CEBM025500
Shop Manual
HYDRAULIC EXCAVATOR SERIAL NUMBERS PC200LC-8 ENGINE
A90301 and up
SAA6D107E-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2011 Komatsu Printed in U.S.A. Komatsu America Corp. September 2011
FOREWORD
CONTENTS
12 CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90
DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
PC200LC-8
FOREWORD
SAFETY
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4.
When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine.
00-4
PC200LC-8
FOREWORD
GENERAL
12 GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts. STANDARD VALUE TABLE This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. TROUBLESHOOTING Troubleshooting charts correlating Problems to Causes are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. DIAGRAMS AND SCHEMATICS This section has the foldout drawings for the machine.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
PC200LC-8
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12 HOW TO READ THE SHOP MANUAL
Volumes
00
00
Revisions
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Chassis volume: Engine volume:
Symbols
Issued for every machine model Issued for each engine series
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
Distribution And Updating
Filing Method 1. 2.
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. 00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item
3.
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
00
10-4 10-4-1 10-4-2
Added pages
10-5
Revised Edition Mark When a manual is revised, an edition mark ( recorded on the bottom outside corner of the pages.
00-6
00
) is
PC200LC-8
This is the sample of the manual Click on the download link for complete manual
Download Link
FOREWORD
HOISTING INSTRUCTIONS
12 HOISTING INSTRUCTIONS
00
Hoisting
can result. Hooks have maximum strength at the middle portion.
00
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol.
1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
Wire Ropes 1.
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
00
Wire ropes (Standard Z or S twist ropes without galvanizing)
2.
3.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
PC200LC-8
00-7
FOREWORD 12 PUSH PULL COUPLER
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 Disconnection 1.
2.
3. 4.
2.
00
Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold the rubber cap portion (4). After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks. Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare an oil receiving container.
Connection 1.
00
00
Hold the hose adapter (1) or hose (5) and insert it in the mating adapter (3), aligning them with each other. Do not hold the rubber cap portion (4). After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality.
00-8
PC200LC-8
FOREWORD
Type 2 Disconnection
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and turn the lever (4) to the right clockwise.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
Connection 1.
00
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
PC200LC-8
00-9
FOREWORD 12 Type 3
Disconnection
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
Connection 1.
00
Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-10
PC200LC-8
FOREWORD
COATING MATERIALS
12 COATING MATERIALS
00
The recommended coating materials prescribed in the shop manuals are listed below.
Adhesive
Category
Komatsu code
Part No.
Qty
Container
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene container
Features: Resistance to heat and chemicals. Used to fix and seal bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardener)
Adhesive: 1 kg Hardener: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-129-9120
75 g
Tube
50 g
Polyethylene container
Quick-setting adhesive. Setting time: Within 5 sec. to 3 min. Used mainly to stick metals, rubbers, plastics, and woods.
790-129-9130
2g
Polyethylene container
Quick-setting adhesive. Quick-setting type. (max. strength is obtained after 30 minutes) Used mainly to stick rubbers, plastics, and metals.
Loctite 64879A-129-9110 50
50 cc
Polyethylene container
Features: Resistance to heat and chemicals. Used for fitted portions used at high temperatures.
200 g
Tube
Used to stick or seal gaskets and packings of power train case, etc.
1 kg
Can
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat-resistant gasket for high temperature locations such as engine pre-combustion chamber, exhaust pipe. Used to seal various threaded portions, pipe joints, and flanges. Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
ThreeBond 1735
Aron-alpha 201
LG-1
Gasket sealant
LG-3
790-129-9140
790-129-9010
790-129-9070
Main features and applications
Used to stick and seal metal, glass, and plastics.
Used to seal plugs. Heat-resistant seal used to repair engines.
LG-5
790-129-9080
1 kg
Polyethylene container
LG-6
790-129-9020
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant. Used to seal flange surfaces and threaded portions. Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
ThreeBond 1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
ThreeBond 1207B
419-15-18131
100 g
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Used to seal transfer case, etc.
PC200LC-8
00-11
FOREWORD
LM-G
Primer
Content
Container
Main feature, application
09940-00051
60g
Can
To be used as lubricant (anti squeaking) for sliding part. To be used for press fit, shrink fit and preventing scratching or seizure of thread. To be used as lubricant for linkage and bearing etc..
LM-P
09940-00040
200g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
Various kinds
Various kinds
Versatile type
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various kinds
Various kinds
To be used for the place where the bearing designed for normal temperature and low load condition is used and contacts water and steam.
Grease with SYG2-400M molybdenum SYG2-400M-A disulphide LMSYGA-16CNM G(G2-M)
400gx10 400gx20 16kg
Bellows type
To be used for heavy load places.
Can
Hyper white grease G2-T GO-T(*) *: For cold region
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400g 16kg
Bellows type Can
Higher anti seizure and heat resistance than grease with molybdenum disulphide Body dirt is not distinctive due to white color.
Biological grease G2-B G2-BT(*) *: For heat resistance and heavy load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400g 16kg
Bellows type Can
To be shortly dissolved by a bacteria in nature so that the influence to microorganism and animals and plants is suppressed to the minimum.
