: ...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 10 Structure function and maintenance standard 1 300 Un...

Page 100: ...pring 1 1 Idler 2 Track frame 3 Carrier roller 4 Final drive 5 Track roller 6 Track shoe 7 Center guard 8 Front guard q The dimensions and the number of track roll ers depend on the model but the basi...

Page 101: ...Standard dimen sion Tolerance Repair limit Rebuild by build up weld ing or replace Track frame 107 3 1 111 Idler support 105 0 5 103 10 Horizontal width of idler guide Track frame 250 4 1 255 Idler su...

Page 102: ...SEN06118 00 10 300 4 PC200 200LC 220 220LC 8M0 300 Undercarriage and frame Idler Idler 1...

Page 103: ...ad 19 25 5 Total width 159 6 Width of tread 37 5 7 Clearance between shaft and bushing Standard dimension Tolerance Standard clearance Allowable clearance Replace bushing Shaft Hole 65 0 250 0 350 0 1...

Page 104: ...f tread 43 4 Thickness of tread 23 16 5 Width of flange 14 6 Clearance between shaft and bushing Standard dimension Tolerance Standard clearance Allowable clearance Shaft Hole 40 0 170 0 190 0 301 0 1...

Page 105: ...width 225 5 Width of tread 44 5 6 Width of flange 25 5 7 Clearance between shaft and bushing Standard dimension Tolerance Standard clearance Allowable clearance Replace bushing Shaft Hole 60 0 215 0...

Page 106: ...8 00 10 300 8 PC200 200LC 220 220LC 8M0 300 Undercarriage and frame Track shoe Track shoe 1 a P portion shows the link of bushing press fitting end 1 Triple grouser shoe 2 Road liner 3 Swamp shoe 4 Fl...

Page 107: ...t Repair or replace 105 97 5 Thickness of link metal bushing press fitting portion 28 5 20 5 6 Shoe bolt pitch 160 4 Adjust or replace 7 124 4 8 62 9 Link Inside width 84 8 10 Overall width 45 4 11 Tr...

Page 108: ...een bushing and link Standard dimen sion Tolerance Standard interference Adjust or replace Shaft Hole 59 0 434 0 394 0 074 0 0 320 to 0 434 22 Interference between regular pin and link 38 0 222 0 162...

Page 109: ...SEN06118 00 PC200 200LC 220 220LC 8M0 10 300 11 300 Undercarriage and frame Track shoe...

Page 110: ...SEN06118 00 10 300 12 PC200 200LC 220 220LC 8M0 300 Undercarriage and frame Track shoe Triple grouser shoe Swamp shoe Road liner...

Page 111: ...item Criteria Remedy 1 Height Standard dimension Repair limit Rebuild by build up welding or replace 26 16 2 Thickness 10 8 5 3 Length of base 26 4 Length of base 19 5 Length at tip 20 6 Length at ti...

Page 113: ...20LC 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 10 Structure function and maintenance standard 1 401 Hydraulic...

Page 114: ...travel motor 7 Swing motor 8 Hydraulic pump 9 Control valve 10 Oil cooler 11 L H travel motor 12 L H PPC valve 13 Lock lever 14 Center swivel joint 15 R H PPC valve 16 Travel PPC valve 17 Attachment P...

Page 115: ...SEN06119 00 PC200 200LC 220 220LC 8M0 10 401 3 401 Hydraulic system Part 1 Hydraulic equipment layout drawing...

Page 116: ...2 Oil filler port cap 3 Filter element 4 Strainer 5 Bypass valve 6 Suction strainer 7 Sight gauge Specifications Tank capacity 190 l Amount of oil inside tank 135 l Pressure valve Relief cracking pre...

Page 117: ...SEN06119 00 PC200 200LC 220 220LC 8M0 10 401 5 401 Hydraulic system Part 1 Hydraulic tank and filter...

Page 118: ...SEN06119 00 10 401 6 PC200 200LC 220 220LC 8M0 401 Hydraulic system Part 1 Hydraulic pump Hydraulic pump 1 Model HPV95 95...

Page 119: ...in plug PENF Front control pressure detection port PENR Rear control pressure detection port PEPC EPC basic pressure port PEPCC EPC basic pressure detection port PFC Front pump discharge pressure dete...

Page 120: ...0 200LC 220 220LC 8M0 401 Hydraulic system Part 1 Hydraulic pump 1 Front shaft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12...

Page 121: ...oe 5 constitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil...

Page 122: ...q In this way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston 6 suctions and discharges the oil by the a...

Page 123: ...cylindrical surface rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side M...

Page 124: ...ence between main pump pressure PP and control valve outlet port pressure PLS q Main pump pressure PP pressure PLS called the LS pressure coming from the con trol valve output and pressure PSIG called...

Page 125: ...tor pressure of the EPC valve for the LS valve entering port G also changes the position of spool 6 Setting force of the spring is changed q Before the engine is started servo piston 12 is pushed to t...

Page 126: ...alve q The PC valve is connected to the drain port so the pressure across circuits D and K becomes drain pressure PT The operation of the PC valve is explained later q The pressure at the large diamet...

Page 127: ...ump pressure PP pushes spool 6 to the right q When spool 6 moves main pump pressure PP flows from port C to port D and from port K it enters the large diameter end of the piston q Main pump pressure P...

Page 128: ...be held at the intermediate position Spool 6 will be stopped at a position where the distance of the opening from port D to port E and the dis tance from port C to port D is almost the same q At this...

Page 129: ...ed the engine hose power q If the pump discharge pressure increases due to increased load during operation this valve decreases the pump discharge q And if the pump discharge pressure goes low it incr...

Page 130: ...n where the com bined spool pushing force is balanced by the setting force of springs 4 and 6 as well as the pump pressures PP1 self pressure and PP2 another pump s pressure q The pressure port C pres...

Page 131: ...ush ing piston 2 q Spring load of springs 4 and 6 is also affected by the command current X to PC EPC valve solenoid q Port C of the PC valve is connected to port E of the LS valve q Self pressure PP1...

Page 132: ...are con nected q As a result the pressure on port C rises and the pressure on the large diameter end of the piston also rises Thus the leftward move of servo piston 9 is stopped q Servo piston 9 stop...

Page 133: ...t J enters the large diameter end of servo piston 9 stopping servo piston 9 q If main pump pressure PP2 increases further and spool 3 moves further to the right main pump pressure PP1 flows to port C...

Page 134: ...ncreases further the relationship between average pump pressure PP1 PP2 2 and pump discharge Q is proportional to the force of the PC EPC valve solenoid and moves in parallel q Namely the force of PC...

Page 135: ...is set in between to con trol the current flowing to PC EPC valve sole noid 1 q The current becomes constant so the force pushing piston 2 is also constant q If the main pump pressures PP1 and PP2 are...

Page 136: ...oad is light and is balanced at the position in the figure above q In this case the pressure from port B flows to port C so servo piston 9 moves to the right smaller pump discharge and stops at a posi...

Page 137: ...00 200LC 220 220LC 8M0 10 401 25 401 Hydraulic system Part 1 Hydraulic pump 3 LS PC EPC valve C To LS PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool...

Page 138: ...s sure in proportion to the size of the signal and outputs it to the LS PC valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller...

Page 139: ...rt C and port T are connected q Spool 5 moves up and down so that the pro pulsion force of plunger 7 may be balanced with pressure of port C spring load of spring 4 q The circuit pressure between the...

Page 140: ...em Part 1 Pilot oil filter Pilot oil filter 1 For breaker 1 Filter 2 Case 3 Head cover 4 Relief valve Specifications Rated pressure 6 57 MPa 67 kg cm2 Flow rate 16 l min Relief valve cracking pressure...

Page 141: ...SEN06119 00 PC200 200LC 220 220LC 8M0 10 401 29 401 Hydraulic system Part 1 Pilot oil filter...

Page 143: ...0LC 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 10 Structure function and maintenance stan...

Page 144: ...SEN06120 00 10 402 2 PC200 200LC 220 220LC 8M0 402 Hydraulic system Part 2 Control valve Control valve 1 a In this section only the 7 spool valve 6 spool valve service valve is shown...

Page 145: ...RD P11 From L H work equipment PPC valve arm OUT P12 From L H work equipment PPC valve arm IN P 1 From R H attachment PPC valve P 2 From R H attachment PPC valve PLS1 To rear pump LS valve PLS2 To fro...

Page 146: ...SEN06120 00 10 402 4 PC200 200LC 220 220LC 8M0 402 Hydraulic system Part 2 Control valve...

Page 147: ...LEFT 12 Pressure compensation valve R H travel FORWARD 13 Pressure compensation valve arm IN 14 Main relief valve 15 Unload valve 16 Main relief valve 17 Spool service 18 Spool bucket 19 Spool L H tr...

Page 148: ...SEN06120 00 10 402 6 PC200 200LC 220 220LC 8M0 402 Hydraulic system Part 2 Control valve...

Page 149: ...Suction valve R H travel FORWARD 12 Suction safety valve arm IN 13 LS shuttle valve arm 14 LS shuttle valve R H travel 15 LS selector valve 16 LS shuttle valve boom 17 LS shuttle valve L H travel 18...

Page 150: ...SEN06120 00 10 402 8 PC200 200LC 220 220LC 8M0 402 Hydraulic system Part 2 Control valve...

Page 151: ...valve REVERSE 19 Pressure compensation valve REVERSE Swing valve 20 LS selector valve 21 Pressure compensation valve L H 22 Spool 23 Pressure compensation valve R H Unit mm No Check item Criteria Rem...

Page 152: ...SEN06120 00 10 402 10 PC200 200LC 220 220LC 8M0 402 Hydraulic system Part 2 Control valve...

Page 153: ...ion valve REVERSE Bucket valve 23 LS shuttle valve 24 Pressure compensation valve CURL 25 Spool 26 Suction safety valve CURL 27 Suction safety valve DUMP 28 Pressure compensation valve DUMP Unit mm No...

Page 154: ...service valve 7 spool valve 6 spool valve with service valve q This control valve consists of a 6 spool valve unit type and a set of service valve A merge divider valve a variable back pressure valve...

Page 155: ...influenced by load q Control performance that allows digging even when fine control operation is turned on q Ease of combined operation enabled by the flow divider function that is determined by the...

Page 156: ...alve outlet is constant q LS differential pressure dPLS Pump dis charge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure dPLS is...

Page 157: ...each control valve to balance the load pressure q When actuators are operated in combination the pressure difference dP between the upstream inlet port and downstream outlet port of the spool of each...

Page 158: ...lustration shows the state when actuator 7 is relieved at the stroke end in the merge mode 1 Front pump 2 Rear pump 3 Main relief valve 4 Unload valve 5 Merge divider valve 6 Control valve 7 Actuator...

Page 159: ...SEN06120 00 PC200 200LC 220 220LC 8M0 10 402 17 402 Hydraulic system Part 2 Functions and operation by valve Functions and operation by valve 1 Hydraulic circuit diagram and name of valves...

Page 160: ...om hydraulic drift prevention valve 32 Main relief valve for boom L H travel bucket and attachment circuits Set pressure 35 4 0 3 MPa 360 5 3 kg cm2 When one touch power max switch is set to ON positi...

Page 161: ...p circuit 3 stops at valve 2 and the pressure rises as no relief is available q If this pressure grows larger than the force of spring 5 valve 2 moves to the left q Ports b and c are interconnected an...

Page 162: ...the pump discharge pressure PP and LS pressure PLS do not flow neither to the upstream nor downstream they become approximately the same and LS differential pressure dPLS becomes 0 MPa 0 kg cm2 q As...

Page 163: ...essure q Connected to actuator port B through valve 4 and makes LS pressure C actuator load pressure q In main spool 2 leading hole a with a small diameter also acts as an orifice q LS pressure works...

Page 164: ...ircuit Function q This valve relieves the residual pressure in LS pressure circuit 6 from orifices a and b q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres sure...

Page 165: ...ssure is lower than the load pressure at port c shuttle valve 3 in pressure compensation valve piston 4 interconnects spring chamber E and port C q The force of spring 5 operates piston 4 and valve 2...

Page 166: ...q Since the spool meter in upstream pressure of port A is the pump pressure the spool meter in differential pressure upstream pressure port A pressure downstream pressure port B pressure becomes equiv...

Page 167: ...ream pressure is equal to the maximum load pressure the oil flow is divided in the ratio as same as the opening area ratio q When the area ratio is more than 1 As the spool meter in downstream pressur...

Page 168: ...higher than LS pressure in spring chamber B 1 Main pump 2 Valve 3 Shuttle valve 4 Piston 5 Pressure compensation valve Operation q Shuttle valve 3 is pressed to the right side by the pressure of port...

Page 169: ...0 10 402 27 402 Hydraulic system Part 2 Functions and operation by valve When traveling Structure q Since no holding pressure is generated at port A of the travel circuit a pressure compensation valve...

Page 170: ...Function q The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the cylinder head when the boom is lowered Operation q When the cylinder head pressure...

Page 171: ...ulic system Part 2 Functions and operation by valve When cylinder head pressure is higher than bottom pressure digging operation etc Function q Check valve 6 provided to regeneration circuit C closes...

Page 172: ...en the cylinder head and cylinder bottom increases the oil flow ing to the cylinder bottom pump discharge regeneration flow during arm IN operation in order to accelerate the cylinder Operation q When...

Page 173: ...Hydraulic system Part 2 Functions and operation by valve When cylinder head pressure is lower than bottom pressure Function q Check valve 6 installed to regeneration circuit C closes and shuts off th...

Page 174: ...arm valve 9 Pump merge divider EPC valve for main spool changeover 10 Pump merge divider EPC valve for LS spool changeover Function q This valve merges the pressurized oil P1 and P2 from the two pumps...

Page 175: ...to the control valve which requires the oil q Since drive signal IS2 of the EPC valve for LS spool 3 is also OFF LS spool 3 is pressed to the right by spring 4 As a result ports A and B are interconn...

Page 176: ...disconnected from port F q The pressurized oil from the two pumps are sent to respective control valve groups Pressure P1 To bucket left travel boom Pressure P2 To swing right travel arm q When drive...

Page 177: ...quipment by blocking the high pressure generated during swing operation Operation When pilot pressure BP is shut off q Since pilot pressure BP is shut off piston 3 is pressed to the left by force of s...

Page 178: ...ssure of main pump and provide it for sole noid valves EPC valves etc for use as the control pressure Operation When engine is stopped q Poppet 11 is pressed against the seat by spring 12 so port PR i...

Page 179: ...ure generated across orifice a in spool 14 moves spool 14 in the direc tion that the spool closes the opening between ports P2 and PR q Pressure P2 is reduced to a constant pres sure the set pressure...

Page 180: ...nerated q If pressure PR of the self pressure reducing valve becomes abnormally high ball 16 con tracts spring 15 and separates from the seat q This allows the pressurized oil to flow to drain port TS...

Page 181: ...n solenoid valve thus right and left travel circuits interconnect each other and equal amount of oil is supplied to right and left travel motors to secure straight travel ability q When travel control...

Page 182: ...nction spool 2 is pressed back towards right by the force of spring 1 As a result ports PTL and PTR are intercon nected q If the oil flow rates to the R H and L H travel motors become different from e...

Page 183: ...ve When pilot pressure PST is supplied travel independent q When pilot pressure PST from the travel junction solenoid valve is supplied travel junction spool 2 compresses spring 1 to the left side and...

Page 184: ...at the oil flow rates to respective cylinders are restricted q To limit the travel of the boom arm or bucket spool the pilot pressure from the travel PPC valve passes through the internal circuit of r...

Page 185: ...e 5 is closed As a result stroke limiting signal chamber a and the drain circuit from the travel PPC valve are disconnected q At this time the pilot pressure from the travel PPC valve passes through o...

Page 186: ...1 to prevent the boom from drifting hydraulically Operation In boom RAISE operation q When operating boom RAISE the pressurized oil from the control valve exerts a left hand force on the right side o...

Page 187: ...pilot piston 2 q The holding pressure of boom cylinder bottom exerts a right hand force on the left side of ring shaped area S of which outside diameter is poppet 5 diameter d1 and of which inside di...

Page 188: ...ston 2 q The pressurized oil of the boom cylinder bottom flows from orifice c to drain port T through orifice a and chamber b q Chamber b inside poppet and drain port T are interconnected and the pres...

Page 189: ...f abnormally high pressure is generated in the boom cylinder bottom circuit the pressurized oil in port B opens check valve 1a to actuate safety valve for hydraulic drift prevention valve 2 q The pres...

Page 190: ...e c to drain port T through orifice a and chamber b q Chamber b and drain port T are interconnected and the pressure of chamber b drops q If the pressure in chamber b drops lower than that of port A t...

Page 191: ...ressurized oil that flows in through orifice a in valve 2 and is drained is stopped by pilot piston 1 q The holding pressure of the arm cylinder bottom side exerts a left hand force on the right side...

Page 192: ...b of valve 6 When engine is running during swing or travel operation q The pressurized oil PR from self pressure reducing valve 1 flows to variable back pres sure solenoid valve 3 q Since drive signa...

Page 193: ...ring chamber C of variable back pressure valve 4 is drained through variable back pressure solenoid valve 3 q Only the reaction force of spring 5 pushes valve 6 to the right q Pressure PA of drain cir...

Page 194: ...oad at installed length of spring 1 1st stage set pressure q When the 1st stage set pressure is set correctly the 2nd stage set pressure does not need to be set Setting the 1st stage set pressure comp...

Page 195: ...sure q This valve is set to the low pressure setting when the pilot pressure is applied to it from the attachment circuit selector solenoid valve q ON OFF of the pilot pressure changes the set pressur...

Page 196: ...q Passage B is interconnected to the drain cir cuit via passage C and chamber D When pilot pressure P is supplied low pres sure setting q When pilot pressure P is supplied the pilot pressure is transm...

Page 197: ...SEN06120 00 PC200 200LC 220 220LC 8M0 10 402 55 402 Hydraulic system Part 2 Functions and operation by valve...

Page 199: ...0001 and up PC200LC 8M0 400001 and up PC220 8M0 100001 and up PC220LC 8M0 100001 and up 10 Structure function and maintenance standard 1 403 Hydraulic system Part 3 Swing motor 2 Center swivel joint 1...

Page 200: ...ing RIGHT MB From control valve swing LEFT S From control valve T To hydraulic tank 1 Reverse prevention valve 2 Safety valve Specifications Machine models Item PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC...

Page 201: ...SEN06121 00 PC200 200LC 220 220LC 8M0 10 403 3 403 Hydraulic system Part 3 Swing motor...

Page 202: ...Center shaft 13 Center spring 14 Check valve 15 Shuttle valve Unit mm No Check item Criteria Remedy Standard dimension Repair limit 16 Check valve spring Free length x Outside diameter Installed lengt...

Page 203: ...m control valve swing RIGHT MB From control valve swing LEFT S From control valve T To hydraulic tank 1 Safety valve Specifications Machine models Item PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 Mode...

Page 204: ...SEN06121 00 10 403 6 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 Swing motor...

Page 205: ...Center shaft 13 Center spring 14 Check valve 15 Shuttle valve Unit mm No Check item Criteria Remedy Standard dimension Repair limit 16 Check valve spring Free length x Outside diameter Installed lengt...

Page 206: ...it T q Brake piston 7 is pushed down by brake spring 1 q Disc 5 and plate 6 are pushed together and the brake is applied 2 When solenoid valve is energized Operation q As the swing holding brake solen...

Page 207: ...ing torque is generated in the motor and the motor starts to rotate q The pressurized oil from the outlet port of the motor passes from port MB through the con trol valve 6 and returns to the tank 2 W...

Page 208: ...PA B2 From control valve L H travel REVERSE port C1 To R H travel motor Port PA C2 From control valve R H travel FORWARD port D1 To R H travel motor port PB D2 From control valve R H travel REVERSE po...

Page 209: ...0LC 8M0 10 403 11 403 Hydraulic system Part 3 Center swivel joint Unit mm No Check item Criteria Remedy 8 Clearance between rotor and shaft Standard dimension Standard clearance Allowable clearance Re...

Page 210: ...valve L H travel FORWARD port PB From control valve L H travel REVERSE port R H travel motor PA From control valve R H travel REVERSE port PB From control valve R H travel FORWARD port P From travel s...

Page 211: ...SEN06121 00 PC200 200LC 220 220LC 8M0 10 403 13 403 Hydraulic system Part 3 Travel motor...

Page 212: ...mit 20 Check valve spring Free length x Outside diameter Installed length Load at installed length Free length Load at installed length Replace spring if damaged or deformed 32 5 x 6 5 24 2 7 16 N 0 7...

Page 213: ...e to end cover 8 by pressing check valve 22 is shut off by regulator valve 9 q Fulcrum a of rocker cam 4 is eccentric to the working point b of the combined force of the propulsion force of cylinder 6...

Page 214: ...from the self pressure reducing valve flows to port P q Regulator valve 9 is pushed to the left q The pressurized oil from the control valve passes through passage d in regulator valve 9 and enters r...

Page 215: ...is operated pressurized oil from the pump activates counterbalance valve spool 19 opening the parking brake circuit q The pressurized oil is conducted to chamber e of brake piston 12 and compresses s...

Page 216: ...brake circuit q The pressurized oil in chamber e of brake piston 12 passes through orifice f of brake piston 12 and is drained to the motor case q Brake piston 12 is pushed to the right by spring 11 q...

Page 217: ...weight q If the machine travels with the engine at low speed the motor may rotate without load causing the machine to run away resulting in a very dangerous situation q These valves are used to preven...

Page 218: ...travelling downhill the motor will be caused to rotate without load to decrease the inlet side oil pressure q Pressure in chamber S1 is released through orifices E1 and E2 q As the pressure in chamber...

Page 219: ...en it drops beyond the spool switching pressure spool 19 is returned to the left by spring 20 reducing the pressure at outlet passage B1 q The motor tries to continue rotation resorting to inertial fo...

Page 220: ...ing PPC valve 1 P From self pressure reducing valve P1 L H PPC valve Arm OUT port R H PPC valve Boom LOWER port P2 L H PPC valve Arm IN port R H PPC valve Boom RAISE port P3 L H PPC valve Swing LEFT p...

Page 221: ...SEN06121 00 PC200 200LC 220 220LC 8M0 10 403 23 403 Hydraulic system Part 3 PPC valve...

Page 222: ...10 Centering spring for ports P3 and P4 Standard dimension Repair limit Replace spring if damaged or deformed Free length x Outside diameter Installed length Load at installed length Free length Load...

Page 223: ...port P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at p...

Page 224: ...s supplied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole...

Page 225: ...PC valve 1 PPC Abbreviation for Proportional Pressure Control P From self pressure reducing valve P1 To control valve L H travel REVERSE port P2 To control valve L H travel FORWARD port P3 To control...

Page 226: ...SEN06121 00 10 403 28 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 PPC valve 1 Plate 2 Case 3 Piston 4 Seal 5 Spool 6 Damper...

Page 227: ...Remedy 7 Centering spring Standard dimension Repair limit Replace spring if damaged or deformed Free length x Outside diameter Installed length Load at installed length Free length Load at installed...

Page 228: ...en the pressure at port P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to releas...

Page 229: ...supplied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole...

Page 230: ...6121 00 10 403 32 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 PPC valve Service PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment and swing PPC va...

Page 231: ...on 3 Lever 4 Plate 5 Retainer 6 Body 7 EPC valve Unit mm No Check item Criteria Remedy 8 Centering spring Standard dimension Repair limit Replace spring if damaged or deformed Free length x Outside di...

Page 232: ...ve T To hydraulic tank 1 Body 2 Spool 3 Push pin 4 Coil 5 Plunger 6 Connector Unit mm No Check item Criteria Remedy 7 Return spring Standard dimension Repair limit Replace PPC valve assembly if spring...

Page 233: ...lve Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion q When it receives signal current i from the pump controller it generates the EPC output pres...

Page 234: ...ergized q When there is no signal current flowing from the controller to coil 4 coil 4 is de energized q Spool 2 is pushed to the left by spring 3 q Port C closes and the pressurized oil from the fron...

Page 235: ...il flows from port P to port C q Pressures on port C increases and the force to act on surface a of spool 2 and the spring load on spring 3 become larger than the propulsion force of plunger 5 q Spool...

Page 236: ...n this happens the signal current is at its maximum so the propulsion force of plunger 5 is also at its maximum q Spool 2 is pushed to the left by push pin 6 q The maximum volume of pressurized oil is...

Page 237: ...SEN06121 00 PC200 200LC 220 220LC 8M0 10 403 39 403 Hydraulic system Part 3 PPC valve...

Page 238: ...SEN06121 00 10 403 40 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 PPC valve Service PPC valve 1 a For the details of operation see the paragraph of Work equipment and swing PPC valve...

Page 239: ...2 Piston 3 Lever 4 Plate 5 Retainer 6 Body Unit mm No Check item Criteria Remedy 7 Centering spring Standard dimension Repair limit Replace spring if damaged or deformed Free length x Outside diameter...

Page 240: ...SEN06121 00 10 403 42 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 Valve control Valve control 1...

Page 241: ...el lever 6 R H PPC valve 7 R H work equipment control lever 8 Solenoid block 9 Accumulator 10 Control valve 11 Hydraulic pump 12 Junction box 13 L H work equipment control lever 14 L H PPC valve Lever...

Page 242: ...06121 00 10 403 44 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 Solenoid valve Solenoid valve 1 PPC lock travel junction ATT selector travel speed swing brake and 2 stage relief solenoid valv...

Page 243: ...mulator Operation When solenoid is de energized q Since the signal current does not flow from the controller solenoid 9 is de energized For this reason spool 10 is pushed to the left by spring 12 Sinc...

Page 244: ...121 00 10 403 46 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 PPC accumulator PPC accumulator 1 1 Gas plug 2 Shell 3 Poppet 4 Holder 5 Bladder 6 Oil port Specifications Gas capacity 300 cc fo...

