Komatsu PC200-8, PC200LC-8, PC220-8, PC220LC-8 Hydraulic Excavator Service Manual
1,158 pages · Publication SEN00084-20
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What's inside
From the manual's own table of contents: 188 sections, 349 entries. See sample pages (PDF, 821 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Power train
Final drive
Swing machinery
Swing circle
Track frame and recoil spring
Idler
Show all 188 sections
Carrier roller
Track roller
Track shoe
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Pilot oil filter
Control valve
CLSS
Functions and operation by valve
Swing motor
Center swivel joint
Travel motor
PPC valve
Work equipment and swing PPC valve47 topics
- Travel PPC valve
- Service PPC valve (with EPC valve)
- Service PPC valve
- Valve control
- Solenoid valve
- PPC accumulator
- Anti-drop valve for boom
- Anti-drop valve for arm
- Return oil filter
- Attachment circuit selector valve
- Hydraulic cylinder
- Work equipment
- Dimensions of arm
- Dimensions of bucket
- Air conditioner piping
- Engine control
- Electrical control system
- Monitor system
- Sensor
- KOMTRAX system
- Standard value table for engine related parts
- Standard value table for chassis related parts
- Tools for testing, adjusting, and troubleshooting
- Sketch of special tool
- Testing engine speed
- Testing intake air pressure (boost pressure)
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Handling fuel system parts
- Releasing residual pressure from fuel system
- Testing fuel pressure
- Testing fuel delivery, return and leak amount
- Bleeding air from fuel circuit
- Checking fuel circuit for leakage
- Checking and adjusting air conditioner compressor belt tension
- Replacing fan belt
- Testing swing circle bearing clearance
- Checking and adjusting track shoe tension
- Inspection and adjustment oil pressure in work equipment, swing, and travel circuits
- Testing control circuit source pressure
- Testing and adjusting oil pressure in pump PC control circuit
- Testing and adjusting oil pressure in pump LS control circuit
- Testing solenoid valve output pressure
- Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Checking parts which cause hydraulic drift of work equipment
Releasing residual pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Checking cab tipping stopper
Adjusting mirrors
Angle adjustment of rear view camera
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service
Failure codes table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press. Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hydr Oil Overheat
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error56 topics
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA322] Inj #1 Open/Short Error
- Failure code [CA323] Inj #5 Open/Short Error
- Failure code [CA324] Inj #3 Open/Short Error
- Failure code [CA325] Inj #6 Open/Short Error
- Failure code [CA331] Inj #2 Open/Short Error
- Failure code [CA332] Inj #4 Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
- Failure code [CA428] Water in Fuel Sensor High Error
- Failure code [CA429] Water in Fuel Sensor Low Error
- Failure code [CA435] Eng Oil Press Sw Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA488] Chg Air Temp High Torque Derate
- Failure code [CA553] Rail Press High Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Continuous Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1633] KOMNET Datalink Timeout Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2311] IMV Solenoid Error
- Failure code [CA2555] Grid Htr Relay Volt High Error
- Failure code [CA2556] Grid Htr Relay Volt Low Error
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D862KA] GPS Antenna Discon
- Failure code [DA22KK] Pump Solenoid Power Low Error
- Failure code [DA25KP] 5V Sensor 1 Power Abnormality
- Failure code [DA29KQ] Model Selection Abnormality
- Failure code [DA2RMC] CAN Discon (Pump Con Detected)
- Failure code [DAF8KB] Short circuit in camera power supply
- Failure code [DAFGMC] GPS Module Error
- Failure code [DAFRMC] CAN Discon (Monitor Detected)
- Failure code [DGH2KB] Hydr Oil Sensor Short
- Failure code [DHPAMA] F Pump Press Sensor Abnormality
- Failure code [DHPBMA] R Pump Press Sensor Abnormality
- Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
- Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
- Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
- Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
- Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
- Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
- Failure code [DHX1MA] Overload Sensor Abnormality (Analog)
- Failure code [DW43KA] Travel Speed Sol Discon
- Failure code [DW43KB] Travel Speed Sol Short
- Failure code [DW45KA] Swing Brake Sol Discon
- Failure code [DW45KB] Swing Brake Sol Short
Failure code [DW91KA] Travel Junction Sol Discon
Failure code [DW91KB] Travel Junction Sol Short
Failure code [DWA2KA] Service Sol Discon
Failure code [DWA2KB] Service Sol Short
Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KB] 2-stage Relief Sol Short
Failure code [DXA8KA] PC-EPC (F) Sol Discon
Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DXA9KA] PC-EPC (R) Sol Discon
Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE4KA] Service Current EPC Discon
Failure code [DXE4KB] Service Current EPC Short
Failure code [DXE5KA] Merge-divider Main Sol Discon
Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DXE6KA] Merge-divider LS Sol Discon
Failure code [DXE6KB] Merge-divider LS Sol Short
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKB] Washer Drive Short
Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short
Before carrying out troubleshooting of electrical system
Information in troubleshooting table
When starting switch turned ON, machine monitor displays nothing
When starting switch turned ON (before starting engine), basic check item lights up
Engine does not start (Engine does not turn)
Preheater does not operate
Automatic warm-up system does not operate (in cold season)
All work equipment, swing, and travel mechanism do not move or cannot be locked
Precaution lights up while engine is running
Emergency stop item lights up while engine is running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Contents of display by machine monitor are different from applicable machine
Machine monitor does not display some items
Function switch does not work
Auto-decelerator does not operate normally
Working mode does not change
Travel speed does not change
Alarm buzzer cannot be stopped
Windshield wiper and window washer do not operate
Power maximizing function does not operate normally
Swing holding brake does not operate normally
Travel alarm does not sound or does not stop sounding1 topic
- (including air conditioner abnormality record)
While starting switch is in OFF position, service meter is not displayed
Machine monitor cannot be set in service mode
Monitoring function does not display lever control signal normally
KOMTRAX system does not operate normally
System diagram of hydraulic and mechanical system52 topics
- Information in troubleshooting table
- Speed or power of whole work equipment, swing, and travel is low
- Engine speed lowers significantly or engine stalls
- Work equipment, swing, and travel systems do not work
- Abnormal sound comes out from around hydraulic pump
- Auto-decelerator does not operate
- Fine control performance or response is low
- Speed or power of boom is low
- Speed or power of arm is low
- Speed or power of bucket is low
- Work equipment does not move singly
- Hydraulic drift of work equipment is large
- Time lag of work equipment is large
- When part of work equipment is relieved singly, other parts of work equipment move
- Power maximizing function does not work
- In compound operation of work equipment, speed of part loaded more is low
- When machine swings and raises boom simultaneously, boom rising speed is low
- When machine swings and travels simultaneously, travel speed is low
- Machine deviates during travel
- Travel speed is low
- Machine is not steered well or steering power is low
- Travel speed does not change or travel speed is low/high
- Travel system does not move (only one side)
- Upper structure does not swing
- Swing acceleration or swing speed is low
- Upper structure overruns remarkably when it stops swinging
- Large shock is made when upper structure stops swinging
- Large sound is made when upper structure stops swinging
- Hydraulic drift of swing is large
- Attachment circuit is not changed
- Oil flow in attachment circuit cannot be controlled
- Method of using troubleshooting chart
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lack output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
- Oil consumption is excessive (or exhaust smoke is blue)
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts back or coolant level goes down)
- Oil pressure drops
- Oil level rises (Entry of coolant/fuel)
- Coolant temperature becomes too high (overheating)
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler assembly
Removal and installation of engine and hydraulic pump assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of idler, recoil spring assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of sprocket
Expansion and installation of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Removal and installation of anti-drop valve assembly for boom
Removal and installation of anti-drop valve assembly for arm
Disassembly and assembly of anti-drop valve assembly
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly5 topics
- Hydraulic circuit diagram (PC200, 200LC-8)
- Hydraulic circuit diagram (PC220, 220LC-8)
- Electrical circuit diagram
- Connector arrangement diagram
- Electrical circuit diagram for air conditioner
Inside this manual
Real pages from this service manual (1,158 pages). Open the sample pages (PDF, 820 KB)
- Specifications, page 270: 10 Structure, function and maintenance standard
- Troubleshooting, page 729: Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
- Diagram, page 780: Circuit diagram related to merge-divider LS EPC solenoid
- Foldout diagram, page 1,149: Electrical circuit diagram (1/6)
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,158 pages
Quantity one is the manual described above.
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Other editions and similar models
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