20ml (0.7 oz)
Glass container
To be used as primer for cab side. (Term of validity: 4 months after manufacturing)
Sunstar primer for glass 580 super
20ml (0.7 oz)
Glass container
To be used as primer for glass side. (Term of validity: 4 months after manufacturing)
Sunstar primer for painting plane 435-95
20ml (0.7 oz)
Glass container
Sunstar primer for painting plane 580 super
Sunstar primer for glass 435-41 Sunstar primer for sash GP-402
00-12
Part number
417-926-3910
22M-54-27230
22M-54-27240
150ml (5.1 oz)
Can
22M-54-27250
20ml (0.7 oz)
Glass container
For adhesion of cab glass
Grease
Lubricant with molybdenum disulfide
ClassiKomatsu code fication
COATING MATERIALS
To be used as primer for painting plane of cab side. (Term of validity: 4 months after manufacturing) To be used as primer for black ceramic coated plane of glass side and polycarbonate hard coat plane. (Term of validity: 4 months after manufacturing) To be used as primer for sash (Alumite surface treatment) (Term of validity: 4 months after manufacturing)
PC200LC-8
FOREWORD Part number
Content
Container
Main feature, application
Sunstar penguine seal 580 super "S" or "W"
417-926-3910
320ml (10.8 oz)
Polyethylene container
"S" and "W" are used as glass adhesive compound in high temperature (April -October) and in low temperature (October -April) respectively. (Term of validity: 4 months after manufacturing)
Sika Ltd, Japan Sika Flex 256HV
20Y-54-39850
310ml (10.5 oz)
Polyethylene container
To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing)
Sunstar penguine super 560
22M-54-27210
320ml (10.8 oz)
ECOCART (special container)
Sunstar penguine seal No. 2505
417-926-3920
320ml (10.8 oz)
Polyethylene container
Sekisui silicone sealant
20Y-54-55130
333ml (11.3 oz)
Polyethylene container
To be used for seal of front window. (Term of validity: 6 months after manufacturing)
22M-54-27220
333ml (11.3 oz)
Cartridge
To be used as seal for joints of glass. semi-transparent white seal (Term of validity: 12 months after manufacturing)
GE Toshiba Silicones Tosseal 381
PC200LC-8
For adhesion of cab glass
Caulking compound
Adhesive compound
ClassiKomatsu code fication
COATING MATERIALS
To be used as glass adhesive compound. (Term of validity: 6 months after manufacturing) To be used as seal for joints of glass. (Term of validity: 4 months after manufacturing)
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
12 STANDARD TIGHTENING TORQUE
00
Standard Tightening Torque Of Bolts And Nuts
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
N m
lbf ft
6
10
11.8 - 14.7
8.70 - 10.84
8
13
27 - 34
19.91 - 25.07
10
17
59 - 74
43.51 - 54.57
12
19
98 - 123
72.28 - 90.72
14
22
153 - 190
112.84 - 140.13
16
24
235 - 285
173.32 - 210.20
18
27
320 - 400
236.02 - 295.02
20
30
455 - 565
335.59 - 416.72
22
32
610 - 765
449.91 - 564.23
24
36
785 - 980
578.98 - 722.81
27
41
1150 - 1440
848.19 - 1062.09
30
46
1520 - 1910
1121.09 - 1408.74
33
50
1960 - 2450
1445.62 - 1807.02
36
55
2450 - 3040
1807.02 - 2242.19
39
60
2890 - 3630
2131.55 - 2677.35
Thread diameter of bolt
Width across flats
mm
mm
N m
lbf ft
6
10
5.9 - 9.8
4.35 - 7.22
8
13
13.7 - 23.5
10.10 - 17.33
10
14
34.3 - 46.1
25.29 - 34.00
12
27
74.5 - 90.2
54.94 - 66.52
00-14
PC200LC-8
FOREWORD
STANDARD TIGHTENING TORQUE
12 Tightening Torque Of Hose Nuts
00
Use these torques for hose nuts. Thread diameter
Width across flat
mm
mm
N m
lbf ft
02
14
19
19.6 - 29.4
14.5 - 21.7
03
18
24
29.4 - 68.6
21.7 - 50.6
04
22
27
58.9 - 98.1
44.4 - 72.4
05
24
32
107.9 - 166.7
79.6 - 123.0
06
30
36
147.1 - 205.9
108.5 - 151.9
10
33
41
147.1 - 245.1
108.5 - 180.8
12
36
46
196.2 - 294.2
144.7 - 217.0
14
42
55
245.2 - 343.2
180.9 - 253.1
Nominal No.
Tightening torque
Tightening Torque Of Split Flange Bolts
00
Use these torques for split flange bolts. Thread diameter
Width across flat
Tightening torque
mm
mm
N m
lbf ft
10
14
59 - 74
43.51 - 54.57
12
17
98 - 123
72.28 - 90.72
16
22
235 - 285
173.32 - 210.20
Tightening Torque For Flared Nuts
00
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
N m
lbf ft
14
19
24.5 ± 4.9
18.0 ± 3.6
18
24
49 ± 19.6
36.1 ± 14.4
22
27
78.5 ± 19.6
57.8 ± 14.4
24
32
137.3 ± 29.4
101.2 ± 21.6
30
36
176.5 ± 29.4
130.1 ± 21.6
33
41
196.1 ± 49
144.6 ± 36.1
36
46
245.2 ± 49
180.8 ± 36.1
42
55
294.2 ± 49
216.9 ± 36.1
PC200LC-8
Tightening torque
00-15