Page 245: ...urn oil filter Return oil filter 1 For breaker 1 Drain plug 2 Filter 3 Case 4 Head cover 5 Relief valve Specifications Rated pressure 6 9 MPa 70 kg cm2 Flow rate 200 l min Relief valve cracking pressu...

Page 246: ...om attachment selector solenoid valve T To hydraulic tank TS To hydraulic tank V To control valve 1 Spool Unit mm No Check item Criteria Remedy 2 Spool return spring Standard dimension Repair limit Re...

Page 247: ...other than breaker is installed q Spool 1 is pressed to the left by the force of spring 2 q Ports ATT and V are interconnected and ports ATT and T are shut off Attachment is thus interconnected to th...

Page 248: ...SEN06121 00 10 403 50 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 Hydraulic cylinder Hydraulic cylinder 1 PC200 8M0 and PC200LC 8M0 Boom cylinder Arm cylinder Bucket cylinder...

Page 249: ...400 to 0 517 1 0 Replace pin and bushing Arm 80 0 030 0 076 0 457 0 370 0 400 to 0 533 1 0 Bucket 70 0 030 0 060 0 424 0 350 0 380 to 0 484 1 0 3 Clearance between cyl inder bottom support shaft and b...

Page 250: ...SEN06121 00 10 403 52 PC200 200LC 220 220LC 8M0 403 Hydraulic system Part 3 Hydraulic cylinder PC220 8M0 and PC220LC 8M0 Boom cylinder Arm cylinder Bucket cylinder...

Page 251: ...400 to 0 517 1 0 Replace pin and bushing Arm 80 0 030 0 076 0 457 0 370 0 400 to 0 533 1 0 Bucket 80 0 030 0 060 0 457 0 370 0 400 to 0 517 1 0 3 Clearance between cyl inder bottom support shaft and...

Page 253: ...C200LC 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 10 Structure function and maintenance s...

Page 254: ...SEN06122 00 10 500 2 PC200 200LC 220 220LC 8M0 500 Work equipment Work equipment Work equipment 1 a The portion B in the figure shows L H boom cylinder...

Page 255: ...and bucket 80 0 030 0 076 0 166 0 086 0 116 to 0 242 1 0 6 Clearance between mounting pin and bushing of link and link 70 0 030 0 076 0 154 0 074 0 104 to 0 230 1 0 7 Connected part of revolving frame...

Page 256: ...1 or 3 0 mm 1 3 L11 Insert the shim 1 5 mm 1 R11 Adjust with combination of shims 0 8 mm 1 and 1 5 mm 2 12 Connected part of arm cylinder and arm 106 1 2 109 3 1 5 0 2 1 to 6 0 Replace shim 2 L12 Inse...

Page 257: ...riterion indicates the L H boom cylinder The shim adjustment place for the R H boom cylinder is opposite to L H 2 Use plastic shim with flange 3 Use iron shim without flange 4 Use the separated iron s...

Page 258: ...ombination of shims 0 8 mm 1 and 1 5 mm 3 R7 Insert the shim 1 5 mm 1 8 1 Connected part of revolving frame and boom cylinder 96 1 2 99 3 1 5 0 2 1 to 6 0 Adjust with shims so that the clear ance is 1...

Page 259: ...15a Connected part of bucket cylinder and link 96 1 2 100 2 0 5 2 5 to 5 9 L15a R15a 15b Connected part of link and link 280 0 0 5 Adjust with shims so that the clear ance is 1 5 mm or below 3 R15b L...

Page 260: ...The purpose of using plastic shim is to reduce the lateral play of work equipment and to pre vent the squeal or galling caused when iron connected parts are rubbed each other q When the plastic shim i...

Page 261: ...pment Type B Shims to adjust play of bucket Outline q The separated iron shims are used for the con nection of arm and bucket q By adjusting the number of shims play at con necting part can be adjuste...

Page 262: ...SEN06122 00 10 500 10 PC200 200LC 220 220LC 8M0 500 Work equipment Dimensions of arm Dimensions of arm 1...

Page 263: ...5 0 0 3 305 5 0 5 0 5 305 5 0 5 0 5 4 90 0 054 0 000 90 0 054 0 000 5 402 1 1 423 9 1 6 187 2 0 5 206 1 0 5 7 829 1 1 918 6 1 8 2 919 3 037 9 2 630 5 1 2 562 6 1 10 410 1 465 1 11 640 0 2 585 0 2 12 6...

Page 264: ...SEN06122 00 10 500 12 PC200 200LC 220 220LC 8M0 500 Work equipment Dimensions of bucket Dimensions of bucket 1...

Page 265: ...ze Tolerance Standard size Tolerance 1 457 6 0 5 442 4 0 5 2 22 0 5 59 2 0 5 3 92 45 97 37 4 458 1 446 3 5 1 477 3 1 540 3 6 158 6 185 6 7 8 15 54 7 48 9 80 0 1 0 1 80 0 1 0 1 10 326 5 1 326 5 1 11 56...

Page 267: ...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 10 Structure function and maintenance standard 1 600 Electr...

Page 268: ...e fuel control dial and sets the engine speed to the speed set by the fuel control dial Engine speed control q The fuel control dial sends a signal voltage cor responding to the rotation angle to the...

Page 269: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 3 600 Electrical system Engine control Component 1 Fuel control dial 1 Knob 2 Dial 3 Spring 4 Ball 5 Potentiometer 6 Connector...

Page 270: ...or q Turning knob 1 rotates the shaft of potentiom eter 5 q The rotation of the shaft changes the resis tance of the variable resistor in potentiometer 5 sending any throttle signal to the engine cont...

Page 271: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 5 600 Electrical system Engine control...

Page 272: ...SEN06123 00 10 600 6 PC200 200LC 220 220LC 8M0 600 Electrical system Engine control Engine controller...

Page 273: ...B 28 NC 29 NC 30 NC 31 NC 32 IMA return C 33 5V electric power supply for sensor A 34 NC 35 NC 36 NC 37 5V electric power supply for sensor A 38 GND C 39 NC 40 NC 41 NC Never connect to NC or malfunc...

Page 274: ...air heater relay drive D 41 NC 42 Electrical intake air heater relay return C 43 NC 44 NC 45 NC 46 CAN E 47 CAN E 48 NC 49 PWM OUTPUT D 50 NC CN CE03 Pin No Signal name Input output 1 GND C 2 NC 3 Ele...

Page 275: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 9 600 Electrical system Engine control Coolant temperature sensor 1 Sensor 2 O ring 3 Connector Oil pressure switch 1 Connector 2 Sensor 3 O ring...

Page 276: ...SEN06123 00 10 600 10 PC200 200LC 220 220LC 8M0 600 Electrical system Engine control Rotation sensor 1 Connector 2 Sensor 3 O ring Boost pressure and temperature sensor 1 Connector 2 Sensor 3 O ring...

Page 277: ...0 PC200 200LC 220 220LC 8M0 10 600 11 600 Electrical system Engine control WIF water in fuel detection sensor 1 Connector 2 Tube 3 Sensor 4 O ring Engine oil level sensor 1 Connector 2 Bracket 3 Float...

Page 278: ...SEN06123 00 10 600 12 PC200 200LC 220 220LC 8M0 600 Electrical system Electrical control system Electrical control system 1 Machine control system diagram...

Page 279: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 13 600 Electrical system Electrical control system...

Page 280: ...SEN06123 00 10 600 14 PC200 200LC 220 220LC 8M0 600 Electrical system Electrical control system 1 Engine and pump composite control function...

Page 281: ...ion torque specified for each mode rotation set by the fuel control dial and actual engine speed 1 Control method in each mode P mode E mode and ATT mode q Matching point q In P E or ATT mode engine s...

Page 282: ...ne torque can be kept at a con stant level along the equal engine horsepower curve 2 Function to control pump during travel q Traveling the machine in P or ATT mode increases engine speed N q Travelin...

Page 283: ...on q Even if any abnormality occurs in the controller or sensor setting emergency pump drive switch 1 to the ON position activates the machine with an absorption torque approxi mately equivalent to th...

Page 284: ...C 220 220LC 8M0 600 Electrical system Electrical control system 2 Pump and valve control function Function q The machine is matched to various types of work properly with the 2 stage relief function t...

Page 285: ...age relief function q The relief pressure in the normal work is 34 8 MPa 355 kg cm2 If the 2 stage relief function is turned on however the relief pressure rises to about 37 2 MPa 380 kg cm2 By this o...

Page 286: ...iod of time e g when digging up a large rock q Pressing the L H knob switch in P E or ATT mode increases a hydraulic force by approxi mately 7 and horsepower by approximately 3 increasing a digging fo...

Page 287: ...y returns to the speed set with the fuel control dial Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec during operation at a engine speed abov...

Page 288: ...n function Function q The engine automatic warm up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts The overheat prevention function...

Page 289: ...d Low idle Monitor alarm lamp Lights up Alarm buzzer Sounds Coolant temperature hydraulic oil temperature Below 105 C Fuel control dial Return to low idle position once Under above condition controlle...

Page 290: ...00 10 600 24 PC200 200LC 220 220LC 8M0 600 Electrical system Electrical control system 6 Swing control function Function The swing lock and swing holding brake function are provided as a swing control...

Page 291: ...t if swinging is stopped on a slope the upper structure may swing by its gravity 2 Quick hydraulic oil warm up function when swing lock switch is turned on q If swing lock switch 2 is turned on the pu...

Page 292: ...rical control system 7 Travel control function Function q The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during t...

Page 293: ...tch stays at Hi If the machine starts traveling on level ground or downhill during operation of the above mentioned function and the travel pressure goes below 14 7 MPa 150 kg cm2 and continues such t...

Page 294: ...s available only with attachment specification q The function acts as follows according to the flow command and working mode from the monitor 1 It throttles the attachment PPC pressure and controls th...

Page 295: ...ch 3 Connector Specifications Type of contacts Normally open contacts Operating ON pressure 0 5 0 1 MPa 5 0 1 0 kg cm2 Resetting OFF pressure 0 3 0 05 MPa 3 0 0 5 kg cm2 Function q The attachment PPC...

Page 296: ...mit it to the pump controller Operation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part the diaphragm is deformed q The deformation in the diap...

Page 297: ...0LC 8M0 10 600 31 600 Electrical system Electrical control system 3 Pump pressure sensor 1 Sensor 2 Connector Operation q The relationship between the pressure applied to sensors P and output voltage...

Page 298: ...SEN06123 00 10 600 32 PC200 200LC 220 220LC 8M0 600 Electrical system Electrical control system 4 Pump controller...

Page 299: ...Back of R H travel oil pressure sensor Input 37 NC 38 Swing brake cancel switch Input 39 Machine select 5 Input 40 Machine select 1 Input 41 Knob SW Input 42 NC 43 Key SW ACC Input 44 NC 45 CAN_H Inp...

Page 300: ...Output 97 Service current EPC Output 98 NC 99 NC 100 NC 101 Swing holding brake SOL Output 102 NC 103 NC 104 PC EPC R Output 105 NC 106 NC 107 Travel alarm Output 108 Battery relay Output 109 2 stage...

Page 301: ...l e Camera signal Function q The monitor system keeps the operator informed of all machine functions by monitor ing the machine conditions by using the sen sors and switches installed in various parts...

Page 302: ...lay q li One of the features of liquid crystal display panels is that there may be black spots spots that do not light up or white spots spots that stay lit up on the screen If there are fewer than 10...

Page 303: ...ff relay for personal code Output 7 NC 8 System operating lamp Input Output 9 Lamp switch Input 10 Starting switch ACC Input 11 Starting switch C Input 12 Preheating Input 13 Engine shutdown secondary...

Page 304: ...NC 15 NC 16 NC 17 NC 18 NC 19 NC 20 NC 070 20P CN CM03 Pin No Signal name Input Output signal Pin No Signal name Input Output signal 1 Camera power supply 8 V Output 2 Camera NTSC signal 1 Input 3 Ca...

Page 305: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 39 600 Electrical system Machine monitor system...

Page 306: ...sage monitor 2 Air conditioner monitor 3 Wiper monitor 4 Swing lock monitor 5 Engine preheating monitor 6 Service meter 7 Auto deceleration monitor 8 Working mode monitor 9 Travel speed monitor 10 Fue...

Page 307: ...8M0 10 600 41 600 Electrical system Machine monitor system 22 Air cleaner clogging monitor 23 Water separator monitor 24 Clock 25 Maintenance due time warning monitor 26 System status monitor 27 Acti...

Page 308: ...If the monitor background appears white warm up the hydraulic components H1 105 Red H2 102 Red H3 100 Blue H4 85 Blue H5 40 Blue H6 20 White 1 Fuel level gauge Range Quantity l Background color Indic...

Page 309: ...depending on the remaining fuel level Min 41 l Lights up Blue 1 Radiator coolant level When abnormal When below specified level Lights up Yellow 3 L01 When failure is detected with the engine stopped...

Page 310: ...he alarm buzzer sounds When action level L01 is detected Lights up Yellow 3 L01 State of engine system When action level L04 or L03 is detected Lights up Red L04 and L03 When failure is detected in th...

Page 311: ...ntenance mode display setting of the service mode 3 Monitor goes out after lighting up for 2 seconds Action level When action level L04 is detected Lights up Red L04 When failure is detected on the ma...

Page 312: ...n ON Lights up Goes out if pressed for 8 5 seconds OFF Lights out Swing lock Swing lock switch Swing brake cancel switch Monitor display Indicates swing lock operating status OFF OFF Lights off ON OFF...

Page 313: ...ouble acting attachment and low fuel consumption operation Displays working mode Travel speed Lo Low speed Mi Middle speed Hi High speed Displays travel speed setting ECO guidance Idle stop guidance G...

Page 314: ...nd low fuel operation 3 Travel speed selector switch Numeric keypad 3 Changes the travel speed Lo lights up Low speed Mi lights up Medium speed Hi lights up High speed Speed is sequentially changed as...

Page 315: ...mperature inside the cab 18 0 C to 32 0 C Setting is available in 0 5 C steps The preset temperature increases immediately after the air conditioner adjustment screen appears 8b Temperature control sw...

Page 316: ...witching to camera screen Switches to camera image display screen Enter Enters selected setting item Background colors allow confirming the type of information transmitted Gray When the condition is n...

Page 317: ...fuel consumption on fuel consumption display screen Saving Saves setting Switching to the name setting screen Switches the current screen to the name setting screen Switching to ATT1 oil flow setting...

Page 318: ...occurring failures list screen Switches to the currently occurring failures list screen Background colors allow confirming the type of information transmitted Red When an action level of L2 L3 or L4...

Page 319: ...ine start lock is set effective W When engine start lock is disabled X When working mode at start is set to Breaker Mode B Category 1 Item Display order 2 V W X Y Z A KOMATSU logo screen 1 1 1 1 1 Pas...

Page 320: ...ed during check before starting Z When a maintenance time overdue is detected for an item a For how to operate the operator mode functions see the Operation and Maintenance Manual or Oper ator mode Ou...

Page 321: ...Items available in the service mode are as follows a For how to operate the service mode functions see section in Testing and adjusting Monitoring Pre defined Monitoring Custom Abnormality Record Mech...

Page 322: ...ither side of a sensor of contact type is always connected to the chassis ground Hydraulic oil level sensor 1 1 Connector 2 Bracket 3 Float 4 Switch Sensor name Type of sensor When normal When abnorma...

Page 323: ...00 PC200 200LC 220 220LC 8M0 10 600 57 600 Electrical system Sensor Fuel level sensor 1 1 Float 2 Connector 3 Cover 4 Variable resistor Air cleaner clogging sensor 1 1 Adapter 2 Hood 3 Indicator 4 Co...

Page 324: ...SEN06123 00 10 600 58 PC200 200LC 220 220LC 8M0 600 Electrical system Sensor Coolant level sensor 1 1 Reserve tank 2 Float 3 Sensor 4 Connector...

Page 325: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 59 600 Electrical system Sensor...

Page 326: ...OMTRAX operator to refer the information and provide various services to the customers q Information transmittable from the KOMTRAX system are as follows 1 Operation map 2 Service meter reading 3 Loca...

Page 327: ...pins Malfunctions or failures may occur Pin No Signal name Input Output signal 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 CAN C _H Input Output 11 CAN C _L Input Output 12 1 13 1 14 External start signal...

Page 328: ...nsmit data via the com munication antenna q The status of the terminal can be checked by using the menu of KOMTRAX setting in the service mode of the machine monitor q Use of KOMTRAX terminal must be...

Page 329: ...SEN06123 00 PC200 200LC 220 220LC 8M0 10 600 63 600 Electrical system KOMTRAX system...

Page 331: ...220 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 20 Standard value table 1 100 Standard service value...

Page 332: ...clearance Normal temperature Intake valve mm 0 25 0 152 to 0 381 Exhaust valve mm 0 51 0 381 to 0 762 Compression pressure Oil temperature 40 to 60 C Compression pressure MPa kg cm2 Min 2 41 Min 24 6...

Page 333: ...e Intake valve mm 0 25 0 152 to 0 381 Exhaust valve mm 0 51 0 381 to 0 762 Compression pressure Oil temperature 40 to 60 C Compression pressure MPa kg cm2 Min 2 41 Min 24 6 1 69 17 2 Engine speed rpm...

Page 334: ...950 100 1 950 100 Speed when auto deceleration is operated Engine at high idle Auto deceleration switch in ON condition All control levers in NEUTRAL condition rpm 1 050 100 1 050 100 Spool stroke Bo...

Page 335: ...asurement circuits relieved Normal relief MPa kg cm2 34 8 1 5 1 2 355 15 12 33 1 to 37 2 338 to 380 Power max MPa kg cm2 37 3 1 5 1 2 380 15 12 36 1 to 39 7 368 to 405 Arm relief Normal relief MPa kg...

Page 336: ...e turns after making initial one turn For measuring posture see Swing 1 sec 24 2 2 5 Max 30 Swing drift on a slope Hydraulic oil temperature Within operating range Engine stopped Keeping upper structu...

Page 337: ...nd 3 mm Max 150 Max 250 Machine drift on a slope Hydraulic oil temperature Within operating range Engine stopped Parking machine on slope of 12 with sprocket facing upslope Sliding distance for 5 minu...

Page 338: ...e end till bucket touches ground For measuring posture see Work equipment 2 RAISE sec 3 3 0 4 Max 4 8 LOWER sec 2 4 0 3 Max 3 7 Arm Hydraulic oil temperature Within operating range Engine running at h...

Page 339: ...until it starts moving again For measuring posture see Work equipment 7 sec Max 1 0 Max 3 6 Internal leakage Cylinders Hydraulic oil temperature Within operating range Engine running at high idle Lea...

Page 340: ...uel control dial take the pump discharge amount and the engine speed at the point of measurement and use them as a base for calculating the pump discharge amount at the specified speed Applicable mode...

Page 341: ...when auto deceleration is operated Engine at high idle Auto deceleration switch in ON condition All control levers in NEUTRAL condition rpm 1 050 100 1 050 100 Spool stroke Boom control valve Engine...

Page 342: ...easurement circuits relieved Normal relief MPa kg cm2 34 8 1 5 1 2 355 15 12 33 1 to 37 2 338 to 380 Power max MPa kg cm2 37 3 1 5 1 2 380 15 12 36 1 to 39 7 368 to 405 Arm relief Normal relief MPa kg...

Page 343: ...after making initial one turn For measuring posture see Swing 1 sec 25 7 2 8 Max 31 Swing drift on a slope Hydraulic oil temperature Within operating range Engine stopped Keeping upper structure tran...

Page 344: ...nd 3 mm Max 150 Max 250 Machine drift on a slopel Hydraulic oil temperature Within operating range Engine stopped Parking machine on slope of 12 with sprocket facing upslope Sliding distance for 5 min...

Page 345: ...d till bucket touches ground For measuring posture see Work equipment 2 RAISE sec 3 4 0 5 0 3 Max 4 7 LOWER sec 2 7 0 3 Max 4 4 Arm Hydraulic oil temperature Within operating range Engine running at h...

Page 346: ...until it starts moving again For measuring posture see Work equipment 7 sec Max 1 0 Max 3 6 Internal leakage Cylinders Hydraulic oil temperature Within operating range Engine running at high idle Lea...

Page 347: ...uel control dial take the pump discharge amount and the engine speed at the point of measurement and use them as a base for calculating the pump discharge amount at the specified speed Applicable mode...

Page 348: ...models Posture of machine for measur ing performance and measurement procedure Control valve spool stroke Swing 1 Overswing time required for starting swing time required to complete turns Swing 2 Swi...

Page 349: ...vice value table Standard value table for chassis related parts Travel 4 Machine drift on a slope Work equipment 1 Hydraulic drift of work equipment Work equipment 2 Boom speed Work equipment 3 Arm sp...

Page 350: ...200 200LC 220 220LC 8M0 100 Standard service value table Standard value table for chassis related parts Work equipment 6 Arm time lag Work equipment 7 Bucket time lag Work equipment 8 Characteristics...

Page 351: ...SEN06125 00 PC200 200LC 220 220LC 8M0 20 100 21 100 Standard service value table Standard value table for chassis related parts...

Page 353: ...g 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 press...

Page 354: ...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 out...

Page 355: ...m2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 2 799 401 2320 Hydraulic tester 1 Pressure gauge 1 MPa 10 kg cm2 Testing fuel pressure F 1 799 101 5002 Hydraulic tester 1 P...

Page 356: ...2 799 401 2701 Differential pressure gauge 1 49 MPa 500 kg cm2 3 799 101 5220 Nipple 4 Size 10 1 25 mm 07002 11023 O ring 4 Testing solenoid valve output pressure N 1 799 101 5002 Hydraulic tester 1...

Page 357: ...ter for S 1 For S8P 799 601 7050 Adapter for SWP 1 For SW6P Does not include 799 601 8000 799 601 7060 Adapter for SWP 1 For SW8P Does not include 799 601 8000 799 601 7010 Adapter for X 1 For X1P Doe...

Page 358: ...troubleshooting List of T boxes and T adapters Removal and installation of engine oil pressure sensor 795 799 6210 Deep socket 1 27 mm deep socket Removal and installation of engine coolant temperatu...

Page 359: ...SEN06127 00 PC200 200LC 220 220LC 8M0 30 101 7 101 Testing and adjusting Part 1 Sketch of special tool Sketch of special tool 1 Socket...

Page 360: ...stroke end 2 Set the fuel control dial in the high idle MAX position and set the working mode in the power mode P 3 Operate the left work equipment control lever to relieve the arm circuit at the IN s...

Page 361: ...o gauge 2 3 Run the engine at middle or higher speed and bleed oil from the hose a Install the connecting parts of the gauge and hose approximately a half and open the self seal on the hose side repea...

Page 362: ...ched scale 5 After finishing measurement remove the measuring tools and return the removed parts 2 Checking with smoke meter A2 1 Insert probe 1 of smoke meter A2 in the outlet of the exhaust pipe and...

Page 363: ...our hand not to move 3 Remove five head cover mounting bolts 6 a After loosening the bolts hold the head cover and blow off the sludge and foreign matters attached around with air so that they do not...

Page 364: ...just the valve clearance according to the fol lowing procedure 1 Insert clearance gauge B2 into the clear ance between rocker arm 12 and cross head 13 2 Loosen locknut 14 and adjust the valve clearanc...

Page 365: ...lts 4 a After loosening the bolts hold the head cover and blow off the sludge and foreign matters attached around with air so that they do not get into the head cover mount ing section 4 Remove head c...

Page 366: ...the injector holder 11 a Tighten the holder mounting bolts alter nately 3 Holder mounting bolt 8 0 8 Nm 0 8 0 08 kgm 14 Connect gauge assembly C2 to adapter C3 a Engine oil if applied thinly to the p...

Page 367: ...k 4 Lightly tighten retainer 9 of fuel inlet con nector 10 3 Retainer 15 5 Nm 1 5 0 5 kgm a Tighten above retainer 11 to the specified torque in step 6 5 Tighten injector holder mounting bolts 13 alte...

Page 368: ...er of the hydraulic pump 2 Install tool and adapter 1 of blowby checker D1 or blowby tool D2 to breather hose 1 and connect gauge 2 3 Start the engine set the working mode in the power mode P and turn...

Page 369: ...e Within oper ating range 1 Open the side cover of the pump room and remove oil pressure pickup plug 1 from the engine oil filter 2 Install nipple 1 of hydraulic tester E1 and con nect hydraulic teste...

Page 370: ...e vent foreign matter from entering it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure from fuel syste...

Page 371: ...c tester F1 and connect them to oil pres sure gauge 2 a Use the oil pressure gauge of 2 5 MPa 25 kg cm2 3 Run the engine at low idle and measure the pressure in the fuel low pressure cir cuit a If the...

Page 372: ...he engine at low idle and measure the pressure in the fuel return circuit a If the pressure in the fuel return circuit is in the following range it is normal k If the engine cannot be started you may...

Page 373: ...29 4 Nm 2 0 to 3 0 kgm 3 Connect tool F4 to tool F5 4 Run the engine and measure the circuit negative pressure at high idle Circuit standard negative pressure Max 50 7 kPa 380 mmHg 5 If the negative p...

Page 374: ...e mechanism Moving valve system q Defect in electrical system 3 Since the common rail fuel injection system controls the injector of each cylinder electroni cally the operator can perform the reduced...

Page 375: ...nd measure the discharge with measuring cylinder G4 a Adjust the route of the test hose so that it will not slacken and put its end in an oil receiving pan a Do not crank the engine for more than 30 s...

Page 376: ...g container 5 Start the engine By using measuring cyl inder G4 measure the return rate for 1 minute with the engine speed at low idle a You may make the measurement for 20 seconds and multiply the mea...

Page 377: ...ing standard value it is normal 5 Remove the tool used after measurement Be sure to restore the machine 3 Joint bolt 24 4 Nm 2 4 0 4 kgm 4 Measuring return rate from injector 1 Open the right engine s...

Page 378: ...fuel is used up or if a fuel circuit part is removed and installed bleed air from the fuel circuit according to the following procedure k Stop the machine on a level ground and lower the work equipme...

Page 379: ...s for fuel leak age a Check mainly around the high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check again from step 2 4 Run t...

Page 380: ...nection of the connector between the engine controller and engine must be done after turning off the starting switch 2 It is prohibited to start the engine when T adapter is inserted or connected for...

Page 381: ...t q Belt pressing force 60 N 6 2 kg Adjusting a If the belt deflection is abnormal adjust it according to the following procedure 1 Loosen bolts 1 and 2 2 Move compressor 3 and bracket 4 together to a...

Page 382: ...he portion A width across flats T 12 7 mm of the tensioner assembly 2 and rotate it to the opposite to the winding up direction to decrease the fan belt 3 tension k Make sure that the wrench is secure...

Page 383: ...maximum reach position and set the bucket tip to the height of the under side of the revolving frame a At this time the front of the upper structure lowers and the rear rises 3 Set dial gauge H to th...

Page 384: ...eel bar 1 and track shoe q Standard maximum clearance a 10 to 30 mm Adjusting a If the track tension is abnormal adjust it according to the following procedure 1 Increasing tension 1 Add grease throug...

Page 385: ...se and then tighten it k Do not loosen the valve more than 1 turn If it is loosened more it may jump out because of the high pressure grease in it 2 To check that the tension is normal run the engine...

Page 386: ...ischarge pressure pickup plug 2 Install nipples J2 and connect oil pressure gauges 1 of hydraulic tester J1 a Use the oil pressure gauge with capacity 60 MPa 600 kg cm2 2 Combination of pump actuator...

Page 387: ...ept turned ON and the relief valve is relieved at high pressure Accordingly keep the swing lock switch turned OFF 5 Measuring swing relief pressure 1 Start the engine set the working mode in the power...

Page 388: ...holder is q Turned to the right the set pres sure is increased q Turned to the left the set pres sure is decreased a Quantity of adjustment per turn of holder Approx 20 5 MPa Approx 209 kg cm2 4 While...

Page 389: ...up plug 1 2 Install nipple K2 and connect oil pressure gauge 1 of hydraulic tester K1 a Use the oil pressure gauge with capacity 6 MPa 60 kg cm2 3 Start the engine set the working mode in the power mo...

Page 390: ...the PC valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously to compare them 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 2 3 a...

Page 391: ...urement remove the measuring tools and return the removed parts 2 Measuring PC EPC valve output pressure 1 Open the side cover of the pump room and remove oil pressure pickup plugs 5 and 6 5 Front PC...

Page 392: ...idth is 4 mm Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance 1 Loosen locknut 9 a Before loosening the locknut make coun ter mark at the adjustmen...

Page 393: ...e them 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 2 3 and 4 q 1 Front pump discharge pressure pickup plug q 2 Rear pump discharge pressure pickup plug q 3 Front LS v...

Page 394: ...is normal 6 After finishing measurement remove the measuring tools and return the removed parts 2 Measurement of LS differential pressure a Measure the pump discharge pressure and LS pressure actuato...

Page 395: ...o be measured with the work equipment and prepare for running track shoe idle q When measuring front circuit Right track shoe q When measuring rear circuit Left track shoe k Since the raised track sho...

Page 396: ...gine at high idle operate the travel speed selector switch and travel lever and measure the output pressure in each case a Measuring condition and method of judgment If the output pressures are the fo...

Page 397: ...knut 11 2 Turn adjustment screw 10 to adjust the differ ential pressure a If the adjustment screw is q Turned to the right the differential pressure is increased q Turned to the left the differential...

Page 398: ...ose again 3 Fit nipple 1 of hydraulic tester N1 and then connect it to oil pressure gauge 2 a Use the oil pressure gauge of 6 MPa 60 kg cm2 a The figure shows the measuring tools con nected to outlet...

Page 399: ...ng solenoid valve output pressure a If the output pressure is as follows the solenoid valve is normal 6 After finishing measurement remove the mea suring tools and return the removed parts Solenoid va...

Page 400: ...ode is selected Left knob switch is ON Signals other than swing single signal are ON Swing single signal is ON OFF Other than above condition Operating condition Operation Work equipment swing and tra...

Page 401: ...e output pressure Testing PPC valve output pressure 1 Connecting points of PPC piping a The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation...

Page 402: ...piping 2 Install adapter P2 and connect the discon nected hoses again 3 Install nipple 1 of hydraulic tester P1 and con nect it to oil pressure gauge 2 a Use the oil pressure gauge of 6 MPa 60 kg cm2...

Page 403: ...ing procedure a The play of the lever terminal must be 0 5 3 mm at a position of 200 mm from the center of lever rotation 1 Remove the work equipment and swing PPC valve assembly 2 Remove bellows 1 3...

Page 404: ...ore the IN stroke end and stop the engine 2 Operate the arm control lever in the IN position q If the lowering speed is increased at this time the cylinder packing is defective q If the lowering speed...

Page 405: ...ver to the LOCK FREE position and measure the lowering distance a Operate the control lever while the starting switch is in the ON position a If the pressure in the accumulator is lost run the engine...

Page 406: ...hydraulic tank removed 2 Turn the starting switch to ON position and set the lock lever to the FREE posi tion and then operate the right and left work equipment control levers forward backward to the...

Page 407: ...t by raising the boom k Take care not to lower the boom 4 Start measuring the oil leakage 30 sec onds after relieving is started and mea sure for 1 minute 5 After finishing measurement return the remo...

Page 408: ...to block the hose side 07379 00640 Flange 06 3 Run the engine at high idle and relieve the bucket circuit by curling the bucket k Take care not to dump the bucket 4 Start measuring the oil leakage 30...

Page 409: ...ock the hose side 07376 70422 Plug 04 4 Run the engine at high idle relieve the travel circuit and measure the oil leakage k Before operating the travel lever check the position and locking direction...

Page 410: ...e installing it to the work equipment In particular the boom cylinder does not move to the lowering stroke end if it is installed to the work equipment 1 Run the engine at low idle for approxi mately...

Page 411: ...air bleeder 2 and check that oil oozes out through the air bleeder 3 After the oil oozes out tighten air bleeder 2 3 Air bleeder 27 5 to 35 3 Nm 2 8 to 3 6 kgm 6 Checking oil level and starting work 1...

Page 412: ...e additional under cover at the rear of the operator s cab Only for the machine equipped with the reinforced type under cover 2 Check the tightening torque of the mounting bolt 2 of the lock plate 1 3...

Page 413: ...SEN06127 00 PC200 200LC 220 220LC 8M0 30 101 61 101 Testing and adjusting Part 1 Adjusting mirrors Adjusting mirrors 1...

Page 414: ...que of mirror stay bolt 3 3 Bolt 15 to 19 6 Nm 1 5 to 2 kgm a If the tightening torque is low the bolts may be dragged If the former is too high the body may be broken 4 Retract the mirror into positi...

Page 415: ...and stay mounting bolts 3 and 4 and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator s seat a Adjust the mirror so that the...

Page 416: ...Adjustment of unretractableble mirrors 1 See the Adjusting mirrors page adjust mirrors c1 and d1 so that the operator can see persons at 1 m around the machine hatched area from the opera tors seat a...

Page 417: ...on the machine monitor in the operator cab If the image displayed on the monitor is out of posi tion remove cover 2 of camera 1 and adjust the installation angle A of the rear view camera 1 Remove cov...

Page 418: ...of camera so that the side line of camera is matched with the corner B of the bracket Angle A 48 2 0 a A part of the machine is displayed on the monitor screen Adjust the camera so that the image of t...

Page 419: ...SEN06127 00 PC200 200LC 220 220LC 8M0 30 101 67 101 Testing and adjusting Part 1 Angle adjustment of rear view camera...

Page 421: ...NUAL 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 30 Testing and adjustin...

Page 422: ...SEN06128 00 30 102 2 PC200 200LC 220 220LC 8M0 102 Testing and adjusting Part 2 Special functions of machine monitor Special functions of machine monitor 1...

Page 423: ...ti information display panel a a If the icon for a function switch is not displayed that function switch is not working Lower part of machine monitor switch portion 1 Numeral 1 input switch Auto decel...

Page 424: ...the configuration of the machine monitor and the others are displayed according to the operation of the switches 1 Ordinary functions Operator mode The information items in this mode are displayed ord...

Page 425: ...p alarm buzzer B Operation of windshield wiper B Operation of window washer B Operation of air conditioner heater B Operation to display camera mode if camera is installed B Operation to display clock...

Page 426: ...hen an overdue maintenance item is dis covered Display pattern A B C D E Display of KOMATSU logo 1 1 1 1 1 Display of inputting password 2 Display of check of breaker mode 2 Display of check before st...

Page 427: ...e engine start lock Those functions are independent from one another a The following screen may be displayed instead of the above Password input screen a If this screen is displayed call the person re...

Page 428: ...isplayed on the screen a The figure shows how air cleaner clogging monitor a warns of clogging on air cleaner Display of maintenance due time over If the check before starting detected a maintenance i...

Page 429: ...eceleration switch is pressed the auto deceleration is changed in the order of ON o OFF o ON a If the auto deceleration is set to ON large monitor a and auto deceleration monitor b are displayed simul...

Page 430: ...components may be damaged q After the breaker mode is selected the screen to confirm the selection of the breaker mode is displayed The buzzer sounds intermittently while this screen is displayed q I...

Page 431: ...er switch is pressed the washer fluid is splashed only while the switch is held down a Even if the window washer switch is pressed the screen display does not change Operation of air conditioner heate...

Page 432: ...ge of cameras 1 and 2 to appear on the right side and which on the left side from Camera in the service mode Operation to display clock and service meter While the standard screen is displayed if F4 i...

Page 433: ...machine is set in a certain operating con dition the ECO Guidance screen is displayed auto matically to urge the operator to perform the energy saving operation a ECO Guidance screen is displayed whe...

Page 434: ...fuel control dial from MAX to a lower position helps reduce fuel consumption a The lamp for the travel partial recommen dation guidance goes out automatically after 10 seconds has passed since it app...

Page 435: ...eturn to standard screen On the Error list screen the following information is displayed a Alarm monitor b Action level 3 digits c Failure code 5 or 6 digits d Failure code name e Message f Telephone...

Page 436: ...e the numeral input switches as follows to display only the service meter section q Switch operations simultaneous 4 1 a There is some time lag in start of the LCD so hold down the switches until the...

Page 437: ...s the entered numbers Restores the standard screen q F6 Validates the entered password a Default password 000000 a If the input password is correct the screen changes to the next screen a If the input...

Page 438: ...password is incorrect the mes sage to request inputting the password again is displayed a Set a new password in 4 to 6 digits a password of 3 or less digits or 7 or more digits is not accepted After...

Page 439: ...F3 Moves to lower item q F4 Moves to upper item q F5 Returns the display to the standard screen operator mode q F6 Validates the selection a If you input a 2 digit code by using the numeral input swit...

Page 440: ...ing Pre defined on the Ser vice Menu screen 2 Check of monitoring pre defined information After the Monitoring Pre defined screen is displayed you can check the items displayed in the troubleshooting...

Page 441: ...7 Coolant temperature C ENG 3 36400 Rail pressure MPa ENG 4 36200 Rail pressure command MPa ENG 5 18500 Boost temperature C ENG 6 37400 Ambient pressure kPa ENG Support screen 3 7 F R pumps basic item...

Page 442: ...screen 6 7 PPC pressure No ID Item name Unit SI Applicable equip ment 1 01002 Engine speed r min ENG 2 09002 Swing Right PPC pressure MPa PUMP 3 09001 Swing Left PPC pressure MPa PUMP 4 07300 Bucket...

Page 443: ...ce in this order Pressing F1 induces the sequential switching in the reverse order a Selection with function switches Select an applicable equipment using F1 or F2 and select an item using F3 or F4 an...

Page 444: ...ased with the function switches q F4 Selects hold or its releasing If hold is selected a diagonal line is dis played on the HOLD portion q F5 Returns the display to monitoring selection menu screen 6...

Page 445: ...the screen that confirms whether you want to display the once saved item a When you saved an item you can display it as may times as you want until it is deleted a If you save an item when another it...

Page 446: ...V ENG 36501 Charge pressure sensor volt V V V ENG 17500 Engine power mode ENG 31701 Throttle Position ENG 31706 Final throttle position ENG 18600 Inject fueling command mg st mg st mg st ENG 36200 Rai...

Page 447: ...ntroller Output 2 PUMP 04402 Hydr temp sensor volt V V V PUMP 01602 2nd Eng Speed Command PUMP 13113 Main Pump Absorb Torque Nm kgm lbft PUMP 15900 Boom Bottom Pressure MPa kg cm2 psi PUMP 01900 Press...

Page 448: ...230 Pump controller prog P N PUMP 20212 PUMP 04300 Battery charge volt V V V MON 04200 Fuel level sensor volt V V V MON 04500 Monitor Input 1 Key switch ON OFF MON Start ON OFF MON Preheating ON OFF M...

Page 449: ...al fuel consumption ratio Since it is a theoretical value there is some differences between the actual fuel consumption ratio 04505 Monitor 3rd 4th Row Switches SW7 ON OFF MON SW8 ON OFF MON SW9 ON OF...

Page 450: ...ality record screen the following information is dis played a Occurrence order of abnormalities from latest one Total number of abnormalities in the log b Failure codes c Detail of failure d Number of...

Page 451: ...reen On the Electrical Systems abnormality record screen the following information is displayed a Occurrence order of abnormalities from latest one Total number of abnormalities in the log b Failure c...

Page 452: ...Select the item to be cleared by using F3 or F4 and press F6 a To clear all items together Press F2 and all the items are cleared regardless of selection of the items a If E is displayed on the left o...

Page 453: ...itches q F1 Moves to the next page screen q F2 Moves to the previous page screen q F3 Moves to lower item q F4 Moves to upper item q F5 Returns the display to the service menu screen a You may enter a...

Page 454: ...nter it by using F6 a The following items can be selected on the Maintenance Mode Setting screen 3 Contents of Maintenance Mode Change After selecting Maintenance Mode Change and the screen is display...

Page 455: ...creen q F6 Enters selection and returns to the Maintenance Mode Setting screen 5 Setting of each maintenance item After selecting each maintenance item to dis play its setting screen perform the setti...

Page 456: ...creen a After entering the selection with the F6 key return to the Maintenance Mode Set ting screen by pressing F5 and the set ting will be made a If the set value of an item of which mainte nance rem...

Page 457: ...to left position if not blank q F4 Moves to right position if not blank q F5 Resets input digit Returns the dis play to the service menu screen q F6 Confirms input q Up to 14 digits can be input from...

Page 458: ...previous key off The mode selected the last time is displayed when the starting switch is set to the ON posi tion q F3 Moves to lower item q F4 Moves to upper item q F5 Cancels the selection and retu...

Page 459: ...tachment Use the menu of Default to check or change vari ous settings of the machine monitor and machine Use the sub menu of With Without Attachment to configure attachment setting when the attachment...

Page 460: ...the Service Menu screen 3 Selection of camera setting After the Camera screen for setting is dis played select the setting by using the function switches q Without Attachment Camera is not selected q...

Page 461: ...monitor a If the camera is installed check that the right and left portions of the displayed image are correct a If two or more cameras are connected be sure to configure them from camera 1 in order...

Page 462: ...F4 Selects hold or release If hold is selected a diagonal line is dis played on the HOLD portion q F5 Returns to the testing screen q F6 Validates the selection a This operation may be performed while...

Page 463: ...d the following phenomena occur 1 The engine speed lowers 2 The value quantity of final injection com mand increases q If the engine is running near the full speed however the engine speed may not low...

Page 464: ...The sub menu of Pump Absorption Torque R is used to finely adjust the absorption torque of the rear hydraulic pump 1 Selecting the menu Select Adjustment on the Service Menu screen 2 Selecting sub me...

Page 465: ...machine monitor The sub menu of Low Speed is used to finely adjust the travel speed at Low setting 1 Selecting the menu Select Adjustment on the Service Menu screen 2 Selecting sub menu After the Adj...

Page 466: ...hine with the machine monitor The sub menu of Attachment Flow Adjustment allows for fine adjustment of the oil flow to the attachment during combined operation 1 Selecting the menu Select Adjustment o...

Page 467: ...the engine controller is available The following screen is displayed during the communication After checking the communication the mes sage to ask if no injection cranking should be performed appears...

Page 468: ...not normal q Engine was started before the message No injection cranking is available appears on the screen KOMTRAX Settings Terminal Status The setting and operating status of KOMTRAX can be checked...

Page 469: ...Status is used to check the positioning and communication status of the KOMTRAX terminal 1 Selecting the menu Select KOMTRAX Settings on the Service Menu screen 2 Selecting sub menu After the KOMTRAX...

Page 470: ...ion switches or numeral input switches a Select this sub menu as in the case of selecting a menu on the Service Menu screen 3 Modem status displayed IP addresses 2 addresses of the modem are displayed...

Page 471: ...n it is received with the machine monitor in the operator mode 3 Displaying message message with return mail function If a message provides the Numeric Input line under the text input a proper number...

Page 473: ...200 8M0 400001 and up PC200LC 8M0 400001 and up PC220 8M0 100001 and up PC220LC 8M0 100001 and up 30 Testing and adjusting 1 103 Testing and adjusting Part 3 Handling voltage circuit of engine control...

Page 474: ...efore disconnecting or connecting a connec tor between the engine controller and engine be sure to turn the starting switch OFF 2 If a T adapter is inserted in or connected to a connector between the...

Page 475: ...ors according to the follow ing procedure a Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below 1 Machine monitor 1 Remove the screws three p...

Page 476: ...ng connectors CE01 and CE02 tighten the screws to the spec ified torque 3 Screw 3 1 Nm 0 3 0 1 kgm 3 Pump controller 1 Slide the operator s seat and seat stand to the forward end 2 Remove the 5 mounti...

Page 477: ...3 Remove the two mounting bolts one fas tener and magazine box 10 4 Remove the three mounting bolts and cover 11 5 Remove the seven mounting bolts and cover 14 6 Connect troubleshooting T adapters to...

Page 478: ...emoval and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor See Tools for test ing adjusting and troubleshooting 7 Supply p...

Page 479: ...for connecting connector Take care not to connect the connector reversely Engage lock e on the wiring harness side with triangular notch f on the sensor side Do not engage lock e with square guide g...

Page 480: ...d value does not change The diode does not have continuity Defective q The indicated value changes The diode has continuity Normal Note In the case of a silicon diode a value in the range from 460 to...

Page 481: ...and adjusting Part 3 Handling battery disconnect switch Handling battery disconnect switch 1 1 Pull out switch key 1 whenever you have turned the battery disconnect switch OFF k A serious accident ca...

Page 482: ...aulic oil When necessary T Damper case oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical equipment system fau...

Page 483: ...SEN06129 01 PC200 200LC 220 220LC 8M0 30 103 11 103 Testing and adjusting Part 3 Pm Clinic service Items related to engine...

Page 484: ...SEN06129 01 30 103 12 PC200 200LC 220 220LC 8M0 103 Testing and adjusting Part 3 Pm Clinic service Items related to oil pressure...

Page 485: ...850 to 2 050 6 Blow by pressure kPa mmH2O Max 0 98 Max 100 1 96 200 7 Engine speed ON OFF All levers in neutral rpm 950 to 1 050 950 to 1 050 No Check item Condition for check Unit Standard value for...

Page 486: ...S valve Right track driven idle Lever moved halfway E1 E2 Left track driven idle Lever moved halfway E1 E2 6 Swing motor safety valve Swing lock Right swing relief F F Swing lock Left swing relief F F...

Page 487: ...60K 60K 60K Fuel control dial Work ing mode Left knob switch Operation of work equipment F pump main R pump main F pump F R pump R LS EPC 9 PC EPC F valve PC EPC R valve MIN P OFF All levers in neutr...

Page 488: ...850 to 2 050 6 Blow by pressure kPa mmH2O Max 0 98 Max 100 1 96 200 7 Engine speed ON OFF All levers in neutral rpm 950 to 1 150 950 to 1 150 No Check item Condition for check Unit Standard value for...

Page 489: ...S valve Right track driven idle Lever moved halfway E1 E2 Left track driven idle Lever moved halfway E1 E2 6 Swing motor safety valve Swing lock Right swing relief F F Swing lock Left swing relief F F...

Page 490: ...60K 60K 60K Fuel control dial Work ing mode Left knob switch Operation of work equipment F pump main R pump main F pump F R pump R LS EPC 9 PC EPC F valve PC EPC R valve MIN P OFF All levers in neutr...

Page 491: ...SEN06129 01 PC200 200LC 220 220LC 8M0 30 103 19 103 Testing and adjusting Part 3 Pm Clinic service...

Page 493: ...AL 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 40 Troubleshooting 1 100...

Page 494: ...ix Damper Abnormality MON L01 Electrical system 879GKX Refrigerant Abnormality MON L01 Electrical system 989L00 Engine Controller Lock Caution1 MON Electrical system 989M00 Engine Controller Lock Caut...

Page 495: ...ystem CA238 Ne Speed Sens Supply Volt Error ENG L01 Electrical system CA271 IMV PCV1 Short Error ENG L03 Electrical system CA272 IMV PCV1 Open Error ENG L03 Electrical system CA322 Inj 1 L 1 Open Shor...

Page 496: ...553 Rail Press High Error ENG L01 Electrical system CA559 Rail Press Low Error ENG L01 Electrical system CA689 Eng Ne Speed Sensor Error ENG L01 Electrical system CA731 Eng Bkup Speed Sens Phase Error...

Page 497: ...p Con MON L03 Electrical system DAF0MB Monitor ROM Abnormality MON Electrical system DAF0MC Monitor Error MON Electrical system DAF8KB Camera Power Supply Short Circuit MON L03 Electrical system DAF9K...

Page 498: ...system DHSGMA Travel FW R PPC Press Sensor Abnormality PUMP L01 Electrical system DHSHMA Travel BW L PPC Press Sensor Abnormality PUMP L01 Electrical system DHSJMA Travel BW R PPC Press Sensor Abnorm...

Page 499: ...R Sol Short Circuit PUMP L03 Electrical system DXE0KA LS EPC Sol Open Circuit PUMP L01 Electrical system DXE0KB LS EPC Sol Short Circuit PUMP L01 Electrical system DXE4KA Attachment Flow EPC Open Circ...

Page 500: ...p controller KOMTRAX KOMTRAX terminal a The failure codes that do not have numbers in the action level columns are not displayed on the stan dard screen even when a failure related to them occurs They...

Page 501: ...perated in emergency Swing holding brake solenoid valve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oil pressure lock solenoid valve Sta...

Page 502: ...SEN06131 00 Fuse locations 40 100 10 PC200 200LC 220 220LC 8M0 100 Failure code table and fuse locations Locations of fusible links Location of fuse box and fuse Nos...

Page 503: ...Fuse locations SEN06131 00 PC200 200LC 220 220LC 8M0 40 100 11 100 Failure code table and fuse locations...

Page 505: ...0 General Information on troubleshooting Symptom and troubleshooting numbers 2 Sequence of events in troubleshooting 4 Checks before troubleshooting 6 Classification and procedures for troubleshooting...

Page 506: ...anhours parts or oil or grease and at the same time will also lose the confidence of the user or operator For this reason when performing troubleshoot ing it is necessary to perform thorough prior in...

Page 507: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 3 200 General Information on troubleshooting Symptom and troubleshooting numbers...

Page 508: ...200 General Information on troubleshooting Sequence of events in troubleshooting 40 200 4 PC200 200LC 220 220LC 8M0 SEN06132 01 Sequence of events in troubleshooting Rev 2011 7...

Page 509: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 5 200 General Information on troubleshooting Sequence of events in troubleshooting...

Page 510: ...9 Check of fuel pre filter Replace 10 Check of fuel main filter Replace 11 Check of level in oil pan and type of engine oil Between H L Refilling 12 Check of coolant level in sub tank Between H L Ref...

Page 511: ...ing of wiring harness Repair 8 Check of grounding Repair 9 Check for loose connector and damaged lock Repair or replace 10 Check of connector pin for corrosion bends and deformation Repair or replace...

Page 512: ...and an electrical system failure code with the abnormality record function of the machine monitor See 1 1 If a code is recorded carry out troubleshooting for the Display of code corresponding to the...

Page 513: ...to the Abnormality Record screen 7 Enter the Electrical System Abnormality Record screen similarly to steps 2 and 3 8 Press the F3 switch R on the panel switch to see if the next failure code is displ...

Page 514: ...excessive S 10 15 Oil is in coolant or coolant spurts back or coolant level goes down S 11 16 Oil pressure drops S 12 17 Oil level rises coolant or fuel in oil S 13 18 Coolant temperature rises too hi...

Page 515: ...drift on a slope is large E 21 H 27 Symptom is related to machine monitor 55 When starting switch is turned to ON position machine monitor dis plays nothing E 3 56 When starting switch is turned ON be...

Page 516: ...lumn is the actual cause of the failure q If the check result shows no failure and unless otherwise specified proceed to the next step next cause item q If a defect is found and repaired check that th...

Page 517: ...rs Example T C Torque Converter 2 Different connector number at male and female sides Example BREAK OUT E24 q The circuit diagram contains the destination or source of the branch line in a wiring harn...

Page 518: ...W 9 CE01 DRC 60 Engine controller AG 1 CE02 DRC 50 Engine controller AF 1 CE03 DTP 4 Engine controller AG 1 CK01 070 18 KOMTRAX communication module X 7 CK02 070 12 KOMTRAX communication module X 7 C...

Page 519: ...tance AH 1 L01 DT 2 Working lamp Boom E 8 L02 DT 2 Right headlamp F 9 L03 M 2 Room lamp T 9 L05 SWP 2 Intermediate connector AC 8 L09 DT 2 Rear working lamp Rear working lamp specification L15 DT 2 Ro...

Page 520: ...coolant level switch L 3 P25 AMP 3 F pump pressure sensor J 9 P26 AMP 3 R pump pressure sensor J 9 P31 2 Air conditioner daylight sensor O 6 P44 DT 2 Engine oil level sensor AH 8 P47 DT 2 Water in fue...

Page 521: ...ving frame ground S 1 T06 Terminal 1 Revolving frame ground T 1 T07 Terminal 1 Revolving frame ground T 1 T08 Terminal 1 Ground B 8 T09 Terminal 1 Revolving frame ground T 1 T10 Terminal 1 Revolving f...

Page 522: ...200 General Information on troubleshooting Connector list and layout 40 200 18 PC200 200LC 220 220LC 8M0 SEN06132 01 Layout of connector 1 6...

Page 523: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 19 200 General Information on troubleshooting Connector list and layout 2 6...

Page 524: ...200 General Information on troubleshooting Connector list and layout 40 200 20 PC200 200LC 220 220LC 8M0 SEN06132 01 3 6...

Page 525: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 21 200 General Information on troubleshooting Connector list and layout 4 6...

Page 526: ...200 General Information on troubleshooting Connector list and layout 40 200 22 PC200 200LC 220 220LC 8M0 SEN06132 01 5 6...

Page 527: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 23 200 General Information on troubleshooting Connector list and layout 6 6...

Page 528: ...nnector pin numbers 40 200 24 PC200 200LC 220 220LC 8M0 SEN06132 01 Connection table for connector pin numbers Rev 2009 04 a The terms of male and female refer to the pins while the terms of male hous...

Page 529: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 25 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 530: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 26 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 531: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 27 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 532: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 28 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 533: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 29 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 534: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 30 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 535: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 31 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 536: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 32 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 537: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 33 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 538: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 34 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 539: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 35 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 540: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 36 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 541: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 37 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 542: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 38 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 543: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 39 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 544: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 40 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 545: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 41 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 546: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 42 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 547: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 43 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 548: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 44 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 549: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 45 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 550: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 46 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 551: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 47 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 552: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 48 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 553: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 49 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 554: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 50 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 555: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 51 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 556: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 52 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 557: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 53 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 558: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 54 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 559: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 55 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 560: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 56 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 561: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 57 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 562: ...200 General Information on troubleshooting Connection table for connector pin numbers 40 200 58 PC200 200LC 220 220LC 8M0 SEN06132 01...

Page 563: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 59 200 General Information on troubleshooting Connection table for connector pin numbers...

Page 564: ...NDIX MS 14 MS 14P q 799 601 3470 Case q 799 601 2710 Adapter for MIC 5 MIC 5P q q q 799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 601 2740 Adapt...

Page 565: ...q 799 601 9070 Adapter for DT Black 8 DT8B q q 799 601 9080 Adapter for DT Green 8 DT8G q q 799 601 9090 Adapter for DT Brown 8 DT8BR q q 799 601 9110 Adapter for DT Gray 12 DT12GR q q 799 601 9120 Ad...

Page 566: ...il pressure 3 1 2 3 L q q 799 601 4230 Socket for engine CRI T3 Air intake pressure temperature 4 1 2 3 4 C q q 799 601 4240 Socket for engine CRI T3 PAMB 3 1 2 3 A q q 799 601 4250 Socket for engine...

Page 567: ...e pressure sensor connector so that their polarities match these of the sensor a If measured value is infinite take measurements by applying the probes of opposite polarities and record the finite val...

Page 568: ...ocations see circuit diagram related to each failure code Sensor Measuring location at sen sor pin Measured internal resis tance of sensor reference Remarks Charge pressure sen sor R2 between 2 and 4...

Page 569: ...SEN06132 01 PC200 200LC 220 220LC 8M0 40 200 65 200 General Information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system...

Page 571: ...ntilating 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...

Page 572: ...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...

Page 573: ...Circuit a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the machine the air conditioner controller or air conditioner unit must be replaced Failu...

Page 574: ...ee chapter 80 Others Failure code 879DKZ Sunlight Sensor Open or Short Circuit Failure code 879EMC Ventilation Damper Abnormality See chapter 80 Others Failure code 879EMC Ventilation Damper Abnormali...

Page 575: ...etected Factor 1 Action of controller q None in particular q If cause of failure disappears machine becomes normal by itself Problem on machine q Engine cannot be started Related information q If this...

Page 576: ...ecomes normal by itself Problem on machine q Engine cannot be started Related information q If this failure code is generated after machine monitor is replaced user password must be changed to one bef...

Page 577: ...s detected Factor 3 Action of con troller q Tries automatic recovery q If cause of failure disappears machine becomes normal by itself Problem on machine Related infor mation q Method of reproducing f...

Page 578: ...re code Start engine Cause Procedure measuring location criteria and remarks 1 Clogged air cleaner when system is normal Air cleaner may be clogged Check it for clogging and then clean or replace if c...

Page 579: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 9 301 Troubleshooting by failure code Part 1 Failure code AA10NX Air Cleaner Clogging Circuit diagram related to air cleaner clogging...

Page 580: ...to connector E12 3 Start engine Between E12 1 and ground Engine speed Medium or higher Voltage 27 5 to 29 5 V 3 Defective diode 1 Turn starting switch to OFF position 2 Disconnect diode D01 and connec...

Page 581: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 11 301 Troubleshooting by failure code Part 1 Failure code AB00KE Charge Voltage Low Electrical diagram related to charging cricuit...

Page 582: ...ine q If machine is operated as it is engine may be damaged Related infor mation q Signal from engine oil pressure switch is input to engine controller If engine oil pressure switch is determined to b...

Page 583: ...Code 04501 Monitor input 2 q Method of reproducing failure code Start engine Cause Procedure measuring location criteria and remarks 1 Engine oil level low when system works properly Check engine oil...

Page 584: ...is engine may seize up Related infor mation q Signal voltage of engine coolant temperature sensor is input to engine controller that transmits in formation to machine monitor through CAN communication...

Page 585: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 15 301 Troubleshooting by failure code Part 1 Failure code B BCNS Eng Water Overheat...

Page 586: ...rn starting switch to ON position Cause Procedure measuring location criteria and remarks 1 Lowered radiator coolant level when system works properly Check radiator sub tank for lowering of coolant le...

Page 587: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 17 301 Troubleshooting by failure code Part 1 Failure code B BCZK Radiator Coolant Level Low Circuit diagram related to radiator coolant level switch...

Page 588: ...onents may be damaged Related information q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit ted to machine monitor through CAN communication system...

Page 589: ...r failure code is displayed perform troubleshooting for it 2 Perform troubleshooting for failure code CA441 Action level Failure code Failure Engine Ne and Bkup speed sensor Error Engine controller sy...

Page 590: ...2 Defective sensor power supply 2 line If failure code CA227 is also displayed perform troubleshooting for it first 3 Defective boost pressure tem perature sensor 1 Turn starting switch to OFF positio...

Page 591: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 21 301 Troubleshooting by failure code Part 1 Failure code CA122 Chg Air Press Sensor High Error Circuit diagram related to charge pressure sensor...

Page 592: ...escriptions of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective power supply system of cha...

Page 593: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 23 301 Troubleshooting by failure code Part 1 Failure code CA123 Chg Air Press Sensor Low Error Circuit diagram related to charge pressure sensor...

Page 594: ...n starting switch to OFF position 2 Disconnect connector P20 and connect T adapters to male side Between P20 male 1 and 3 Resistance 4 0 to 6 0 kz Between P20 male 2 and 3 Resistance 0 25 to 5 0 kz Be...

Page 595: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 25 301 Troubleshooting by failure code Part 1 Failure code CA131 Throttle Sensor High Error Circuit diagram related to throttle sensor...

Page 596: ...sor 1 Turn starting switch to OFF position 2 Disconnect connector P20 and connect T adapters to male side Between P20 male 1 and 3 Resistance 4 0 to 6 0 kz Between P20 male 2 and 3 Resistance 0 25 to...

Page 597: ...e controller If no failure is found by above checks engine controller is defective Since this is an internal defect troubleshooting cannot be performed q Reference 1 Turn starting switch to OFF positi...

Page 598: ...us not usable for checking open circuit not designed as a T adapter Cause Procedure measuring location criteria and remarks 1 Defective wiring harness connec tor See descriptions of wiring harness and...

Page 599: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 29 301 Troubleshooting by failure code Part 1 Failure code CA144 Coolant Temp Sens High Error Circuit diagram related to coolant temperature sensor...

Page 600: ...ecks before troubleshooting of General information on troubleshoot ing and check them 2 Defective coolant temperature sensor 1 Turn starting switch to OFF position 2 Disconnect connector COOLANT TEMP...

Page 601: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 31 301 Troubleshooting by failure code Part 1 Failure code CA145 Coolant Temp Sens Low Error Circuit diagram related to coolant temperature sensor...

Page 602: ...n circuit not designed as a T adapter q This failure code is displayed if temperature sensor connector is disconnected Cause Procedure measuring location criteria and remarks 1 Defective wiring harnes...

Page 603: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 33 301 Troubleshooting by failure code Part 1 Failure code CA153 Chg Air Temp Sensor High Error Circuit diagram related to charge temperature sensor...

Page 604: ...rness and connectors in c Electrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective charge temperature sen sor 1 Turn starting switch...

Page 605: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 35 301 Troubleshooting by failure code Part 1 Failure code CA154 Chg Air Temp Sensor Low Error Circuit diagram related to charge temperature sensor...

Page 606: ...gine stops Related infor mation q Boost temperature can be checked with monitoring function Code 18500 Boost temperature q Method of reproducing failure code Start engine Cause Procedure measuring loc...

Page 607: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 37 301 Troubleshooting by failure code Part 1 Failure code CA155 Chg Air Temp High Speed Derate...

Page 608: ...ng harness and connectors in c Electrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective sensor or wiring harness 1 Turn starting swit...

Page 609: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 39 301 Troubleshooting by failure code Part 1 Failure code CA187 Sens Supply 2 Volt Low Error Circuit diagram related to sensor power supply 2...

Page 610: ...supply 1 system If failure code CA352 or CA386 is displayed simultaneously perform trou bleshooting for it first 3 Defective ambient pressure sensor 1 Turn starting switch to OFF position 2 Disconnec...

Page 611: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 41 301 Troubleshooting by failure code Part 1 Failure code CA221 Ambient Press Sens High Error Circuit diagram related to ambient pressure sensor...

Page 612: ...52 or CA386 is also displayed perform troubleshooting for it first 1 Turn starting switch to OFF position 2 Disconnect connector AMB AIR PRESSURE and connect T adapter to female side 3 Turn starting s...

Page 613: ...r input voltage to engine controller a If no failure is found by checks on causes 1 to 5 and check result of cause 6 is abnormal sensor is defective 1 Turn starting switch to OFF position 2 Insert T a...

Page 614: ...cedure measuring location criteria and remarks Perform troubleshooting for failure code CA187 Action level Failure code Failure Engine Overspeed Engine controller system CA234 Detail of failure q Engi...

Page 615: ...ng location criteria and remarks 1 Defective wiring harness connec tor See descriptions of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General informati...

Page 616: ...onnector CP3 PUMP REGULATOR 3 Turn starting switch to ON position If failure code changes from CA271 to CA272 supply pump actuator is defective 3 Short circuit or ground fault in wir ing harness 1 Tur...

Page 617: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 47 301 Troubleshooting by failure code Part 1 Failure code CA271 IMV PCV1 Short Error Circuit diagram related to IMV PCV1...

Page 618: ...connec tor See descriptions of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective supply pum...

Page 619: ...SEN06133 00 PC200 200LC 220 220LC 8M0 40 301 49 301 Troubleshooting by failure code Part 1 Failure code CA272 IMV PCV1 Open Error Circuit diagram related to IMV PCV1...

Page 621: ...ror 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...

Page 622: ...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 Su...

Page 623: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 3 302 Troubleshooting by failure code Part 2...

Page 624: ...adapters to female side Between ECM female 45 and 53 Resistance Max 2 z Between ECM female 45 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con tact of...

Page 625: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 5 302 Troubleshooting by failure code Part 2 Failure code CA322 Inj 1 L 1 Open Short Error Circuit diagram related to injector 1...

Page 626: ...connect T adapters to female side Between ECM female 46 and 60 Resistance Max 2 z Between ECM female 46 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con...

Page 627: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 7 302 Troubleshooting by failure code Part 2 Failure code CA323 Inj 5 L 5 Open Short Error Circuit diagram related to injector 5...

Page 628: ...T adapters to female side Between ECM female 55 and 52 Resistance Max 2 z Between ECM female 55 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con tact o...

Page 629: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 9 302 Troubleshooting by failure code Part 2 Failure code CA324 Inj 3 L 3 Open Short Error Circuit diagram related to injector 3...

Page 630: ...nect T adapters to female side Between ECM female 57 and 59 Resistance Max 2 z Between ECM female 57 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con ta...

Page 631: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 11 302 Troubleshooting by failure code Part 2 Failure code CA325 Inj 6 L 6 Open Short Error Circuit diagram related to injector 6...

Page 632: ...t T adapters to female side Between ECM female 54 and 51 Resistance Max 2 z Between ECM female 54 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con tact...

Page 633: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 13 302 Troubleshooting by failure code Part 2 Failure code CA331 Inj 2 L 2 Open Short Error Circuit diagram related to injector 2...

Page 634: ...t T adapters to female side Between ECM female 56 and 58 Resistance Max 2 z Between ECM female 56 and ground Resistance Min 100 kz 4 Open circuit in wiring harness wire breakage or defective con tact...

Page 635: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 15 302 Troubleshooting by failure code Part 2 Failure code CA332 Inj 4 L 4 Open Short Error Circuit diagram related to injector 4...

Page 636: ...a Action of con troller q None in particular Problem on machine q Engine may run normally or engine is stopped and cannot be restarted Related infor mation q Method of reproducing failure code Turn st...

Page 637: ...Restricts engine output and allows engine to run Problem on machine q Exhaust gas becomes black q Combustion becomes irregular q Engine output lowers q Engine cannot be started Related infor mation q...

Page 638: ...of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective sensor or wiring harness 1 Turn start...

Page 639: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 19 302 Troubleshooting by failure code Part 2 Failure code CA352 Sens Supply 1 Volt Low Error Circuit diagram related to sensor power supply 1...

Page 640: ...ler system L03 CA386 Detail of failure q High voltage appears in sensor power supply 1 circuit Action of con troller q Takes ambient pressure to be at fixed value and allows engine to run Problem on m...

Page 641: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 21 302 Troubleshooting by failure code Part 2 Failure code CA386 Sens Supply 1 Volt High Error...

Page 642: ...witch to OFF position 2 Disconnect connector P47 and connect T adapters to female side a If water is in water separator drain it Between P47 female 1 and 2 Resistance Min 100 kz 3 Open or short circui...

Page 643: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 23 302 Troubleshooting by failure code Part 2 Failure code CA428 Water in Fuel Sensor High Error Circuit diagram related to water in fuel sensor...

Page 644: ...onnect connector P47 and connect T adapters to female side a If water is in water separator drain it Between P47 female 1 and 2 Resistance Min 100 kz Between P47 female 1 and ground Resistance Min 100...

Page 645: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 25 302 Troubleshooting by failure code Part 2 Failure code CA429 Water in Fuel Sensor Low Error Circuit diagram related to water in fuel sensor...

Page 646: ...gine controller checks if engine oil pressure switch is in CLOSED ON that is if signal voltage is zero or not only when engine is stopped q Failure of engine oil pressure switch with engine running is...

Page 647: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 27 302 Troubleshooting by failure code Part 2 Failure code CA435 Eng Oil Press Sw Error...

Page 648: ...round terminal T12 etc 3 Defective wiring harness connec tor See descriptions of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General information on trou...

Page 649: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 29 302 Troubleshooting by failure code Part 2 Failure code CA441 Battery Voltage Low Error Circuit diagram related to engine controller power supply...

Page 650: ...r higher appears in controller power supply circuit Action of con troller q None in particular Problem on machine q Engine continues to run normally but it may stop during running or may not be able t...

Page 651: ...em If another failure code is displayed perform troubleshooting for it 2 Air in low pressure circuit Air may be in low pressure circuit Check it directly according to following pro cedure 1 Remove fue...

Page 652: ...ctrical equipment in Checks before troubleshooting of General information on troubleshoot ing and check them 2 Defective common rail pressure sensor power supply system If failure code CA227 or CA187...

Page 653: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 33 302 Troubleshooting by failure code Part 2 Failure code CA451 Rail Press Sensor High Error Circuit diagram related to common rail pressure sensor...

Page 654: ...eck them 2 Defective common rail pressure sensor power supply system If failure code CA187 ground fault in sensor power supply system or CA227 is displayed perform troubleshooting for it first 3 Defec...

Page 655: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 35 302 Troubleshooting by failure code Part 2 Failure code CA452 Rail Press Sensor Low Error Circuit diagram related to common rail pressure sensor...

Page 656: ...un Problem on machine q Engine output lowers Related infor mation q Boost temperature can be checked with monitoring function Code 18500 Boost temperature q Method of reproducing failure code Start en...

Page 657: ...rs Related infor mation q Common rail pressure can be checked with monitoring function Code 36400 Common rail pressure q Method of reproducing failure code Start engine Cause Procedure measuring locat...

Page 658: ...t low idle 3 Defect in low pressure circuit parts a For more information on troubleshooting see Note 1 a For check of fuel pressure in low pressure circuit see Testing and adjust ing Testing fuel pres...

Page 659: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 39 302 Troubleshooting by failure code Part 2 Failure code CA559 Rail Press Low Error...

Page 660: ...ystem If failure code CA238 is also displayed perform troubleshooting for it first 3 Breakage or improper installation looseness of engine Ne speed sensor Engine Ne speed sensor may be broken or may h...

Page 661: ...isconnect connector CRANK SENSOR 3 Turn starting switch to ON position Between CRANK SENSOR female 3 and ground Voltage Max 1 V 9 Damage or loose mounting of speed sensing wheel Check speed sensing wh...

Page 662: ...ide Speed sensing wheel on crankshaft side may be installed defectively or bro ken Check it according to following procedure 1 Align paint mark M1 on damper with Ne speed sensor top M2 a Do not align...

Page 663: ...in engine controller are lost Action of con troller q None in particular Problem on machine q Engine may stop and may not be started again q Monitoring function of machine monitor engine controller sy...

Page 664: ...Bkup speed CAM sensor may be damaged or incorrectly loosely installed Check it 4 Defective power input to engine Bkup speed sensor 1 Turn starting switch to OFF position 2 Disconnect connector CAM SEN...

Page 665: ...AM sensor and check ring through hole H a If speed sensing ring B is loosely installed follow instructions given in the Reference column 10 Defective engine Bkup speed CAM sensor If no failure is foun...

Page 666: ...belt For details see Removal and installation of front seal in Disas sembly and assembly 2 Remove damper assembly 1 DP Dowel pin 3 Remove front cover 2 4 Remove front seal 3 RING Ring 5 Check mountin...

Page 667: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 47 302 Troubleshooting by failure code Part 2 Failure code CA778 Eng Bkup Speed Sensor Error...

Page 668: ...t ing and check them 2 Defective throttle sensor fuel con trol dial 1 Turn starting switch to OFF position 2 Disconnect connector P20 and turn starting switch to ON position If this failure code is no...

Page 669: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 49 302 Troubleshooting by failure code Part 2 Failure code CA2185 Throt Sens Sup Volt High Error Circuit diagram related to engine controller power supply...

Page 670: ...on troubleshoot ing and check them 2 Defective throttle sensor fuel con trol dial 1 Turn starting switch to OFF position 2 Disconnect connector P20 and turn starting switch to ON position If this fai...

Page 671: ...oring function Code 36401 V q Common rail pressure sensed by common rail pressure sensor can be checked by using monitor ing function Code 36400 MPa q Method of reproducing failure code Start engine C...

Page 672: ...oting of General information on troubleshoot ing and check them 2 Defective preheater relay R18 1 Turn starting switch to OFF position 2 Disconnect relay R18 and connect T adapters to male side Betwee...

Page 673: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 53 302 Troubleshooting by failure code Part 2 Failure code CA2555 Grid Htr Relay Open Circuit Error Circuit diagram related to intake air heater relay...

Page 674: ...ing location criteria and remarks 1 Defective wiring harness connec tor See descriptions of wiring harness and connectors in c Electrical equipment in Checks before troubleshooting of General informat...

Page 675: ...SEN06134 00 PC200 200LC 220 220LC 8M0 40 302 55 302 Troubleshooting by failure code Part 2 Failure code CA2556 Grid Htr Relay Short Circuit Error Circuit diagram related to intake air heater relay...

Page 677: ...AN2 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...

Page 678: ...code Part 3 40 303 2 PC200 200LC 220 220LC 8M0 SEN06135 00 Failure code DHA4KA Air Cleaner Clog Sensor Open Circuit 42 Failure code DHPAMA F Pump Press Sensor Abnormality 44 Failure code DHPBMA R Pum...

Page 679: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 3 303 Troubleshooting by failure code Part 3...

Page 680: ...ode 03700 Controller output 1 q Method of reproducing failure code Turn starting switch to ON position then turn it to OFF position Cause Procedure measuring location criteria and remarks 1 Defective...

Page 681: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 5 303 Troubleshooting by failure code Part 3 Failure code D110KB Battery Relay Drive Short Circuit Circuit diagram related to battery relay...

Page 682: ...100 to 500 z 1 Turn starting switch to OFF position 2 Replace relay R07 with another one 3 Turn starting switch to ON position If this failure code disappears original personal code relay R07 is defec...

Page 683: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 7 303 Troubleshooting by failure code Part 3 Failure code D19JKZ Personal Code Relay Abnormality Circuit diagram related to personal code relay...

Page 684: ...TRAX system D811MC Detail of failure q KOMTRAX malfunctions Action of con troller Problem on machine q KOMTRAX system does not operate properly Related infor mation q Method of reproducing failure cod...

Page 685: ...ed in GPS antenna circuit Action of machine moni tor q None in particular q If cause of failure disappears machine becomes normal by itself Problem on machine q GPS positioning cannot work Related inf...

Page 686: ...r is operated there is no possibility of ground fault short circuit or hot short circuit in wiring harness CAN communication line q Since each controller and machine monitor are connected to continuou...

Page 687: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 11 303 Troubleshooting by failure code Part 3 Failure code D8AQKR CAN2 Discon KOMTRAX Circuit diagram related to power supply...

Page 688: ...engine Between battery and ground Voltage 20 to 30 V 3 Defective wiring harness 1 Turn starting switch to OFF position and disconnect ground cable 2 Disconnect connector C02 and connect T adapters to...

Page 689: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 13 303 Troubleshooting by failure code Part 3 Failure code DA22KK Pump Solenoid Power Low Error Circuit diagram related to solenoid power supply circuit...

Page 690: ...rs one by one and turn starting switch to ON position for each troubleshooting a If this failure code disappears disconnected sensor is defective 3 After each troubleshooting turn starting swith to OF...

Page 691: ...EN06135 00 PC200 200LC 220 220LC 8M0 40 303 15 303 Troubleshooting by failure code Part 3 Failure code DA25KP 5V Sensor 1 Power Abnormality Circuit diagram related to 5 V sensor 1 power supply circuit...

Page 692: ...sensors one by one and turn starting switch to ON position for each troubleshooting a If this failure code disappears disconnected sensor is defective 3 After each troubleshooting turn starting swith...

Page 693: ...EN06135 00 PC200 200LC 220 220LC 8M0 40 303 17 303 Troubleshooting by failure code Part 3 Failure code DA26KP 5V Sensor 2 Power Abnormality Circuit diagram related to 5 V sensor 2 power supply circuit...

Page 694: ...Between S30 female 1 and 2 Resistance Min 1 Mz Between S30 female 1 and 3 Resistance Min 1 Mz Between S30 female 2 and 3 Resistance Min 1 Mz Between S30 female 3 and 4 Resistance Min 1 Mz Between S30...

Page 695: ...135 00 PC200 200LC 220 220LC 8M0 40 303 19 303 Troubleshooting by failure code Part 3 Failure code DA29KQ Model Selection Abnormality Circuit diagram related to model selection signal PC200 8M0 PC200L...

Page 696: ...ch to OFF position 2 Disconnect connector C01 and connect T adapters to female side Between C01 female 40 and ground Resistance Max 1 z Between C01 female 77 and ground Resistance Max 1 z 3 Short circ...

Page 697: ...135 00 PC200 200LC 220 220LC 8M0 40 303 21 303 Troubleshooting by failure code Part 3 Failure code DA29KQ Model Selection Abnormality Circuit diagram related to model selection signal PC220 8M0 PC220L...

Page 698: ...303 Troubleshooting by failure code Part 3 Failure code DA29KQ Model Selection Abnormality 40 303 22 PC200 200LC 220 220LC 8M0 SEN06135 00...

Page 699: ...r is operated there is no possibility of ground fault short circuit or hot short circuit in wiring harness CAN communication line q Since each controller and machine monitor are connected to continuou...

Page 700: ...If no failure is found by above checks pump controller is defective Since this is an internal defect troubleshooting cannot be performed 7 Defective machine monitor If no failure is found by above ch...

Page 701: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 25 303 Troubleshooting by failure code Part 3 Failure code DA2QKR CAN2 Discon Pump Con Circuit diagram related to pump controller power supply...

Page 702: ...gram of machine monitor is rewritten program error Action of con troller Problem on machine q Indication of machine monitor is unreliable q Machine monitor is incapable of normally exchanging data wit...

Page 703: ...ne monitor malfunctions Action of con troller Problem on machine q Indication of machine monitor is unreliable q Machine monitor is incapable of normally exchanging data with controllers Related infor...

Page 704: ...it 1 Turn starting switch to OFF position 2 Disconnect camera connector s and turn starting switch to ON position After above operation disconnecting camera connector and performing failure code repro...

Page 705: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 29 303 Troubleshooting by failure code Part 3 Failure code DAF8KB Camera Power Supply Short Circuit Circuit diagram related to camera power supply...

Page 706: ...Assembly part No of pump controller program can be checked by using monitoring function Code 20229 q Assembly part No of machine monitor program can be checked by using monitoring function Code 20227...

Page 707: ...modem in 50 seconds after KOMTRAX started Action of machine moni tor q None in particular q If cause of failure disappears machine becomes normal by itself Problem on machine Related infor mation q M...

Page 708: ...ignal from starting switch q Failure code is transmitted to and displayed on machine monitor by CAN communication Accord ingly if CAN communication with machine monitor fails failure code DAFQKR is no...

Page 709: ...air conditioner controller can not be checked by using monitoring function q Model codes registered in machine monitor can be checked by using monitoring function Code 00500 q Air conditioner control...

Page 710: ...tarting switch is received q For CAN communication error over CAN communication 2 line machine monitor can generate four failure codes D8AQKR DA2QKR DAZQKR and DB2QKR When all of these four failure co...

Page 711: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 35 303 Troubleshooting by failure code Part 3 Failure code DAZQKR CAN2 Discon Aircon ECU...

Page 712: ...when failure code is displayed on machine monitor screen If air conditioner is operated there is no possibility of ground fault short circuit or hot short circuit in wiring harness CAN communication...

Page 713: ...d insert T adapters into it 3 Connect battery ground cable and turn starting switch to ON position Between CM01 10 and 3 Voltage 20 to 30 V Between CE02 39 and CE03 1 Voltage 20 to 30 V Between C01 24...

Page 714: ...ale 1 CE02 female 47 Voltage 1 to 4 V 9 Defective engine controller pump controller air conditioner unit or KOMTRAX terminal q If all four failure codes DA2QKR DB2QKR D8AQKR and DAZQKR are displayed a...

Page 715: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 39 303 Troubleshooting by failure code Part 3 Failure code DB2QKR CAN2 Discon Engine Con Circuit diagram related to CAN communication 2...

Page 716: ...round Resistance Min 1 Mz 2 Open circuit or short circuit or ground fault or hot short circuit in wiring harness 1 Turn starting switch to OFF position 2 Disconnect connector P22 and connect T adapter...

Page 717: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 41 303 Troubleshooting by failure code Part 3 Failure code DGH2KB Hyd Oil Sensor Short Circuit Circuit diagram related to hydraulic oil temperature sensor...

Page 718: ...so machine mon itor determines that air cleaner is clogged switch contact is open Action of con troller q Displays air cleaner clogging monitor in red on machine monitor Problem on machine q If machi...

Page 719: ...SEN06135 00 PC200 200LC 220 220LC 8M0 40 303 43 303 Troubleshooting by failure code Part 3 Failure code DHA4KA Air Cleaner Clog Sensor Open Circuit...

Page 720: ...upply voltage is abnormal proceed to check on cause 3 Between P25 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective front pump pressure sensor internal defect 1 Turn starting switch to OFF...

Page 721: ...5 V or 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P25 3 Connect T adapters to female side of connector P25 4 Turn starting switch to ON position Between P25 female 2 a...

Page 722: ...ly voltage is abnormal proceed to check on cause 3 Between P26 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective rear pump pressure sen sor internal defect 1 Turn starting switch to OFF po...

Page 723: ...h 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P26 3 Connect T adapters to female side of connector P26 4 Turn starting switch to ON position Between P26 female 2 and...

Page 725: ...g 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 Pr...

Page 726: ...304 Troubleshooting by failure code Part 4 40 304 2 PC200 200LC 220 220LC 8M0 SEN06136 00 Failure code DW91KA Travel Neutral Sol Open Circuit 44 Failure code DW91KB Travel Neutral Sol Short Circuit 46...

Page 727: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 3 304 Troubleshooting by failure code Part 4...

Page 728: ...oltage is abnormal proceed to check on cause 3 Between P04 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective arm IN PPC pressure sensor internal defect 1 Turn starting switch to OFF positi...

Page 729: ...t with 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P04 3 Connect T adapters to female side of connector P04 4 Turn starting switch to ON position Between P04 female 2 an...

Page 730: ...voltage is abnormal proceed to check on cause 3 Between P01 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective bucket CURL PPC pres sure sensor internal defect 1 Turn starting switch to OF...

Page 731: ...ntact with 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P01 3 Connect T adapters to female side of connector P01 4 Turn starting switch to ON position Between P01 female...

Page 732: ...pressure sensor internal defect 1 Turn starting switch to OFF position 2 Insert T adapters in connector P06 3 Turn starting switch to ON position Between P06 2 and 1 Sensor out put Voltage 0 5 to 4 5...

Page 733: ...Raise PPC Press Sensor Abnormality Circuit diagram related to boom raise PPC pressure sensor Cause Procedure measuring location criteria and remarks 6 Defective pump controller If no failure is found...

Page 734: ...e 3 Between P02 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective boom LOWER PPC pressure sensor internal defect 1 Turn starting switch to OFF position 2 Insert T adapters into connector P...

Page 735: ...a and remarks 5 Hot short circuit in wiring harness contact with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P02 3 Connect T adapters to female side of connector P02...

Page 736: ...pply voltage is abnormal proceed to check on cause 3 Between P07 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective swing RIGHT PPC pres sure sensor internal defect 1 Turn starting switch t...

Page 737: ...ct with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P07 3 Connect T adapters to female side of connector P07 4 Turn starting switch to ON position Between P07 female...

Page 738: ...ly voltage is abnormal proceed to check on cause 3 Between P03 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective swing left PPC pressure sensor internal defect 1 Turn starting switch to OF...

Page 739: ...ct with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P03 3 Connect T adapters to female side of connector P03 4 Turn starting switch to ON position Between P03 female...

Page 740: ...eck on cause 3 Between P08 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective arm OUT PPC pressure sensor internal failure 1 Turn starting switch to OFF position 2 Insert T adapters into co...

Page 741: ...nd remarks 5 Hot short circuit in wiring harness contact with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P08 3 Connect T adapters to female side of connector P08 4...

Page 742: ...MP PPC pres sure sensor internal defect 1 Turn starting switch to OFF position 2 Insert T adapters into connector P05 3 Turn starting switch to ON position Between P05 2 and 1 Sensor out put Voltage 0...

Page 743: ...t Dump PPC Press Sensor Abnormality Circuit diagram related to bucket dump PPC pressure sensor Cause Procedure measuring location criteria and remarks 6 Defective pump controller If no failure is foun...

Page 744: ...ion a If power supply voltage is abnormal proceed to check on cause 3 Between P09 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective left travel FORWARD PPC presure sensor internal defect 1...

Page 745: ...t with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P09 3 Connect T adapters to female side of connector P09 4 Turn starting switch to ON position Between P09 female...

Page 746: ...power supply voltage is abnormal proceed to check on cause 3 Between P11 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective right travel FORWARD PPC pressure sensor internal defect 1 Turn s...

Page 747: ...t with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P11 3 Connect T adapters to female side of connector P11 4 Turn starting switch to ON position Between P11 female...

Page 748: ...ion a If power supply voltage is abnormal proceed to check on cause 3 Between P10 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective left travel REVERSE PPC pressure sensor internal defect...

Page 749: ...t with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P10 3 Connect T adapters to female side of connector P10 4 Turn starting switch to ON position Between P10 female...

Page 750: ...power supply voltage is abnormal proceed to check on cause 3 Between P12 female 3 and 1 Power sup ply Voltage 4 5 to 5 5 V 2 Defective right travel REVERSE PPC pressure sensor internal defect 1 Turn s...

Page 751: ...t with 5 V 24 V circuit 1 Turn starting switch to OFF position 2 Disconnect connector P12 3 Connect T adapters to female side of connector P12 4 Turn starting switch to ON position Between P12 female...

Page 752: ...ailure q Monitor overload alarm monitor which is not set to be displayed is displayed Action of con troller q None in particular q If cause of failure disappears machine becomes normal by itself Probl...

Page 753: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 29 304 Troubleshooting by failure code Part 4 Failure code DHX1MA Overload Sensor Abnormality...

Page 754: ...n starting switch to OFF position 2 Disconnect connectors CM04 and A46 and connect T adapters to each female side Between CM04 female 6 and A46 female 3 Resistance Max 1 z Between CM04 female 5 and A4...

Page 755: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 31 304 Troubleshooting by failure code Part 4 Failure code DR21KX Camera 2 Picture Rev Drive Abnormality Circuit diagram related to camera...

Page 756: ...00 Failure code DR31KX Camera 3 Picture Rev Drive Abnormality a This failure code does not relate to this machine because it is not equipped with camera 3 This failure code is provided in case where c...

Page 757: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 33 304 Troubleshooting by failure code Part 4 Failure code DR31KX Camera 3 Picture Rev Drive Abnormality...

Page 758: ...tor Cause Procedure measuring location criteria and remarks 1 Defective travel alarm internal defect 1 Turn starting switch to OFF position 2 Disconnect connector M14 and connect T adapters to female...

Page 759: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 35 304 Troubleshooting by failure code Part 4 Failure code DV20KB Travel Alarm Short Circuit Circuit diagram related to travel alarm...

Page 760: ...even if solenoid is not energized due to short circuit Code 02300 Solenoid 1 q Method of reproducing failure code Start engine set travel speed to High and operate travel lever Cause Procedure measuri...

Page 761: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 37 304 Troubleshooting by failure code Part 4 Failure code DW43KA Travel Speed Sol Open Circuit Circuit diagram related to travel speed solenoid...

Page 762: ...ilure code Start engine set travel speed to High and operate travel lever Cause Procedure measuring location criteria and remarks 1 Defective travel speed selector solenoid Internal short circuit grou...

Page 763: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 39 304 Troubleshooting by failure code Part 4 Failure code DW43KB Travel Speed Sol Short Circuit Circuit diagram related to travel speed solenoid...

Page 764: ...g failure code Turn starting switch to ON position q Swing brake solenoid circuit is powered from pin 101 of pump controller connector C02 or No 1 of fuse box F01 Cause Procedure measuring location cr...

Page 765: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 41 304 Troubleshooting by failure code Part 4 Failure code DW45KA Swing Brake Sol Valve Open Circuit Circuit diagram related to swing holding brake...

Page 766: ...101 of pump controller connector C02 or pin 1 of fuse box F01 Cause Procedure measuring location criteria and remarks 1 Blown fuse No 1 right top fuse in fuse box F01 Even if fuse is blown perform tro...

Page 767: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 43 304 Troubleshooting by failure code Part 4 Failure code DW45KB Swing Brake Sol Short Circuit Circuit diagram related to swing holding brake...

Page 768: ...n circuit Code 02300 Solenoid 1 q Method of reproducing failure code Start engine and turn machine with right and left travel levers Cause Procedure measuring location criteria and remarks 1 Defective...

Page 769: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 45 304 Troubleshooting by failure code Part 4 Failure code DW91KA Travel Neutral Sol Open Circuit Circuit diagram related to travel junction solenoid...

Page 770: ...d of reproducing failure code Start engine and turn machine with right and left travel levers Cause Procedure measuring location criteria and remarks 1 Defective travel junction solenoid internal shor...

Page 771: ...SEN06136 00 PC200 200LC 220 220LC 8M0 40 304 47 304 Troubleshooting by failure code Part 4 Failure code DW91KB Travel Neutral Sol Short Circuit Circuit diagram related to travel junction solenoid...

Page 773: ...2 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...

Page 774: ...ting by failure code Part 5 40 305 2 PC200 200LC 220 220LC 8M0 SEN06137 00 Failure code DY2CKB Washer Drive Short Circuit 44 Failure code DY2DKB Wiper Drive Fwd Short 46 Failure code DY2EKB Wiper Driv...

Page 775: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 3 305 Troubleshooting by failure code Part 5...

Page 776: ...02301 Solenoid 2 q Method of reproducing failure code Turn starting switch to ON position and set machine in working mode other than breaker mode B Cause Procedure measuring location criteria and rem...

Page 777: ...EN06137 00 PC200 200LC 220 220LC 8M0 40 305 5 305 Troubleshooting by failure code Part 5 Failure code DWA2KA Attachment Sol Open Circuit Circuit diagram related to ATT single multiple selector solenoi...

Page 778: ...is not switched ON due to short circuit Code 02301 Solenoid 2 q Method of reproducing failure code Turn starting switch to ON position and set machine in breaker mode B Cause Procedure measuring loca...

Page 779: ...N06137 00 PC200 200LC 220 220LC 8M0 40 305 7 305 Troubleshooting by failure code Part 5 Failure code DWA2KB Attachment Sol Short Circuit Circuit diagram related to ATT single multiple selector solenoi...

Page 780: ...age cannot be mea sured at pump controller connector q Controller detects open circuit only when it does not drive solenoid q Method of reproducing failure code Turn starting switch to ON position Cau...

Page 781: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 9 305 Troubleshooting by failure code Part 5 Failure code DWK0KA 2 stage Relief Sol Open Circuit Circuit diagram related to 2 stage relief solenoid...

Page 782: ...cuit Code 02300 Solenoid 1 q As T adapter for pump controller connector is socket type box operating voltage cannot be mea sured at pump controller connector q Controller detects open circuit only whe...

Page 783: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 11 305 Troubleshooting by failure code Part 5 Failure code DWK0KB 2 stage Relief Sol Short Circuit Circuit diagram related to 2 stage relief solenoid...

Page 784: ...e set pressure of back pressure value becomes low by solenoid ON q Method of reproducing failure code Turn starting switch to ON position No Cause Procedure measuring location criteria and remarks 1 D...

Page 785: ...06137 00 PC200 200LC 220 220LC 8M0 40 305 13 305 Troubleshooting by failure code Part 5 Failure code DWK2KA Variable Back Press Sol Open Circuit Circuit diagram related to variable back pressure solen...

Page 786: ...ircuit Code 02301 Solenoid 2 q The set pressure of back pressure value becomes low by solenoid ON q Method of reproducing failure code Turn starting switch to ON position No Cause Procedure measuring...

Page 787: ...6137 00 PC200 200LC 220 220LC 8M0 40 305 15 305 Troubleshooting by failure code Part 5 Failure code DWK2KB Variable Back Press Sol Short Circuit Circuit diagram related to variable back pressure solen...

Page 788: ...male 1 and 2 Resistance 3 to 14 z 2 Defective emergency pump drive switch Internal open circuit 1 Turn starting switch to OFF position 2 Disconnect connector S25 and connect T adapters to male side Be...

Page 789: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 17 305 Troubleshooting by failure code Part 5 Failure code DXA8KA PC EPC F Sol Open Circuit Circuit diagram related to PC EPC solenoid...

Page 790: ...Disconnect connector V11 and connect T adapters to male side Between V11 male 1 and 2 Resistance 3 to 14 z Between V11 male 1 and ground Resistance Min 1 Mz 2 Defective emergency pump drive switch int...

Page 791: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 19 305 Troubleshooting by failure code Part 5 Failure code DXA8KB PC EPC F Sol Short Circuit Circuit diagram related to PC EPC solenoid...

Page 792: ...12 male 1 and 2 Resistance 3 to 14 z 2 Defective emergency pump drive switch Internal open circuit 1 Turn starting switch to OFF position 2 Disconnect connector S25 and connect T adapters to male side...

Page 793: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 21 305 Troubleshooting by failure code Part 5 Failure code DXA9KA PC EPC R Sol Open Circuit Circuit diagram related to PC EPC solenoid...

Page 794: ...ct connector V12 and connect T adapters to male side Between V12 male 1 and 2 Resistance 3 to 14 z Between V12 male 1 and ground Resistance Min 1 Mz 2 Defective emergency pump drive switch internal sh...

Page 795: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 23 305 Troubleshooting by failure code Part 5 Failure code DXA9KB PC EPC R Sol Short Circuit Circuit diagram related to PC EPC solenoid...

Page 796: ...h to ON position Cause Procedure measuring location criteria and remarks 1 Defective LS EPC solenoid Internal open circuit 1 Turn starting switch to OFF position 2 Disconnect connector V19 and connect...

Page 797: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 25 305 Troubleshooting by failure code Part 5 Failure code DXE0KA LS EPC Sol Open Circuit Circuit diagram related to LS EPC solenoid...

Page 798: ...osition Cause Procedure measuring location criteria and remarks 1 Defective LS EPC solenoid internal short circuit or ground fault 1 Turn starting switch to OFF position 2 Disconnect connector V19 and...

Page 799: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 27 305 Troubleshooting by failure code Part 5 Failure code DXE0KB LS EPC Sol Short Circuit Circuit diagram related to LS EPC solenoid...

Page 800: ...suring location criteria and remarks 1 Defective attachment flow rate adjustment service current EPC solenoid Internal open circuit 1 Turn starting switch to OFF position 2 Disconnect connector V30 an...

Page 801: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 29 305 Troubleshooting by failure code Part 5 Failure code DXE4KA Attachment Flow EPC Open Circuit Circuit diagram related to service flow throttle EPC...

Page 802: ...measuring location criteria and remarks 1 Defective attachment flow rate adjustment service current EPC solenoid internal short circuit or ground fault 1 Turn starting switch to OFF position 2 Discon...

Page 803: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 31 305 Troubleshooting by failure code Part 5 Failure code DXE4KB Attachment Flow EPC Short Circuit Circuit diagram related to service flow throttle EPC...

Page 804: ...on Code 08000 Merge divider main solenoid current q Method of reproducing failure code Turn starting switch to ON position Cause Procedure measuring location criteria and remarks 1 Defective merge div...

Page 805: ...137 00 PC200 200LC 220 220LC 8M0 40 305 33 305 Troubleshooting by failure code Part 5 Failure code DXE5KA Merge divide Main Sol Open Circuit Circuit diagram related to pump merge divider main EPC sole...

Page 806: ...in solenoid current q Method of reproducing failure code Turn starting switch to ON position Cause Procedure measuring location criteria and remarks 1 Defective merge divider main EPC solenoid interna...

Page 807: ...137 00 PC200 200LC 220 220LC 8M0 40 305 35 305 Troubleshooting by failure code Part 5 Failure code DXE5KB Merge divide Main Sol Short Circuit Circuit diagram related to pump merge divider main EPC sol...

Page 808: ...Code 08001 Merge divider LS solenoid current q Method of reproducing failure code Turn starting switch to ON position Cause Procedure measuring location criteria and remarks 1 Defective merge divider...

Page 809: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 37 305 Troubleshooting by failure code Part 5 Failure code DXE6KA Merge divide LS Sol Open Circuit Circuit diagram related to merge divider LS EPC solenoid...

Page 810: ...olenoid current q Method of reproducing failure code Turn starting switch to ON position Cause Procedure measuring location criteria and remarks 1 Defective merge divider LS EPC solenoid internal shor...

Page 811: ...EN06137 00 PC200 200LC 220 220LC 8M0 40 305 39 305 Troubleshooting by failure code Part 5 Failure code DXE6KB Merge divide LS Sol Short Circuit Circuit diagram related to merge divider LS EPC solenoid...

Page 812: ...ct connector M05 and connect T adapters to female side Between M05 female 6 and 5 Wiper position working area end Resistance Max 1 z Wiper position other than working area end Resistance Min 1 Mz Betw...

Page 813: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 41 305 Troubleshooting by failure code Part 5 Failure code DY20KA Wiper Working Abnormality Circuit diagram related to wiper...

Page 814: ...nect T adapters to female side Between M05 female 4 and 5 Wiper position rest area Resistance Max 1 z Wiper position working area Resistance Min 1 Mz Between M05 female 1 and 3 Wiper position whole ra...

Page 815: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 43 305 Troubleshooting by failure code Part 5 Failure code DY20MA Wiper Parking Abnormality Circuit diagram related to wiper...

Page 816: ...dapters to male side Between M06 male 1 and 2 Resistance 5 to 20 z Between ground and M06 male 1 or 2 Resistance Min 1 Mz 3 Defective diode array D02 Internal short circuit 1 Turn starting switch to O...

Page 817: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 45 305 Troubleshooting by failure code Part 5 Failure code DY2CKB Washer Drive Short Circuit Circuit diagram related to window washer motor...

Page 818: ...ive wiper motor internal short circuit or ground fault 1 Turn starting switch to OFF position 2 Disconnect connector M05 and connect T adapters to female side Between M05 female 3 and 1 Continuity Bet...

Page 819: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 47 305 Troubleshooting by failure code Part 5 Failure code DY2DKB Wiper Drive Fwd Short Circuit diagram related to wiper...

Page 820: ...marks 1 Defective wiper motor internal short circuit or ground fault 1 Turn starting switch to OFF position 2 Disconnect connector M05 and connect T adapters to female side Between M05 female 1 and 3...

Page 821: ...SEN06137 00 PC200 200LC 220 220LC 8M0 40 305 49 305 Troubleshooting by failure code Part 5 Failure code DY2EKB Wiper Drive Rev Short Circuit diagram related to wiper...

Page 823: ...starting switch is turned to ON position with engine stopped basic check monitor lights up 20 E 5 Precaution monitor lights up while engine is running 21 E 6 Emergency stop monitor lights up while en...

Page 824: ...e 48 E 26 BOOM DOWN indicator is not displayed properly with monitoring function 50 E 27 ARM DUMP indicator is not displayed properly with monitoring function 50 E 28 ARM IN indicator is not displayed...

Page 825: ...SEN06138 00 PC200 200LC 220 220LC 8M0 40 400 3 400 Troubleshooting of electrical system E mode...

Page 826: ...ted in emergency Swing holding brake solenoid valve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oil pressure lock solenoid valve Startin...

Page 827: ...SEN06138 00 PC200 200LC 220 220LC 8M0 40 400 5 400 Troubleshooting of electrical system E mode Fuse locations Locations of fusible links Location of fuse box and fuse Nos...

Page 828: ...re is fixed after the failure was found and repaired Failures in wiring harness q Open circuit in wiring The connector connection is defective or the wire is broken q Ground fault A harness not connec...

Page 829: ...diagram contains the connector Nos pin Nos and connector colors related to the failure q The in a connector number is either 1 An abbreviation of more than three letters Example T C Torque Converter 2...

Page 830: ...robably has ground fault See Cause 16 3 Loose terminal connection or open circuit at terminal 1 Turn starting switch to OFF position Check terminals of starting motor alternator battery relay grounds...

Page 831: ...to ON position Resistance Max 1 z Between H15 male 1 and 5 Turn starting switch to OFF position Resistance Min 1 Mz Turn starting switch to ON position Resistance Max 1 z Between H15 male 1 and 4 Turn...

Page 832: ...to 30 V If power supply and starting input to starting motor are normal but starting motor does not rotate starting motor is defective 15 Defective alternator Internal short circuit 1 Turn starting sw...

Page 833: ...le 1 Resistance Max 1 z Between R06 male 2 and ground T04 Resistance Max 1 z 17 Defective battery relay Does not work If only terminal R03 voltage is abnormal during battery relay check for cause 16 b...

Page 834: ...400 Troubleshooting of electrical system E mode E 1 Engine does not start Engine does not crank 40 400 12 PC200 200LC 220 220LC 8M0 SEN06138 00 Circuit diagram related to engine start circuit...

Page 835: ...n circuit or ground fault in wir ing harness 1 Turn starting switch to OFF position 2 Disconnect connectors CM01 and H15 and connect T adapter to female side of H15 a Heater relay coil resistance Betw...

Page 836: ...No 6 in fuse box 01 is broken circuit probably has ground fault In this case perform troubleshooting for cause 5 first 2 Defective auto preheater relay R18 open or short cir cuit in internal wiring 1...

Page 837: ...ge or defective contact 1 Turn starting switch to OFF position 2 Disconnect connectors H15 CM01 and R18 and connect T adapters to each female side Between H15 female 3 and CM01 female 16 Resistance Ma...

Page 838: ...400 Troubleshooting of electrical system E mode E 2 Preheater does not operate 40 400 16 PC200 200LC 220 220LC 8M0 SEN06138 00 Circuit diagram related to preheating of engine...

Page 839: ...ircuit probably has ground fault See Cause 7 4 Defective wiring harness starting switch or machine monitor 1 Turn starting switch to OFF position and disconnect ground cable 2 Insert T adapter into co...

Page 840: ...d C01 3 Connect T adapters to male side of connector F05 and female side of H15 and CM01 Between battery or F05 male 1 and ground Resistance Min 1 Mz Between F05 male 2 and ground or between F01 16E a...

Page 841: ...200LC 220 220LC 8M0 40 400 19 400 Troubleshooting of electrical system E mode E 3 When starting switch is turned to ON position machine monitor displays nothing Circuit diagram related to machine mon...

Page 842: ...witch is turned to ON position with engine stopped engine oil level monitor lights up in yellow Related information Cause Procedure measuring location criteria and remarks 1 Defective engine oil level...

Page 843: ...communication system q Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature Cause Procedure measuring location criteria and remarks 1 Insufficient wa...

Page 844: ...tor light up in yellow because of water separator sensor detection high water level in water separator Related information q Signal of water detection by fuel filter sensor can be checked with monitor...

Page 845: ...rature sensor is input to pump controller and then the data is transmit ted to machine monitor through CAN communication system q Hydraulic oil temperature can be checked with monitoring function Code...

Page 846: ...e Between CM01 female 15 and ground Fuel level FULL Resistance 7 to 11 z Fuel level EMPTY Resistance 85 to 95 z 3 Open circuit in wiring har ness wire breakage or defective contact of connector a If n...

Page 847: ...el level gauge is different from display of fuel level monitor Related infor mation q Signal voltage of fuel level sensor can be checked with monitoring function Code 04200 Fuel sensor voltage Cause P...

Page 848: ...em Engine coolant temperature sensor system may be defective Perform troubleshoot ing for failure codes CA144 and CA145 2 Defective machine monitor If no failure is found by check on cause 1 machine m...

Page 849: ...n 2 Disconnect connector C01 and connect T adapters to female side Between C01 female 29 and 46 a Resistance accords with temperature characteristics table in cause 1 Resistance 3 5 to 90 kz Between C...

Page 850: ...leshooting of electrical system E mode E 9 Hydraulic oil temperature gauge does not indicate properly 40 400 28 PC200 200LC 220 220LC 8M0 SEN06138 00 Circuit diagram related to hydraulic oil temperatu...

Page 851: ...temperature monitor Related infor mation q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit ted to machine monitor through CAN communication system...

Page 852: ...3 ON Model selection 4 OFF Model selection 5 OFF If display on monitor is incorrect perform troubleshooting for failure code DA29KQ 2 Defective machine monitor If no failure is found by check on cause...

Page 853: ...ine monitor LCD panel a Turn starting switch to ON position and perform troubleshooting When following switches are operated if whole LCD panel is lighted up whole surface becomes white LCD panel has...

Page 854: ...ic warm up function in creases engine speed to 1 300 rpm If engine coolant temperature reaches 60 C automatic warm up function is canceled q If engine coolant temperature is below 10 C turbocharger pr...

Page 855: ...achines with arm crane Cause Procedure measuring location criteria and remarks 1 Defective PPC oil pressure signal a Start engine and perform troubleshooting with monitoring function Monitoring code I...

Page 856: ...ure measuring location criteria and remarks 1 Defective machine monitor Machine monitor may be defective Since this is an internal defect trouble shooting cannot be performed Failure 2 When working mo...

Page 857: ...Related information q When failure due to cause 1 occurs actual travel speed does not decrease when travel speed setting is changed to Lo q As T adapter for pump controller connector is socket type b...

Page 858: ...ed service meter is displayed at top center of screen Operation of switches 4 and 1 Press simultaneously Cause Procedure measuring location criteria and remarks 1 Defective backup power supply system...

Page 859: ...hort circuit 1 Turn starting switch to OFF position 2 Remove diode array D01 and connect T adapters to male side a Check the continuity in diode range Between D01 male 8 and 4 Continuity Between D01 m...

Page 860: ...uring location criteria and remarks 1 Defective lock lever switch Internal short circuit 1 Turn starting switch to OFF position 2 Disconnect connector S14 and connect T adapters to male side Between S...

Page 861: ...D01 and D03 and connect T adapters to male side a Check the continuity in diode range Between D01 male 7 and 3 Continuity Between D01 male 3 and 7 No continuity Between D03 male 7 and 3 Continuity Be...

Page 862: ...l switch internal short cir cuit 1 Turn starting switch to OFF position 2 Disconnect connector S25 and connect T adapters to male side Between S25 male 13 and 14 swing brake cancel switch Normal Resis...

Page 863: ...SEN06138 00 PC200 200LC 220 220LC 8M0 40 400 41 400 Troubleshooting of electrical system E mode E 21 Swing holding brake does not operate properly Circuit diagram related to swing brake solenoid...

Page 864: ...d 2 L H knob switch Released Resistance Min 1 Mz L H knob switch Pressed Resistance Max 1 z 4 Open circuit or ground fault in wir ing harness 1 Turn starting switch to OFF position 2 Disconnect connec...

Page 865: ...PC200 200LC 220 220LC 8M0 40 400 43 400 Troubleshooting of electrical system E mode E 22 One touch power maximizing function does not operate properly Circuit diagram related to one touch power maximi...

Page 866: ...switch can be checked with monitoring function Code 02200 Switch Input 1 Cause Procedure measuring location criteria and remarks 1 Hot short circuit in wiring harness contact with 24 V circuit 1 Turn...

Page 867: ...ct of connector 1 Turn starting switch to OFF position 2 Disconnect connectors M14 and C02 and connect T adapters to each female side Between C02 female 107 and M14 female 1 Resistance Max 1 z Between...

Page 868: ...Continuity 5 Defective wiring harness 1 Turn starting switch to OFF position 2 Disconnect connector R08 and connect T adapters to female side 3 Turn starting switch to ON position 4 Press L H knob sw...

Page 869: ...e Procedure measuring location criteria and remarks 1 Defective horn relay R08 internal open or short circuit 1 Turn starting switch to OFF position 2 Remove horn relay connector R08 3 Turn starting s...

Page 870: ...circuit 1 Turn starting switch to OFF position 2 Disconnect connector M05 and connect T adapters to female side Between M05 female 1 and 3 Continuity 3 Open circuit in wiring har ness wire breakage o...

Page 871: ...SEN06138 00 PC200 200LC 220 220LC 8M0 40 400 49 400 Troubleshooting of electrical system E mode E 25 Windshield wiper and window washer do not operate Circuit diagram related to wiper...

Page 872: ...Defective boom DOWN PPC oil pressure sensor system internal open circuit or short circuit Perform troubleshooting for failure code DHS9MA Failure Arm DUMP operation signal is not displayed properly o...

Page 873: ...suring location criteria and remarks 1 Defective boom RAISE PPC pressure sensor system internal open or short cir cuit Perform troubleshooting for failure code DHS8MA Failure Bucket CURL operation sig...

Page 874: ...information q Monitoring code 01900 Pressure switch 1 Cause Procedure measuring location criteria and remarks 1 Defective swing PPC pressure sensor system internal open or short circuit Perform troub...

Page 875: ...Turn starting switch to OFF position 2 Disconnect connector P14 3 Turn starting switch to ON position If Service operation signal displayed on monitoring screen changes to OFF front service PPC pressu...

Page 876: ...C01 P14 and P15 and connect T adapters to each female side Between C01 female 76 and P14 female 1 Resistance Max 1 z Between C01 female 76 and P15 female 1 Resistance Max 1 z Between P14 female 2 and...

Page 877: ...ures open circuit short circuit of attachment oil return selector solenoid are troubleshot for fail ure codes DWA2KA and DWA2KB Cause Procedure measuring location criteria and remarks 1 Defective atta...

Page 878: ...position 2 Display Terminal status screen Monitoring display Check item Station set up check To be completed 2 Defective positioning by GPS 1 Turn starting switch to ON position 2 Display GPS Communic...

Page 879: ...SEN06138 00 PC200 200LC 220 220LC 8M0 40 400 57 400 Troubleshooting of electrical system E mode E 36 KOMTRAX system does not operate properly...

Page 881: ...ficantly or engine stalls 11 H 3 Work equipment swing and travel systems do not work 12 H 4 Unusual noise comes out from around hydraulic pump 13 H 5 Fine control performance or response is low 14 H 6...

Page 882: ...speed does not change or travel speed is low high 30 H 21 One of tracks does not run 31 H 22 Upper structure does not swing 32 H 23 Swing acceleration is poor or swing speed is low 34 H 24 Upper stru...

Page 883: ...SEN06139 00 PC200 200LC 220 220LC 8M0 40 500 3 500 Troubleshooting of hydraulic and mechanical system H mode...

Page 884: ...Troubleshooting of hydraulic and mechanical system H mode System diagram of hydraulic and mechanical system 40 500 4 PC200 200LC 220 220LC 8M0 SEN06139 00 System diagram of hydraulic and mechanical sy...

Page 885: ...eshooting of hydraulic and mechanical system H mode System diagram of hydraulic and mechanical system a This system diagram is a rough general hydraulic circuit diagram made as reference material for...

Page 886: ...drift of work equipment is large Boom q q Arm q q Bucket q q Time lag of work equipment operation is large q q q Other wok equipment moves when one of work equip ment is relieved q One touch power max...

Page 887: ...avel junction valve Back pressure valve Service valve safety valve Work equipment lock solenoid 2 stage relief solenoid Travel interconnection solenoid Travel speed selector solenoid Swing holding bra...

Page 888: ...rrying out troubleshooting understand that information fully Failure Description of failure code Related infor mation Information related to detected failure or troubleshooting Probable causes and cri...

Page 889: ...fect Check main relief valve 3 Malfunction of self pressure reducing valve a Be ready with engine stopped then troubleshoot with engine high idle Control lever Control circuit source pressure All leve...

Page 890: ...th engine high idle Measured oil pres sure Operation of levers and oil pressure ratio All levers in the neu tral position Run the track off ground lever at half stroke Pump discharge pressure Almost s...

Page 891: ...levers in the neu tral position Approx 2 9 MPa Approx 30 kg cm2 High idle 0 52 to 0 91 MPa 5 3 to 9 3 kg cm2 3 Defective adjustment or mal function of PC valve a Be ready with engine stopped then trou...

Page 892: ...ith engine high idle Lock lever PPC lock solenoid valve output pressure LOCK 0 MPa 0 kg cm2 FREE Approx 2 9 MPa Approx 30 kg cm2 2 Malfunction of self pressure reducing valve a Be ready with engine st...

Page 893: ...Criteria and troubleshooting procedure 1 Lowering of hydraulic oil level Hydraulic oil level may be low Check it 2 Defective hydraulic oil Air may be mixed in hydraulic oil Check oil 3 Clogging of hyd...

Page 894: ...valve output pressure Lo Neutral Approx 2 9 MPa Approx 30 kg cm2 Hi Operation 0 MPa 0 kg cm2 2 Clogging of LS circuit orifice Orifice of LS circuit pump piping control valve may be clogged Check it 3...

Page 895: ...boom control valve may malfunction Check it 7 Malfunction of boom control valve pressure compensa tion valve Pressure compensation valve of boom control valve may malfunc tion Check it 8 Malfunction...

Page 896: ...may malfunction Check it 7 Malfunction of arm control valve pressure compensa tion valve Pressure compensation valve of boom control valve may malfunc tion Check it 8 Malfunction of arm control valve...

Page 897: ...et CURL Bucket DUMP 2 84 to 3 43 MPa 29 to 35 kg cm2 2 Malfunction of bucket control valve spool Spool of bucket control valve may malfunction Check it 3 Malfunction of bucket control valve pressure c...

Page 898: ...3 Bucket does not move independently Related infor mation q Perform all troubleshooting with working mode in power mode P Probable causes and cri teria Cause Criteria and troubleshooting procedure 1 M...

Page 899: ...efective Check it Failure 2 Hydraulic drift of arm is large Related infor mation q Perform all troubleshooting with working mode in power mode P Probable causes and cri teria Cause Criteria and troubl...

Page 900: ...dle Left work equipment control lever Leakage from bucket cylinder Bucket CURL relief 20 cc min 2 Defective seal of bucket con trol valve spool Seal of bucket control valve spool may be defective Chec...

Page 901: ...ed Travel lever LS EPC valve output pressure Lo Neutral Approx 2 9 MPa Approx 30 kg cm2 Hi Operation 0 MPa 0 kg cm2 2 Malfunction of control valve regeneration valve Boom and arm only Regeneration val...

Page 902: ...equipment moves when one of work equipment is relieved Failure q Other wok equipment moves when one of work equipment is relieved Related infor mation Probable causes and cri teria Cause Criteria and...

Page 903: ...Related infor mation q Perform all troubleshooting with working mode in power mode P Probable causes and cri teria Cause Criteria and troubleshooting procedure 1 Malfunction of 2 stage relief solenoi...

Page 904: ...ier load moves slower Related infor mation Probable causes and cri teria Cause Criteria and troubleshooting procedure 1 Malfunction of control valve pressure compensation valve on smaller load side Pr...

Page 905: ...re q In combined operations of swing and boom RAISE boom rising speed is low Related infor mation q If boom RAISE speed is also low when it is operated singly perform troubleshooting for H 6 Boom oper...

Page 906: ...g and travel Failure q Travel speed drops largely in combined operation of swing and travel Related infor mation q If speed of single travel operation is also low carry out troubleshooting for H 18 Tr...

Page 907: ...le Measured oil pres sure Operation of levers and oil pressure ratio All levers in the neu tral position Run the track off ground lever at half stroke Pump discharge pressure Almost same pres sure 1 P...

Page 908: ...LS EPC valve a Be ready with engine stopped then troubleshoot with engine high idle Travel speed Travel lever LS EPC valve output pressure Lo Neutral Approx 2 9 MPa Approx 30 kg cm2 Hi Operation 0 MPa...

Page 909: ...ve may malfunction Check it 6 Malfunction of merge divider main valve Merge divider main valve may malfunction Check it 7 Malfunction of merge divider LS valve Merge divider LS valve may malfunction C...

Page 910: ...f LS EPC valve a Troubleshoot with engine high idle with monitoring function Travel speed Travel lever Monitoring code 01500 Lo Operation 663 mA PC200 8M0 PC200LC 8M0 578 mA PC220 8M0 PC220LC 8M0 See...

Page 911: ...ions of the same motor or those of the right and left motors with each other and judge from the change of the phenomenon 3 Defective seal of travel motor check valve Seal of check valve of travel moto...

Page 912: ...spool Spool of swing control valve may malfunction Check the spool 3 Malfunction of swing motor swing holding brake Swing brake may malfunction Check it 4 Improper adjustment or Mal function of swing...

Page 913: ...quipment control lever PPC valve output pressure Neutral 0 MPa 0 kg cm2 Left swing Right swing 2 84 to 3 43 MPa 29 to 35 kg cm2 2 Malfunction of swing control valve spool Spool of swing control valve...

Page 914: ...malfunction Check them 3 Malfunction of swing motor swing holding brake Swing brake may malfunction Check it 4 Improper adjustment or Mal function of swing motor safety valve a Be ready with engine s...

Page 915: ...Neutral 0 MPa 0 kg cm2 Left swing Right swing 2 84 to 3 43 MPa 29 to 35 kg cm2 2 Malfunction of swing control valve spool Spool of swing control valve may malfunction Check the spool 3 Malfunction of...

Page 916: ...ulic relief Below 10 l min Failure 2 Upper structure overruns excessively when stop swinging in only one direction Related infor mation q Perform all troubleshooting with working mode in power mode P...

Page 917: ...ause Criteria and troubleshooting procedure 1 Malfunction of swing PPC valve a Be ready with engine stopped then troubleshoot with engine high idle Left work equipment control lever PPC valve output p...

Page 918: ...e Criteria and troubleshooting procedure 1 Malfunction of back pressure valve Backpressurevalve may have malfunction Check it 2 Malfunction of swing motor safety valve Safety valve of swing motor may...

Page 919: ...ng brake may malfunction Check it Failure 2 Swing drift on a slope is large when swing brake is being released Related infor mation q When swing holding brake release switch is in release position swi...

Page 920: ...sure 2 B mode Service circuit is changed to single acting circuit and safety valve is set to high pressure q Safety valve set pressure on only B port side is changed that on A port side is kept low P...

Page 921: ...r mation q When attachment installation specification is employed oil flow in service circuit changes accord ing to selected user mode q How to adjust flow rate in ATT mode is different from that in B...

Page 923: ...not start 7 S 3 Engine does not pick up smoothly 10 S 4 Engine stops during operation 11 S 5 Engine runs rough or is unstable 12 S 6 Engine lacks power 13 S 7 Exhaust smoke is black incomplete combust...

Page 924: ...are those to be answered by the customer or operator Questions in section A are for basic information about the failure Depth and accuracy of their an swers to the questions in section B may depend o...

Page 925: ...ip with the causes E Reference information for estimation of the cause Q Information and inspection result that indicate the cause of the failure w A cause particularly probable among those marked wit...

Page 926: ...troubleshooting Exhaust gas is black Incomplete combustion Let us assume that a trouble of Exhaust gas is black occurred and we checked the Questions and Check items and found the following 3 items to...

Page 927: ...troubleshooting chart There is a causal relationship between 3 items in the Questions and Check items sections and 6 items in the Causes sections The method of pinpointing the cause from the causal r...

Page 928: ...ne oil must be added more frequently w When engine is preheated or when temperature is low preheating monitor does not indicate proper functioning of preheating system w During operation charge level...

Page 929: ...s heard from battery relay Q w Check items When starting switch is turned to START starter pinion does not plunge Q Q w When starting switch is turned to START starter pinion plunges but Rotation spee...

Page 930: ...ing after short time stoppage w Q w w Fuel other than specified one is used w Filters are not replaced as indicated in the Operation and Maintenance Manual w E Fuel tank is found to be empty w Air bre...

Page 931: ...r when temperature is low preheating monitor does not indicate proper function of preheating system w Dust indicator indicates a red zone w Air breather hole of fuel tank cap is clogged Q Rust and wat...

Page 932: ...ed in the Operation and Maintenance Manual w w Engine oil must be added more frequently w Dust indicator indicates a red zone w Air breather hole in fuel tank cap is clogged w Rust and water are found...

Page 933: ...Q Q Q Q Engine hunted and stopped w Q Q Q Q Q Q Fuel other than specified one is used Q Q Q Q Filters are not replaced as indicated in the Operation and Mainte nance Manual w w Fuel level monitor ind...

Page 934: ...y Machine operation hours Operated for long period E Hunting Occurs at a certain speed range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slope w Filters are not r...

Page 935: ...ters are not replaced as indicated in the Operation and Maintenance Manual w w Oil must be added more frequently Q Q Dust indicator indicates a red zone w w Air breather hole in fuel tank cap is clogg...

Page 936: ...t be added more frequently w Power was lost Suddenly w Q Q Q Gradually Q Q Q Q Dust indicator indicates a red zone w Muffler is crushed w Air leaks at tubing between turbocharger and cylinder head and...

Page 937: ...ecent repair history Machine operation hours Operated for long period E E E E Oil consumption suddenly increased w Q Engine oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w...

Page 938: ...rain tube Exhaust smoke is bad Questions Check recent repair history Machine operation hours Operated for long period E E E Fuel other than specified one is used Q Q Oil must be added more frequently...

Page 939: ...E E Fuel consump tion is more than that on other machines of same model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q External leakage of fuel from engine w Combustion is irregular w Engine...

Page 940: ...Internal cracks in cylinder block Holes caused by pitting Broken oil cooler core or O ring Questions Check recent repair history Machine operation hours Operated for long period E E Oil level rose su...

Page 941: ...ressure Q w Oil other than specified one is used Q Q Filters are not replaced as indicated in the Operation and Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low id...

Page 942: ...ck recent repair history Machine opera tion hours Operated for long period E E E E Fuel must be added more frequently w w Coolant must be added more frequently Q Q Oil in coolant Q Q Q Q w Oil smells...

Page 943: ...ne oil level has risen and oil is milky w Q Fan belt tension is low w Check items When fan pulley is turned it has play w Milky oil is floating on coolant w Unusual air bubbles are found in radiator o...

Page 944: ...oost temperature sensor Questions Check recent repair history Machine opera tion hours Operated for long period E Abnormal noise Gradually occurred Q Q Sudden occurred Q Q Q Fuel other than specified...

Page 945: ...mp Broken parts in damper chamber Questions Check recent repair history Machine opera tion hours Operated for long period E E E Vibration Suddenly increased Q Q Gradually increased Q Q Q Oil other tha...

Page 947: ...Machine model Serial number PC200 8M0 400001 and up PC200LC 8M0 400001 and up PC220 8M0 100001 and up PC220LC 8M0 100001 and up 50 Disassembly and assembly 1 100 General information on disassembly and...

Page 948: ...arting with 79 T means that they are not available from Komatsu Ltd i e tools to be made locally Removal q In Removal section the work procedures precautions and know how to do the work and the amount...

Page 949: ...tool is pre sented in the section of Sketches of special tools q Part No of special tools starting with 79 T means that they are not available from Komatsu Ltd i e tools to be made locally Disassembly...

Page 950: ...ngines ThreeBond 1735 790 129 9140 50 g Polyethylene container q Instantaneous adhesive q Curing time From 5 sec to 3 min q Use mainly to bond metals rubbers plastics and woods Aron alpha 201 790 129...

Page 951: ...ict SYG2 400LI SYG2 350LI SYG2 400LI A SYG2 160LI SYGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various q Feature Lithium grease with extreme pressure lu brication performance general purpose type Mo...

Page 952: ...UNSTAR SASH PRIMER GP 402 22M 54 27250 20 ml Glass con tainer q Use as primer for sash anodized aluminum surface Effective period four months after date of manufacture Adhesive SUNSTAR PENGUINE SEAL58...

Page 953: ...nt oil seal Engine rear oil seal 2 795 799 6500 Seal puller t 1 N Installation of engine rear oil seal Cylinder head assembly fuel injector assembly 3 795 799 6700 Primer t 1 N Removal of fuel injecto...

Page 954: ...assembly t 1 Removal and installation of ring nut 5 796 427 1520 Installer t 1 Installation of floating seal 6 796T 427 1510 Push tool t 1 Q Installation of hub assembly 790 101 2510 Block t 1 790 10...

Page 955: ...t 1 Track shoe assembly R 791 630 3000 Remover and installer t 1 Separation and installation of track shoe assembly 790 101 1300 Cylinder 980 kN 100 ton t 1 790 101 1102 Pump t 1 Hydraulic pump assemb...

Page 956: ...3 796 946 1320 Guide f21 8 mm t 1 For 723 46 40100 796 946 1620 Guide f21 4 mm t 1 For 723 46 41100 796 946 1820 Guide f21 2 mm t 1 For 723 46 43100 and 723 46 43400 796 946 1920 Guide f21 0 mm t 1 Fo...

Page 957: ...021 Grip 1 01010 50816 Bolt 2 6 790 201 1500 Push tool kit q 1 Press fit of dust seal 790 201 1650 Push tool for boom and bucket 1 790 201 1660 Plate for arm 1 790 101 5021 Grip 1 01010 50816 Bolt 2 W...

Page 958: ...0LC 8M0 100 General information on disassembly and assembly Sketches of special tools Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according...

Page 959: ...220LC 8M0 50 100 13 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketch...

Page 960: ...200LC 220 220LC 8M0 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketch...

Page 961: ...220LC 8M0 50 100 15 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketch...

Page 963: ...of fuel supply pump assembly 2 Removal and installation of fuel injector assembly 6 Removal and installation of engine front oil seal 13 Removal and installation of engine rear oil seal 18 Removal an...

Page 964: ...nk B section 3 Close the fuel stop valve 4 Remove cover 1 5 Open the engine hood 6 Disconnect fuel filter hoses 2 and 3 from fuel supply pump 16 1 a Remove dirt on the connector in advance Because dir...

Page 965: ...2 17 Remove 3 nuts A parts and remove fuel injec tion pump assembly 16 4 a Fuel injection pump assembly 16 comes off in one piece with the gear No treat ment tooth extraction etc has been given to the...

Page 966: ...q How to install high pressure pipe 9 1 Tighten the sleeve nuts by hand both sides 2 Tighten the sleeve nuts in the order of firstly the pump side then the common rail side 3 Sleeve nut 35 3 5 Nm 3 5...

Page 967: ...dirt or foreign material and dry prior to assembly 1 Install the gear 19 onto the shaft 21 2 Install the lock washer 20 and nut 18 and finger tighten 3 Use the support A12 and 1 2 inch spinner han dl...

Page 968: ...ial sticking around the head cover by blowing air while holding the head cover with the hand in order to prevent entry of mud and foreign material a When removing head cover 9 take care not to hit it...

Page 969: ...nting bolts to remove rocker arms 16 a Loosen locknut 17 and loosen adjust ment screw 18 two to three turns so that an excessive force is not applied to the push rod when the rocker arm is installed 9...

Page 970: ...e sure to replace the inlet connector with a new one as well a Check that the fuel injector sleeve is free from flaws and dirt 1 Fit O ring 24 and gasket 25 to fuel injector 22 2 Apply engine oil EO15...

Page 971: ...mark on sealing surface e at the front end of the inlet con nector a If high pressure fuel leaks through the inlet connector the sealing surface has fine streaks or cracks 7 Apply engine oil EO15W 40...

Page 972: ...n in the reverse order to removal 1 3 Head cover mounting bolt 24 4 Nm 2 4 0 4 kgm 2 3 Fuel injector wiring harness nut 1 5 0 25 Nm 0 15 0 025 kgm a Check the wiring harness that does not interfere wi...

Page 973: ...highly heated portions of the engine if fuel leaks 5 q Fuel pressure sensor and relief valve 1 Replace fuel pressure sensor 2 if neces sary according to the following procedure a Do not remove fuel pr...

Page 974: ...kage through the relief valve exceeds the specified value do not reuse the relief valve 4 Check that there is no damage on high pressure sealing surfaces A on the relief valve and common rail 5 Instal...

Page 975: ...o the section of Removal and instal lation of hydraulic oil cooler assembly 3 Remove the aftercooler assembly referring to the section of Removal and installation of aftercooler assembly 4 Remove moun...

Page 976: ...ioner assembly 16 and rotate it to the oppo site to the winding up direction R to decrease the fan belt 12 tension then remove k Make sure that the wrench is secured at the portion A before rotating i...

Page 977: ...clockwise to remove engine front oil seal 14 a Take care not to damage the crankshaft while removing the seal Installation 1 Install front oil seal 14 using tool A1 a Before installing the seal check...

Page 978: ...bration damper 13 2 Tighten mounting bolts 15 according to the following procedure 1 Tighten the bolts diagonally with a torque of 55 5 Nm 5 6 0 5 kgm 2 Loosen bolts by 180 degrees 3 Tighten the bolts...

Page 979: ...llows q Insert a wrench to the portion A width across flats T 12 7 mm of the tensioner assembly 16 and rotate it to the oppo site to the winding up direction R to install the fan belt 12 k Make sure t...

Page 980: ...3 Remove damper assembly 2 4 Remove mounting bolt 3 and insert guide bolts 2 1 a Width across flats 18 mm 5 Lift temporarily flywheel assembly 4 and pull out flywheel assembly 4 a Be careful not to l...

Page 981: ...the crankshaft a Before installing the oil seal degrease clean and dry the crankshaft sealing face and the seal lip face to prevent oil leak age 2 Insert pilot 5 to crankshaft 6 and push oil seal 5 in...

Page 982: ...dial gauge probe into contact with faucet joint portion a or the outer perimeter surface of the flywheel at a right angle 3 Rotate the flywheel 360 and measure the difference of the maximum swing of...

Page 983: ...mp assembly steps 5 to 20 in Removal q Engine hood q Top cover on control valve q Cover between hydraulic pump and en gine q Frame between control valve and engine q Cover between control valve and en...

Page 984: ...p a Mark the hose edge and tube to show the original hose installation positions See figure below a If disconnecting air intake connector C replace the gasket 11 Disconnect radiator hoses 11 4 12 Disc...

Page 985: ...pressure pipe 21 between the common rail and fuel supply pump 6 19 Remove cap 22 and remove high pressure pipe 21 7 20 Remove caps 23 and remove six high pres sure pipes 24 8 21 Remove common rail 20...

Page 986: ...es 15 28 Lift temporarily exhaust manifold and turbo charger assembly 80 and remove the remaining mounting bolts 16 29 Lift off exhaust manifold and turbocharger assembly 80 to remove it 4 Exhaust man...

Page 987: ...ve clamp 43 and two bands 44 of wir ing harness 42 39 Remove five head cover mounting bolts 45 to remove head cover 46 together with blowby duct 47 a After loosening head cover mounting bolts 45 remov...

Page 988: ...h rod when the rocker arm is installed 46 Remove crossheads 55 a Record the installed position and direction shapes of holes a and b of each crosshead When reassembling install the crosshead in the re...

Page 989: ...ad gasket 64 Installation 1 Cylinder head assembly 1 Measure stem length a of mounting bolt for every cylinder head and check that it is less than the using limit q Using limit length of bolt Below 13...

Page 990: ...en the bolts by 90 5 degrees a When angle tightening tool A6 is not used 4 After above steps 1 to 2 are finished put a paint mark across cylinder head and mounting bolts 5 Retighten the bolts by 90 5...

Page 991: ...b of the inlet connector 2 There is foreign material in the edge filter at rear end c of the inlet con nector 3 The O ring at upper part d of the inlet connector is cracked or deterio rated 4 There is...

Page 992: ...sshead and rocker arm a Since the hole shapes at parts a and b of each crosshead are differ ent install them to their respective intake and exhaust valves in the origi nal directions a Check that the...

Page 993: ...rule 2 Install muffler assembly 8 according to the follow ing procedure 1 Sling muffler assembly 8 and set it to the mounting position 3 Whole circumference of e of exhaust pipe 8a Heat hardening sea...

Page 994: ...g a new hose Tighten until dimension BDG is 7 10 mm 4 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 5 3 Fuel return hose joint bolt 24 4 Nm 2 4 0 4 kgm 6 k When installing keep the distance of more t...

Page 995: ...high pressure pipes 72 73 74 and 75 3 Tighten the sleeve nut of high pressure pipe 25b temporarily 4 Tighten high pressure pipe 25b in the order of firstly pump FSP side then com mon rail 20 side 3 S...

Page 996: ...nect the engine wiring harness At this time take care not to connect the wiring harness in reverse 5 Start the engine and check that fuel does not leak a For the testing procedure see Testing and adju...

Page 997: ...ioner compressor belt tension section in the Testing and adjusting chapter of this man ual 19 a Install fan belt 38 as follows q Insert a wrench to the portion A width across flats T 12 7 mm of the te...

Page 998: ...til the coolant temperature drops before starting the work 1 Turn the upper structure by 90 2 Remove cover 1 3 Drain the engine coolant 6 Coolant 20 3 l PC200 200LC 8M0 19 9 l PC220 220LC 8M0 4 Open u...

Page 999: ...se length q 45 mm Radiator side q 40 mm Engine side 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 3 a Confirm that the heat insulating seal material sponge of the radiator peripheral part is not dama...

Page 1000: ...position k Disconnect the cable from the negative terminal of the battery 1 Turn the upper structure by 90 2 Remove cover 1 3 Open up the engine hood 4 Remove hydraulic oil cooler drain plug 2 to dra...

Page 1001: ...order of re moval 1 a Confirm that the heat insulating seal material sponge of the radiator peripheral part is not damaged If the heat insulating seal material sponge is damaged replace it to the new...

Page 1002: ...e work equipment to the ground stably and stop the engine k Disconnect the cable from the negative terminal of the battery 1 Turn the upper structure by 90 2 Remove cover 1 3 Open up the engine hood 4...

Page 1003: ...verse order of removal 1 1 Install hose and tube assembly 4 a Use a new MIKALOR clamp 1 Align the hose to the original position marking position a Inserted air hose length q Aftercooler side 60 mm q E...

Page 1004: ...2 a Replace the O ring to the new one 3 a Confirm that the heat insulating seal material sponge of the radiator peripheral part is not damaged If the heat insulating seal material sponge is damaged r...

Page 1005: ...drain the fuel in order to stop the fuel flow from the fuel tank return hose 1 Disconnect fuel hoses 1 and 2 with the pre caution described below a Be sure to disconnect the hoses in avoid ing the in...

Page 1006: ...ation tag to each piping to avoid a mistake in the position of installation later 1 Turn the upper structure by 90 2 Remove hydraulic tank strainer and stop oil flow out using tool A10 A11 a If tool A...

Page 1007: ...12 14 Remove frame 13 15 Remove covers 14 and 15 a Cover 15 cannot be removed unless removing cover 9 a The hatched area is made of rubber lower side 16 Remove mounting bolt 16 17 Remove mounting bol...

Page 1008: ...d tube to show the original hose installation positions See figure below a If disconnecting air intake connector C replace the gasket 25 Disconnect radiator hose 27 3 a Mark the hose edge and tube to...

Page 1009: ...t air conditioner compressor assembly 37 8 36 Remove fan belt 38 37 Disconnect connector AC02 39 38 Remove air conditioner compressor assembly 37 a Remove air conditioner compressor as sembly in one p...

Page 1010: ...54 51 Remove filter and bracket assembly 55 a Put it on hose bracket HB 52 Disconnect 6 hoses q 56 Rear load pressure input port hose Color band No color q 57 58 EPC basic pressure port hose Color ba...

Page 1011: ...no color q 70 V19 LS EPC solenoid valve Color band red q 71 V11 PC EPC F solenoid valve Color band white a It is behind bracket 72 58 Disconnect bracket 72 59 Disconnect clamp 73 60 Disconnect hydraul...

Page 1012: ...firstly fix nut locking tool plate A8 with bolt B to restrict nut N from turning then remove engine mounting bolt 83 68 Lift out engine and hydraulic pump assembly 84 a Lift it at the 3 points i e 2...

Page 1013: ...new hose Tighten until dimension BDG is 7 10 mm 3 a Align the hose to the original position marking position a Align the clamp to the original position a Reference Inserted air hose length 49 mm 3 Rad...

Page 1014: ...s and radiator hoses q Refilling engine coolant Refill coolant through the coolant filler port up to the specified level Start the engine and cir culate the coolant and then check the coolant level 5...

Page 1015: ...SEN06143 00 PC200 200LC 220 220LC 8M0 50 200 53 200 Engine and cooling system Removal and installation of engine and hydraulic pump assembly...

Page 1017: ...20 8M0 100001 and up PC220LC 8M0 100001 and up 50 Disassembly and assembly 1 300 Power train Removal and installation of final drive assembly 2 Disassembly and assembly of final drive assembly 4 Remov...

Page 1018: ...l of the battery 2 Remove cover 1 3 Disconnect the travel speed selector hose 2 the motor hoses 3 and 4 and the drain hose 5 a PC200 8M0 PC200LC 8M0 4 Temporarily sling the final drive assembly 6 5 Re...

Page 1019: ...245 309 Nm 25 31 5 kgm 2 3 Mounting bolts 265 309 Nm 27 31 5 kgm Average torque 275 Nm or more 28 kgm or more q Refilling with oil Fill the power train oil TO30 via the oil filler port to the specifie...

Page 1020: ...1 Remove No 1 planetary carrier assembly 3 2 Disassemble No 1 planetary carrier assembly in the following procedure 1 Drive pin 4 into shaft 5 to remove shaft 5 from No 1 planetary carrier 6 a Remove...

Page 1021: ...r 14 9 Thrust washer Remove thrust washer 15 10 No 2 planetary carrier assembly 1 Remove No 2 planetary carrier assembly 16 2 Disassemble No 2 planetary carrier assembly in the following procedure 1 D...

Page 1022: ...nd remove from travel motor 4 Hub assembly 80 kg 2 Remove bearing 27 3 Remove bearing outer races 29 and 30 from hub 28 13 Remove floating seals 32 and 33 from travel motor 31 a The floating seals 32...

Page 1023: ...After floating seal installation apply a thin coat of power train oil TO30 on the sliding surfaces 2 Install bearing 34 to travel motor 31 a Warm the inner race of the bearing 34 to 50 70 C with heate...

Page 1024: ...a under the condi tion described in 6 above a After measuring the size a remove the tool J2 8 b is the thickness of the ring nut 25 itself 9 Calculate the value of c by subtract b from a 10 Using tool...

Page 1025: ...ng the No 2 planetary gear 21 Take care so the thrust washer is not dam aged 3 Insert pin 17 a When inserting the pin take care so that any of the three pawls on the circumference Portion f may not to...

Page 1026: ...y carrier Remove the caulked metal from the inside diameter of the hole before starting to assemble 1 Assemble bearings 8 and 9 fit top and bottom thrust washers 7 and 10 and then set the No 1 planeta...

Page 1027: ...smoothly a After the pin is inserted stake the pins C on the carrier at 2 loca tions 2 Install No 2 planetary carrier assembly 3 14 Washer Install washer 2 a After installing washer 2 measure dis tanc...

Page 1028: ...r and ring gear Liquid gasket LG 6 2 Using tool J7 tighten the 18 mounting bolts 3 Mounting bolts First time 98 Nm 10 kgm Sencond time 80 90 rotating angle 16 Oil refill Tighten drain plug and fill po...

Page 1029: ...y 1 Remove No 1 planetary carrier assembly 3 2 Disassemble No 1 planetary carrier assembly according to the following pro cedure 1 Drive pin 4 into shaft 5 to remove shaft 5 from No 1 planetary carrie...

Page 1030: ...sun gear Remove No 2 sun gear 14 9 Thrust washer Remove thrust washer 15 10 No 2 planetary carrier assembly 1 Remove No 2 planetary carrier assembly 16 2 Disassemble the No 2 planetary carrier assembl...

Page 1031: ...ly 1 Using eyebolts 2 sling and remove hub assembly 26 from the travel motor 4 Hub assembly 80 kg 2 Remove bearing 27 3 Remove bearing outer races 29 and 30 from hub 28 13 Remove floating seals 32 and...

Page 1032: ...al installation apply a thin coat of power train oil on the slid ing surfaces 2 Sliding surface Power train oil TO30 2 Install bearing 34 to travel motor 31 a Warm the inner race of the bearing 34 to...

Page 1033: ...ing inner race pressed 4 Release the pressing force 5 Press the bearing again a Pressing force 17 7 to 21 6 kN 1 8 to 2 2 ton 6 Rotate the hub two to three times 7 Measure dimension a under the condit...

Page 1034: ...of punching 1 Install needle bearing 22 to No 2 planetary gear 21 Fit upper and lower thrust washers 20 and 23 and set the gear assembly to No 2 planetary carrier 19 2 Align the pin holes on shaft 18...

Page 1035: ...case end face to install 8 Thrust washer Install thrust washer 15 9 No 2 sun gear Install No 2 sun gear 14 10 No 1 sun gear shaft Install No 1 sun gear shaft 11 11 Thrust washer Install thrust washer...

Page 1036: ...1 plan etary carrier 6 2 Align the pin holes in shaft 5 and the No 1 planetary carrier and install the shaft 5 by tapping it lightly with a plastic hammer a Install the shaft while rotating No 1 plane...

Page 1037: ...he assembly is built incorrectly Recheck 15 Cover 1 Using eyebolts 1 install cover 1 4 Cover 25 kg 2 Mating faces of cover and ring gear Liquid gasket LG 6 a Do not apply liquid gasket LG 6 to tap 2 U...

Page 1038: ...om the negative terminal of the battery a Attach an identification tag to each piping to avoid a mistake in the position of installation later 1 Remove cover 1 2 Open engine hood 2 and remove cover 3...

Page 1039: ...very careful for the drain hose lift them a Lift them with full attention until surpass the hose of the center swivel joint 4 Swing motor and swing machinery assembly 250 kg Installation q Installatio...

Page 1040: ...assembly 1 Set the swing motor and the swing machinery assembly into block 1 2 Oil drain Loosen drain plug 39 and drain the oil inside the swing machinery case 5 Swing machinery case PC200 200LC 8M0 7...

Page 1041: ...earing 8 thrust washer 9 in order 2 Remove plate 10 3 Reverse carrier 34 and remove snap ring 35 a PC200 8M0 PC200LC 8M0 a PC220 8M0 PC220LC 8M0 3 Using push tool 2 remove shaft 11 from carrier 34 q I...

Page 1042: ...rier 18 a After removing the shaft remove pin 16 2 Remove thrust washer 19 gear 20 and bearing 21 3 Remove plate 22 a PC200 8M0 PC200LC 8M0 a PC220 8M0 PC220LC 8M0 11 Shaft and case assembly 1 Reverse...

Page 1043: ...29 from cover 28 a PC220 8M0 PC220LC 8M0 only 13 Remove spacer 41 and O ring 42 from shaft 26 14 Remove bearing 31 from case 30 a Apply a suitable tool on the circumference of the outer race thick li...

Page 1044: ...of the oil seal up and down 2 Outside perimeter of oil seal Gasket sealant LG 6 a When press fitting take care so that gas ket sealant LG 6 will not stick to the lip surface of the oil seal a If tool...

Page 1045: ...ked 5 Set into the press 6 Using tool F1 push tools 13 14 press fit inner race section of bearing 27 a Put in push tool 14 for the cases that the case assembly is inclined a lot a If case assembly 32...

Page 1046: ...ith plastic hammer etc align pin hole location of shaft 17 and carrier and install shaft 17 a Install the shaft rotating the plan etary gear Take care so the thrust washer is not damaged 5 Insert pin...

Page 1047: ...d in the following figure and then install it 3 Mounting bolts 157 196 Nm 16 20 kgm 9 Install O ring 37 a PC200 8M0 PC200LC 8M0 a PC220 8M0 PC220LC 8M0 10 No 1 carrier assembly 1 Assemble No 1 carrier...

Page 1048: ...220 8M0 PC220LC 8M0 a P Press fit plate 12 Swing motor assembly Put swing motor assembly 2 on ring gear 13 4 Swing motor assembly 70 kg a Degrease mating face of swing motor assembly 2 and ring gear 1...

Page 1049: ...Confirm mounting angle of elbow for drain 38 15 and the tightening torque 3 Elbow mounting nut 128 186 Nm 13 0 19 0 kgm 14 Install the drain hose a As installing the hose be careful that the drain plu...

Page 1050: ...in the reverse order of removal 1 a Let the soft zone position S mark of an inner race a and the soft zone position S mark of an outer race b to be right side of the body as mentioned below and insta...

Page 1051: ...SEN06144 00 PC200 200LC 220 220LC 8M0 50 300 35 300 Power train Removal and installation of swing circle assembly...

Page 1053: ...ndercarriage and frame Disassembly and assembly of carrier roller assembly 2 Disassembly and assembly of track roller assembly 5 Removal and installation of idler and idler cushion assembly 7 Disassem...

Page 1054: ...the end surface of a shaft and remove followings from carrier roller 1 q Roller 4 ring 5 assembly shaft 2 and cover 3 q Press fitting force reference 59 kN 6 000 kg min a The press fitted shaft 2 and...

Page 1055: ...ng 5 a When installing the floating seal completely wash degrease and dry both O ring and the surfaces where the O ring and the floating seal will contact each other hatched area in the sketch And tak...

Page 1056: ...between roller 4 and ring 5 1 8 0 2 mm put washer 7 between push tool 6 and roller 4 then press fit ring 5 to shaft 2 a The thickness of washer 7 is 1 8 0 2 mm a Use push tool 5 to support shaft 2 on...

Page 1057: ...5 6 Remove bushings 9 and 10 from roller 4 Assembly 1 Using push tool 1 press fit bushings 9 and 10 to roller 4 2 Fit an O ring and install collar 8 to shaft 5 and insert pin 7 3 Using tool L2 instal...

Page 1058: ...Install shaft 5 to roller 4 6 Put roller 4 and shaft 5 assembly upside down 7 Using tool L2 install floating seal 3a to collar 2 a As to notes for installation of floating seal 3a refer to a marked c...

Page 1059: ...tion and connection of track shoe assembly 2 By using bar 1 move idler and idler cushion assembly 1 forward to a position where it can be lifted 3 Lift idler and idler cushion assembly 1 pull it forwa...

Page 1060: ...and idler 4 3 Remove idler 4 from the assembly of shaft 5 and support 7 a Since approximately 250 cc of oil is filled in drain it at this timing or underlay some cloth against any careless smearing 4...

Page 1061: ...dler 4 and the assembly of shaft 5 and sup port 2 a Completely clean degrease and dry the contact surfaces hatched area shown in the figure of the floating seal and the O ring a Apply oil to the slidi...

Page 1062: ...in the figure of the floating seal and the O ring a Apply oil to the sliding surface of the float ing seal and take care not to have any dirt stuck on it a After inserting the floating seals check th...

Page 1063: ...nut becomes loose a Release the hydraulic pressure slowly to release the compression of the spring a Free length of spring PC200 8M0 503 mm PC200LC 8M0 PC220 8M0 PC220LC 8M0 561 mm 3 Remove yoke 6 an...

Page 1064: ...spring 5 Install the assembly to tool M1 2 Sliding surface of cylinder Grease G2 LI 5 Apply hydraulic pressure slowly to com press the spring and then tighten nut 4 so that the installed length of th...

Page 1065: ...s with work equipment and place block 1 between track frame and track shoe 3 Remove sprocket 2 hanging as follows 1 Remove fixing bolt 1 1 a Before removing the final fixing bolt place block 2 under s...

Page 1066: ...Lift tracks 3 by stretching the work equip ment against ground 2 Move master pin 2 to a position above the idler where it can be removed easily 3 Relieve the extended work equipment and lower the mac...

Page 1067: ...pin 1 and remove block 2 so that track shoe 3 can be separated 8 Move the machine slowly in reverse to sepa rate the track shoe 3 4 Installation 1 While tensing wire 3 with a forklift truck work equip...

Page 1068: ...oe 5 and link and the seating faces of bolt 7 and nut 2 Install shoe 5 3 Mounting bolts 7 4 pieces 1 Tighten to 490 50 Nm 50 5 kgm a Finger tighten the four bolts until the mating faces of the link ar...

Page 1069: ...B of the bushing end and dust seal 2 Contact surface B portion between bushing and dust seal Grease NIGTIGHT LYK 2 from Nippon grease Co Ltd part No 44392708 a Press fit master pin 2 to push guide pin...

Page 1070: ...sassemble the counterweight assembly referring to the Removal and installation of counterweight assembly section in this man ual 3 Disconnect 4 boom cylinder hoses 1 a Plug the hose to stop oil flow o...

Page 1071: ...ving frame assembly front and rear and left and right k When removing the revolving frame assembly take care so that it does not hit the center swivel joint assembly 4 Revolving frame assembly 5 100 k...

Page 1072: ...uipment to the ground stably and stop the engine k Disconnect the cable from the negative terminal of the battery 1 Mirror specification 1 Remove mirror 1 2 Sling counterweight assembly 2 tempo rarily...

Page 1073: ...olts 1 180 1 470 Nm 120 150 kgm 2 a Installation and adjustment of counterweight 1 Using shims adjust the differences in level or gaps between the counterweight and the exterior of machine body 2 Fix...

Page 1075: ...nter swivel joint assembly 2 Disassembly and assembly of center swivel joint assembly 4 Removal and installation of hydraulic tank assembly 5 Removal and installation of control valve assembly 9 Disas...

Page 1076: ...M0 3 Disconnect 6 center swivel joint horses 1 through 6 from the travel motor q 1 Center swivel joint T port L H travel motor T port q 2 Center swivel joint T port R H travel motor T port q 3 Center...

Page 1077: ...CSJ facing in the direction shown in the figure The figure shows the machine body as seen from above a S Sprocket A D Port name q Refilling with oil hydraulic tank Refill hydraulic oil through the oi...

Page 1078: ...to cover 12 3 Install cover 12 to swivel shaft 8 4 Set swivel shaft 8 to block then using push tool tap swivel rotor 7 with a plastic hammer to install 2 Contact surface of rotor shaft Grease G2 LI a...

Page 1079: ...battery Removal a Attach an identification tag to each piping to avoid a mistake in the position of installation later 1 Swing to right 45 For hydraulic tank oil drain 2 Remove cover 1 3 Drain hydraul...

Page 1080: ...cooler upper side 8 Disconnect filter bracket 11 9 Remove frame 12 10 Disconnect drain hoses 13 through 18 q 13 Solenoid valve drain q 14 Main valve drain q 15 Pressure reducing valve drain q 16 PPC d...

Page 1081: ...ps 1 Apply adhesive evenly over the tube side 2 Apply evenly over the tube side Adhesive THREEBOND No 4314 2 Set the hose to the original position a Reference Hose insertion length 85 mm L H and R H 3...

Page 1082: ...ank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate in the hydraulic system by starting the engine Then check the oil level again 5 Hydraulic tank 237 l P...

Page 1083: ...or below 3 6 and to remove the control valve mounting bolt 6 Hydraulic tank 237 l PC200 200LC 8M0 244 l PC220 220LC 8M0 a For the way not to drain the hydraulic tank oil by using oil stopper see Remov...

Page 1084: ...Boom LOWER Hose band brown R H swing Hose band no color R H travel forward Hose band green Arm IN Hose band blue 15 Disconnect hose 19 Hose band brown q 19 PST port hose solenoid 16 Disconnect hoses 2...

Page 1085: ...31 Between control valve and hydraulic tank 24 Disconnect back pressure compensation con nector 31a a Rear figure 25 Disconnect hoses 32 through 36 from the rear side q 32 PP1 port hose rear pump q 33...

Page 1086: ...2 tubes q 45 From the top A 1 port hose If equipped A1 port hose Bucket head side A2 port hose Swivel joint B port A3 port tube Boom bottom side A4 port hose Swing motor MA port A5 port hose Swivel jo...

Page 1087: ...e moval q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate in the hydraulic system by starting the engine Then check the...

Page 1088: ...you may install the tool to the piston to push in the seal further Symbol Part number Part name Necessity Q ty T 2 796 946 1310 Guide f21 8 mm t 1 For 723 46 40100 796 946 1610 Guide f21 4 mm t 1 For...

Page 1089: ...he seal on the tool and push it down to the flat part of the tool Then you may install the tool to the piston to push in the seal further 5 Install settling tool T4 on piston 2 and keep it installed f...

Page 1090: ...amber set drilled hole H1 to the direction shown in the following figure a Do the same with section L L q When installing spool 8 to the valve chamber set drilled hole H2 to the direction shown in the...

Page 1091: ...SEN06146 00 PC200 200LC 220 220LC 8M0 50 500 17 500 Hydraulic system Disassembly and assembly of control valve...

Page 1092: ...bolts of the boom hydraulic drift prevention valve in the same order as that for the control valve cover block 3 Mounting bolt of boom hydraulic drift prevention valve 58 8 73 6 Nm 6 7 5 kgm q Arm qui...

Page 1093: ...each piping to avoid a mistake in the position of installation later 1 Swing to right 45 For hydraulic tank oil drain 2 Remove hydraulic tank strainer and stop oil flow out using tools A10 A11 a If to...

Page 1094: ...13 a Cover 13 cannot be removed unless removing cover 7 14 Disconnect clamp 14 15 Remove filter and bracket assembly 15 a Put it on hose bracket HB 16 Disconnect 6 hoses q 16 Rear load pressure input...

Page 1095: ...r case 0 65 l 20 Disconnect pump wiring connectors at 4 points q 27 V12 PC EPC R solenoid valve Color band yellow q 28 P22 hydraulic oil temperature sensor Color band no color q 29 V19 LS EPC solenoid...

Page 1096: ...r torque a Impact wrench is not applicable to use q Refilling with oil damper case Refill hydraulic oil through the oil filler port to the specified level 5 Damper case EO30 DH 0 65 l q Refilling with...

Page 1097: ...n of hydraulic pump assembly 2 Remove snap ring 1 and then remove spacer 2 3 Pry off oil seal 3 with a screwdriver 1 a Take care in removing the oil seal so that the shaft may not be damaged Installat...

Page 1098: ...installing Assembly a Before assembly thoroughly clean the parts and check them for dirt rust or damage to pre vent failure Assemble the parts with utmost care a Install spring 5 with its small diame...

Page 1099: ...int 12 39 49 Nm 4 5 kgm a Apply grease G2 LI to the sliding parts of joint 12 and contact surfaces of disc 13 and pis ton 8 2 Quantity of grease G2 LI The sliding portions of the joint J portion Apply...

Page 1100: ...18 2 Remove mounting bolt 17 and remove case 16 shafts 15 and levers 13 as a unit 3 Remove mounting bolts 11 to remove plate 10 a Note the thickness and installed position of washer 12 a Remove pin 21...

Page 1101: ...13 and piston 7 and contact surfaces on damper 18 and pin 2 Grease G2 LI Rocking parts of shaft 15 4 to 8 cc entire periphery Contact surfaces on lever 13 and piston 7 0 3 to 0 8 cc part Contact surf...

Page 1102: ...sassembly of piston rod 1 Set piston rod assembly 2 on tool U1 Symbol Part number Part name Necessity Q ty U 1 790 502 1003 Cylinder repair stand q 1 790 101 1102 Pump q 1 2 790 102 4300 Wrench assemb...

Page 1103: ...ed squeeze the screw further once and then apply tap T to the threaded por tion to ease the caulking 3 Using tool U2 remove piston assembly 4 a When not using tool U2 use the drilled holes H f10 mm tw...

Page 1104: ...embly a Be careful not to damage the packings dust seals O rings etc a Clean each part After assembling the cylinder cover the piping ports and pin holes to prevent entering of dirt a Before installin...

Page 1105: ...p ring 16 5 Install backup ring 15 and the O ring Assembly of piston 1 Set piston ring 13 on tool U3 Expand piston ring 13 by turning the handle 8 to 10 turns 2 Remove piston ring 13 from tool U3 Inst...

Page 1106: ...om and arm cylinders 4 Install plunger 5 a Only the boom and arm cylinders 5 Place plunger 10 on piston rod assembly 2 Install 12 balls 9 and cap 8 a After installing the plunger check that there is a...

Page 1107: ...the following procedure 1 Using tool U2 screw in piston assembly 4 until it comes into contact with end face b of the rod a If the cylinder has the bottom cushion put a mark on the rod end face to in...

Page 1108: ...n rod assembly 1 Install piston rod assembly 2 to tool U1 2 Install the cylinder assembly to piston rod assembly 2 a Align axial center of the cylinder tube then insert a Check that the ring is not br...

Page 1109: ...SEN06146 00 PC200 200LC 220 220LC 8M0 50 500 35 500 Hydraulic system Disassembly and assembly of work equipment cylinder...

Page 1111: ...AL 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 50 Disassembly and assemb...

Page 1112: ...then retract the piston rod a Bind the piston rod with wire etc and put it down on the blocking tools so that the pis ton rod does not slip out or allot a support so that the cylinder doesn t fall dow...

Page 1113: ...one in the reverse order of removal 1 2 Inside surface of bushing when assembling pin Molybdenum disulfide lubricant LM P 2 Greasing after assembling the pin Grease LM G k When aligning the position o...

Page 1114: ...e air from the circuit between the valve and the hydraulic cylinder For details see Testing and adjusting Bleeding air from each part q Refilling with oil hydraulic tank Refill hydraulic oil through t...

Page 1115: ...SEN06147 00 PC200 200LC 220 220LC 8M0 50 600 5 600 Work equipment Removal and installation of work equipment assembly...

Page 1117: ...and up PC220 8M0 100001 and up PC220LC 8M0 100001 and up 50 Disassembly and assembly 700 Cab and its attachments Removal and installation of operator s cab assembly 2 Removal and installation of oper...

Page 1118: ...e step plate 2 3 Remove floor mat 3 4 Refer to Removal and installation of monitor assembly and remove monitor assembly 4 5 Remove covers 5 and 6 6 Remove cover and duct assembly 7 7 Insert key 8 turn...

Page 1119: ...em K 19 Disconnect connectors CK01 25 and CK02 26 20 Disconnect connector M10 27 from the oper ator s cab If equipped 21 Disconnect cab wiring intermediate connectors H09 28 H08 29 and H16 30 22 Disco...

Page 1120: ...olt 42 under the cab and remove lock plate 43 1 33 Remove bolt 44 2 34 Remove 7 mounting bolts 45 and 4 mounting nuts 46 a Check the bolt length beforehand 35 Lift off and remove operator s cab assemb...

Page 1121: ...stuck glasses is explained a When replacing front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to...

Page 1122: ...p the both ends of the wire with pliers 3 etc or hold them by winding them onto some thing and move the wire to the right and left to cut the adhesive and dam rubber Since the wire may be broken by th...

Page 1123: ...is 4 months after the date of manufacture Do not use the primer after this limit a Use the primer within 2 hours after un packing it a Even if the primer is packed again just after it is unpacked use...

Page 1124: ...g primer If the glass primer etc is applied by mistake wipe it off with white gasoline 4 Apply the glass primer to the sticking sur faces of window glass 9 2 Glass primer Sunstar primer for glass 580...

Page 1125: ...surface to the utmost a Care should be taken not to float the dam rubber of each sticking corner a When sticking dam rubber 6 around a frame do not lap its finishing end over the starting end Or make...

Page 1126: ...rubbers 6 If it is stuck along the inside it will be seen through the transparent part of the glass 5 Position the new window glass 1 Check the clearance between the window glass and the operator s ca...

Page 1127: ...Adhesive Oct to Apr Sunstar penguine seal 580 super W or equivalent a The using limit of the adhesive is 4 months after the date of manufacture Do not use the adhesive after this limit a Keep the adh...

Page 1128: ...dam rubber 6 a Apply the adhesive evenly with same height level a Apply adhesive 15 additionally to additional dam rubber 6a of right side window glass and additional dam rubber 6b of door lower wind...

Page 1129: ...between it and cen ter trim seal 16 with caulking mate rial in range s with dimensions t and u After applying the primer to glass 4 of section A A apply the adhesive as caulking material q Caulking d...

Page 1130: ...them completely 9 After installing the window glass remove any excess of the primer and adhesive from the operator s cab and window glass a By using the white gasoline wipe off the adhesive before it...

Page 1131: ...Mounting bolt 4 and washer 3 for left corner block are used to hang the pull up assist cable in the following step 6 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a li...

Page 1132: ...bottom of front window assembly 10 though the rail opening portion and lower it gradually 8 Lower front window assembly 10 completely a Do not let the front window assembly touch the monitor 9 Twist f...

Page 1133: ...Mounting bolt 34 3 Nm 3 5 kgm 3 Raise the front window assembly and fix it with the rear locks on both sides a Check that the locks in the rear of the operator s cab are securely fastened 4 Install ri...

Page 1134: ...the front window assembly q If right and left locks 16 and 17 do not work normally 1 Loosen lock fitting bolt 18 move lock 16 forward and then tighten the bolt again a The same applies to the right s...

Page 1135: ...cided within the range where this switch works a Limit switch 19 is used to prevent the windshield wiper from moving when turning the wiper switch on by mistake when the front window assembly is in Op...

Page 1136: ...t for one and a half rotation a One turn of rubber stopper 18 to the left is equivalent to squashing the rubber for approxi mately 1 5 mm a When the front window assembly is in Open position the front...

Page 1137: ...e lock of the front window assembly 1 After finishing the adjustment of steps 6 9 check that latching efforts of both right and left locks 16 and 17 are even a Check the latching efforts on both Close...

Page 1138: ...ective goggles while you are collect ing the refrigerant R134a or filling the air conditioner circuit with the refrigerant R134a Collecting and filling work must be conducted by a qualified person 1 T...

Page 1139: ...connect hose 19 a Check the connecting point a Plug the hose to stop oil flow out a Disconnect the work equipment PPC hose P at joint box side See item 30 17 Disconnect hose 20 a Check the connecting...

Page 1140: ...nd 37 together with wiring harness 35 to the boom side 28 Open the engine hood and remove cover 38 29 Disconnect clamp 39 30 Disconnect PPC hose 40 of the work equip ment From the top the color of the...

Page 1141: ...on on the O ring a When connecting the refrigerant piping coat the O ring with compressor oil for new refrig erant R134a Denso ND OIL8 VALEO THERMAL SYSTEMS ZXL100PG PAG 46 or equivalent 3 Mounting bo...

Page 1142: ...igerant R134a a Never release the refrigerant R134a to the atmosphere a Ask a qualified person for collecting adding and filling operations of the refrigerant R134a a Note connector numbers and instal...

Page 1143: ...emove cover 13 seven bolts a Disconnect connector 14 located behind cover 13 q Connector 14 Cigarette lighter M04 10 Remove duct 15 two bolts 11 Remove cover 16 three bolts and bracket 41 two bolts a...

Page 1144: ...t console wiring harness 16 Remove cable tie 40 of the floor wiring har ness 17 Remove four bolts 29 and remove pump con troller assembly A Arrange the assembly neatly and place it on the floor apart...

Page 1145: ...nication antenna GPS q Connector 43 Machine main harness CK01 q Connector 44 Machine main harness CK02 q Connector 45 Communication antenna 20 Remove KOMTRAX terminal C four bolts 21 Remove cover 33 2...

Page 1146: ...or water does not enter them a When connecting the air conditioner hoses and tubes check that O rings are fitted to their joints a Do not reuse an O ring since it is deformed and deteriorated once it...

Page 1147: ...SEN06148 01 PC200 200LC 220 220LC 8M0 50 700 31 700 Cab and its attachments Removal and installation of air conditioner unit assembly...

Page 1149: ...00001 and up PC200LC 8M0 400001 and up PC220 8M0 100001 and up PC220LC 8M0 100001 and up 50 Disassembly and assembly 1 800 Electrical system Removal and installation of machine monitor assembly 2 Remo...

Page 1150: ...he negative terminal of the battery a Note connector numbers and installed posi tions before disconnecting wirings and hoses Removal 1 Pull up front window assembly 1 to the ceiling and lock it a Chec...

Page 1151: ...embly 18 a Loosening mounting bolts 19 first makes easier to remove machine monitor mount ing bolts 9 Remove four mounting bolts 11 of machine monitor 12 10 Disconnect connectors 13 to 16 a Disconnect...

Page 1152: ...r 4 from the engine con troller by pushing the lock 1 6 Remove the mounting bolt and engine control ler 5 a Ground E and harness clamp are tight ened together with Installation q Carry out installatio...

Page 1153: ...SEN06149 00 PC200 200LC 220 220LC 8M0 50 800 5 800 Electrical system Removal and installation of engine controller assembly 2 Remove O ring 7 with tweezers 1...

Page 1154: ...and put it to the right side 4 Disconnect wiring connectors C01 6 and C02 7 as follows q Tilt lock L2 inside while pressing lock L1 a Bar B comes out and the lock is re leased 5 Remove the 4 mounting...

Page 1155: ...Move lever 3 of connector cover 1 from the upper position to the left position lock position in the figure a B C Claws a If the sliders and lever are not set as shown in the following figure the con n...

Page 1156: ...s a Disconnect the hose located under box 1 2 Remove box 2 three bolts a Be careful about connectors 3 and 4 located behind box 2 for machines equipped with 12 V power socket q Connector 3 12 V power...

Page 1157: ...SEN06149 00 PC200 200LC 220 220LC 8M0 50 800 9 800 Electrical system Removal and installation of KOMTRAX terminal assembly...

Page 1159: ...uration and function of refrigeration cycle 6 Outline of refrigeration cycle 7 Air conditioner unit 9 Air conditioner controller 15 Compressor 16 Condenser and Modulator 17 Sensor 18 Procedure for tes...

Page 1160: ...t 51 Failure code 879DKZ Sunlight sensor Open or Short Circuit 52 Failure code 879EMC Ventilating Damper Abnormality 54 Failure code 879FMC Air Mix Damper Abnormality 55 Failure code 879GKX Refrigeran...

Page 1161: ...onditioner compressor or receiver drier and so on a Ask a qualified person for collecting adding and filling operations of the refrigerant R134a a Never release the refrigerant R134a to the atmo spher...

Page 1162: ...100 Air conditioner Air conditioner component 80 100 4 PC200 200LC 220 220LC 8M0 SEN06151 00 Air conditioner component...

Page 1163: ...s 9 Air conditioner controller 10 Air conditioner unit 11 Recirculation air filter 12 Fresh air filter 13 Machine monitor 14 Sunlight sensor Specifications A Front vent B Rear vent C Foot vent D Defro...

Page 1164: ...s and increases its temperature and pres sure so that it can be liquefied easily in con denser Compression of refrigerant Condenses refrigerant to discharge heat absorbed in evaporator condensation of...

Page 1165: ...re also adjusts the refrigerant flow rate simultaneously The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat refrigeration load to be removed...

Page 1166: ...it will be evaporated and part of it will be sucked into the compressor in liquid form which will cause the compressor to compress the liquid and may damage the components q If water gets into the ref...

Page 1167: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 9 100 Air conditioner Air conditioner unit Air conditioner unit a This air conditioner unit is auto temperature control type...

Page 1168: ...nt freezing of the evaporator 1 by operat ing the compressor clutch relay to stop the compressor See Parts and connectors layout for details re garding the compressor clutch relay Air flow adjustment...

Page 1169: ...oor 10 Opening and closing door Angle Opening and closing door Angle Opening and closing door Angle Air vent mode Front Close 0 Close 0 Close 0 Front and rear Open 25 Close 0 Close 0 Front rear and fo...

Page 1170: ...to perform vent mode change over q Whenever a switch on the machine monitor is operated the air conditioner controller delivers power to the servomotor by raising the voltage between terminals 6 and...

Page 1171: ...ve converts high pressure and high temperature liquid refrigerant from the receiver drier to low pressure low temperature misty refrigerant through the throttle action q It controls the flow rate of r...

Page 1172: ...e is in creased q The force Fg of the refrigerant gas 2 pushing the needle valve 1a is increased and the nee dle valve 1a moves leftward q As a result the opening level of the needle valve 1a is incre...

Page 1173: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 15 100 Air conditioner Air conditioner controller Air conditioner controller a See System Diagrams for details regarding in put output signals...

Page 1174: ...ature so that it will be easily regenerated liquefied at the normal tempera ture q Calling into account of the evaporator tempera ture and refrigerant pressure the air conditioner controller activates...

Page 1175: ...a load to the engine or reducing cooling effect Take extreme care not to crush or damage the fins when handling them or checking them in daily inspection Specification Function q Modulator 2 a This ha...

Page 1176: ...istics Outside air temperature sensor 1 Connector 2 Sensor Outline q The outside air temperature sensor is installed on the bracket in the cooling unit See Parts and connectors layout q The outside ai...

Page 1177: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 19 100 Air conditioner Sensor...

Page 1178: ...itioner 2 Narrow down the sections with the self diagnosis function See Check with self diagnosis If however the entire air conditioner unit fails to operate inspect for problems with the supply of po...

Page 1179: ...n be seen i e the liquid is perfectly clear the system contains too much refrigerant or no refrigerant at all The above should be treated as general guidelines as certain exceptions do exist See Troub...

Page 1180: ...100 Air conditioner Circuit diagram and arrangement of connector pins 80 100 22 PC200 200LC 220 220LC 8M0 SEN06151 00 Circuit diagram and arrangement of connector pins...

Page 1181: ...r conditioner Circuit diagram and arrangement of connector pins a Diffuser servomotor means vent mode changeover servomotor a SERVOMOTOR OF INSIDE OUTSIDE AIR means FRESH RECIRC air changeover servomo...

Page 1182: ...100 Air conditioner System diagram 80 100 24 PC200 200LC 220 220LC 8M0 SEN06151 00 System diagram a This air conditioner unit is auto temperature control type...

Page 1183: ...atic air conditioning the air conditioner controller controls the inside air temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor the outside air t...

Page 1184: ...Connectors that are not involved in the troubleshooting Connector No Remarks Location Reference item AC01 Intermediate connector Right rear of cab 2 AC02 Intermediate connector Right rear of cab 2 AC...

Page 1185: ...5 A Fuse for the power supply backup power supply of the air conditioner controller 2 Air conditioner controller 1 q AC01 Intermediate connector q AC02 Intermediate connector q ACECU Air conditioner c...

Page 1186: ...Machine monitor connector a Connector CM03 Not used a Connector CM04 For camera connection 6 Dual pressure switch a Rotate cab undercover 90 degrees and re move it q P17 Dual pressure switch connecto...

Page 1187: ...t window is securely locked 2 Remove front lower window 2 3 Remove floor mat 3 4 Remove cover 4 first and remove cover 5 5 Remove cover 6 6 Remove cap 7 1 7 Remove cover 7 a Disconnect the sunlight se...

Page 1188: ...EN06151 00 11 Remove cover 13 seven bolts a Be careful about connector 14 behind box 13 q Connector 14 Cigarette lighter M04 12 Check whether any of the following ducts or pins are disconnected q Fron...

Page 1189: ...conditioner controller a Even if the cause of a detected problem is re stored to normal the self diagnosis failure condi tion will not automatically be reset To reset the failure condition the starte...

Page 1190: ...ide air temperature sensor a The ventilating sensor means the evaporator temperature sensor frost sensor a The ventilation damper means the vent mode changeover damper door a The air mix damper means...

Page 1191: ...ful about connectors 3 and 4 be hind magazine box 2 for machines equipped with 12 V power socket q Connector 3 12 V power socket intermedi ate harness M13A q Connector 4 12 V power socket intermedi at...

Page 1192: ...k the opening and closing operations of the door damper visually a The system does not have self diagnosis func tion for FRESH RECIRC air changeover servo motor Testing 1 Open outside air filter cover...

Page 1193: ...test sunlight sensor connector P31 q To reset the self diagnosis system detection of abnormality the starting switch must be turned OFF a If the sunlight sensor is measured with the resis tance range...

Page 1194: ...t temperature is below 0 C there is a possibility that the dual pressure switch is OFF In such a case the dual pressure switch is actually normal i e not defective 1 Swing by 90 deg 2 Remove the cab u...

Page 1195: ...heck whether its clicks a The air conditioner controller will not turn on the compressor clutch relay in the following cases 1 When the evaporator temperature is below 3 C depending on the input volta...

Page 1196: ...Air conditioner Troubleshooting chart 1 80 100 38 PC200 200LC 220 220LC 8M0 SEN06151 00 Troubleshooting chart 1 The numbers in the boxes are the item numbers in the troubleshooting table 1 Cooling tro...

Page 1197: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 39 100 Air conditioner Troubleshooting chart 1 2 Heating trouble...

Page 1198: ...e duct Repair Obstruction at evaporator inlet Check evaporator for stain and obstruction Remove obstruc tion and clean Defective evaporator tempera ture sensor defective contact of evaporator temperat...

Page 1199: ...oubleshooting with gauge pressure Dual pres sure switch Defective dual pressure switch See Troubleshooting for compressor and refrigerant system See Testing refrigerant dual pressure switch Replace Pr...

Page 1200: ...ng to these Information described q Procedure q Measuring location a Between A and B means Measure voltage or resistance and so on between A and B q Standard value in normal condition to judge probabl...

Page 1201: ...ory of record Remarks 879AKA A C Inner Sensor Open Circuit MON Electrical system Troubleshooting cannot be performed while the controller is mounted on the machine since the connector cannot be checke...

Page 1202: ...temperature sensor The air conditioner can be operated in manual mode Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code i...

Page 1203: ...ir temperature sensor The air conditioner can be operated in manual mode Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code...

Page 1204: ...tioner controller has small pins and does not have a T adapter perform troubleshooting by using the intermediate connector Although the intermediate connector does not have a T adapter either it does...

Page 1205: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 47 100 Air conditioner Failure code 879BKA A C Outer sensor Open Circuit Circuit diagram related to air conditioner outside air temperature sensor...

Page 1206: ...form troubleshooting by using the intermediate connector Although the intermediate connector does not have a T adapter either it does have large pins q To replace the air conditioner harness between a...

Page 1207: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 49 100 Air conditioner Failure code 879BKB A C Outer sensor Short Circuit Circuit diagram related to air conditioner outside air temperature sensor...

Page 1208: ...rost sensor Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code is displayed in the Electrical Systems electrical systems ab...

Page 1209: ...ture frost sen sor Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code is displayed in the Electrical Systems electrical sys...

Page 1210: ...rts and connectors layout q Since connector ACECU of the air conditioner controller has small pins and does not have a T adapter perform troubleshooting by using the intermediate connector Although th...

Page 1211: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 53 100 Air conditioner Failure code 879DKZ Sunlight sensor Open or Short Circuit Circuit diagram related to sunlight sensor...

Page 1212: ...perated Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code is displayed in the Electrical Systems electrical systems abnor...

Page 1213: ...ure cannot be regulated Related infor mation q Method of reproducing failure code Turn starting switch to ON position q Check whether this failure code is displayed in the Electrical Systems electrica...

Page 1214: ...U of the air conditioner controller has small pins and does not have a T adapter perform troubleshooting by using the intermediate connector Although the intermediate connector does not have a T adapt...

Page 1215: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 57 100 Air conditioner Failure code 879GKX Refrigerant Abnormality Circuit diagram related to refrigerant dual pressure switch...

Page 1216: ...trical equipment of machine q For each connector see Parts and connectors layout q In cases where fuses are blown when the A C switch is pressed see Troubleshooting for compres sor and refrigerant sys...

Page 1217: ...nnect switch to OFF position 3 Disconnect connector AC02 4 Remove fuse No 10 of fuse box F01 Resistance Between connector AC02 female 4 red and F01 10 Min 1 Mz 6 Defective air conditioner controller R...

Page 1218: ...connector ACECU and inter mediate controller the air conditioner unit must be replaced Cause Procedure measuring location criteria and remarks 1 Defective dual pressure switch system a Perform this c...

Page 1219: ...arting switch to OFF position 2 Disconnect connectors AC03 and R21 and connect a T adapter to the female side of AC03 Resistance Between AC03 female 1 and chassis ground Min 1 Mz 6 Short circuit in wi...

Page 1220: ...100 Air conditioner Troubleshooting for compressor and refrigerant system Air is not cooled 80 100 62 PC200 200LC 220 220LC 8M0 SEN06151 00 Circuit diagram related to compressor and refrigerant system...

Page 1221: ...transistor may also be defective a The blower motor cannot be replaced unless the air conditioner unit is removed once q Since connector ACECU of the air conditioner controller has small pins and does...

Page 1222: ...100 Air conditioner Troubleshooting for blower motor system No air comes out or air flow is abnormal 80 100 64 PC200 200LC 220 220LC 8M0 SEN06151 00 Circuit diagram related to blower motor system...

Page 1223: ...abnor mality record screen in the service mode of the machine monitor q Troubleshooting cannot be performed since the connector portion of the servomotor cannot be checked while it is installed on mac...

Page 1224: ...100 Air conditioner Troubleshooting for FRESH RECIRC air changeover 80 100 66 PC200 200LC 220 220LC 8M0 SEN06151 00 Circuit diagram related to FRESH RECIRC air changeover...

Page 1225: ...e line pressure is too low Below approx 1 MPa 10 kg cm2 q Low pressure line pressure is too high Above approx 0 3 MPa 3 kg cm2 q Low pressure line pressure is too low Below ap prox 0 05 MPa 0 5 kg cm2...

Page 1226: ...r defective contact of sensor coming off of mounting clip Evaporator is frozen Flow rate of refrigerant is reduced due to freezing At Cool Max and HI speed of fan later it becomes not to cold Repair o...

Page 1227: ...the thread is coarse care should be taken with regard to loosening Connect the gauge manifold hoses and other ser vice tools according to the following procedure 1 Close high pressure valve 6 and low...

Page 1228: ...100 Air conditioner Connection of service tool 80 100 70 PC200 200LC 220 220LC 8M0 SEN06151 00 A From Cab B To Condenser...

Page 1229: ...ith the refrigerant q When loosening the air conditioner hose nuts af ter collecting the refrigerant be sure to use 2 wrenches Use one wrench to fix and use the other one to loosen the nuts q Cover th...

Page 1230: ...cting air conditioner piping 80 100 72 PC200 200LC 220 220LC 8M0 SEN06151 00 Table of tightening torque for refrigerant pipe joint 1 Engine 2 Compressor 3 Condenser 4 Modulator 5 Air conditioner unit...

Page 1231: ...herefore the cap must be immediately closed after use to limit contact with air Store the oil can in a dry and ventilated place a Precautions for using oil Do not allow oil for use with R134a to come...

Page 1232: ...ec ified quantity 180 cc filled in it q Other cases a New compressor contains compressor oil of 180 cc in it 1 Prepare an oil container and drain oil from the old compressor 2 Measure the quantity of...

Page 1233: ...use of the refrigerant pressure in the cycle 1 Condenser 2 Receiver drier a The desiccant is in receiver drier 2 Taking out desiccant D 1 Remove snap ring SR from receiver drier 2 2 Remove cap C from...

Page 1234: ...ly ND OIL 8 to the periphery of O ring OR of cap C 2 Install filter F to cap C 3 Insert desiccant D in receiver drier 2 4 Install cap C with filter F to receiver drier 2 5 Install snap ring SR to rece...

Page 1235: ...SEN06151 00 PC200 200LC 220 220LC 8M0 80 100 77 100 Air conditioner Desiccant replacement procedure...

Page 1237: ...C200LC 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 90 Diagrams and drawings 1 100 Hydrauli...

Page 1238: ...SEN06153 00 90 100 2 PC200 200LC 220 220LC 8M0 100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram Symbols in hydraulic circuit diagram 1...

Page 1239: ...SEN06153 00 PC200 200LC 220 220LC 8M0 90 100 3 100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram...

Page 1240: ...SEN06153 00 90 100 4 PC200 200LC 220 220LC 8M0 100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram...

Page 1241: ...0 200LC 220 220LC 8M0 PC200 200LC 220 220LC 8M0 SEN06153 00 Hydraulic circuit diagram 1 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 a This figure covers the equipment and devices that are unavailable...

Page 1242: ...SEN06153 00 PC200 200LC 220 220LC 8M0 90 100 7 100 Hydraulic diagrams and drawings Symbols in hydraulic circuit diagram...

Page 1244: ...C200LC 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 90 Diagrams and drawings 1 200 Electric...

Page 1245: ...SEN06154 00 90 200 2 PC200 200LC 220 220LC 8M0 200 Electrical diagrams and drawings Symbols in electric circuit diagram Symbols in electric circuit diagram 1...

Page 1246: ...SEN06154 00 PC200 200LC 220 220LC 8M0 90 200 3 200 Electrical diagrams and drawings Symbols in electric circuit diagram...

Page 1247: ...SEN06154 00 90 200 4 PC200 200LC 220 220LC 8M0 200 Electrical diagrams and drawings Symbols in electric circuit diagram...

Page 1248: ...LC 8M0 Electrical circuit diagram 1 5 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 This figure covers the equipment and devices that are unavailable as optional items in some areas Electrical circuit d...

Page 1249: ...LC 8M0 Electrical circuit diagram 2 5 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 This figure covers the equipment and devices that are unavailable as optional items in some areas Electrical circuit d...

Page 1250: ...LC 8M0 Electrical circuit diagram 3 5 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 This figure covers the equipment and devices that are unavailable as optional items in some areas Electrical circuit d...

Page 1251: ...0LC 8M0 Electrical circuit diagram 4 5 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 This figure covers the equipment and devices that are unavailable as optional items in some areas Electrical circuit...

Page 1252: ...0LC 8M0 Electrical circuit diagram 5 5 PC200 8M0 PC200LC 8M0 PC220 8M0 PC220LC 8M0 This figure covers the equipment and devices that are unavailable as optional items in some areas Electrical circuit...

Page 1253: ...SEN06154 00 PC200 200LC 220 220LC 8M0 90 200 5 200 Electrical diagrams and drawings Symbols in electric circuit diagram 15...

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