PC200LC-8 | SN: A90301-UP | Komatsu | Heavy Equipment Manual PDF

Manual HYDRAULICEXCAVATOR

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Duetothiscontinuousprogramofresearchanddevelopment,revisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.

September2011

10STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD

20STANDARDVALUETABLES

30TESTINGANDADJUSTING.

40TROUBLESHOOTING.

50DISASSEMBLYANDASSEMBLY.

90DIAGRAMSANDSCHEMATICS.

3.Beforestartingwork,removetheleadsfromthebattery.ALWAYSremovetheleadfromthenegative(-)terminalfirst.

4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcrane.

5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.

6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.

7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitupimmediately. Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.

8.Gasolineorotherfuelsshouldneverbeusedtocleanparts.Cleanpartwithappropriatesolvents.

9.Besuretoassembleallpartsagainintheiroriginalplaces.Replaceanydamagedpartwithnewparts.

•Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.

10.Wheninstallinghighpressurehoses,makesurethattheyarenottwisted.Damagedtubesaredangerous,sobeextremely carefulwheninstallingtubesforhighpressurecircuits.Alsocheckthatconnectingpartsarecorrectlyinstalled.

11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorques.Wheninstallingprotectivepartssuchas guards,orpartswhichvibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.

12.Whenaligningtwoholes,neverinsertyourfingersorhand.Becarefulnottogetyourfingerscaughtinahole.

13.Whenmeasuringhydraulicpressure,checkthatthemeasuringtooliscorrectlyassembledbeforetakingany measurements.

14.Takecarewhenremovingorinstallingthetracksoftrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,soneverletanyonestandateitherendofthetrack.

15.Whenjumpstartingthemachine,onlyuseamachineofsimilarsizeandvoltage.Neveruseaarcwelderorotherelectrical generatingequipmenttojumpstartthemachine.Carefullyreviewthesafetyandproceduresforjumpstartingthe machine.

Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.

Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.

GENERAL

Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.

STRUCTURE,FUNCTIONANDMAINTENANCESTANDARD

Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.Inaddition,thissectiongivesthejudgementstandards wheninspectingdisassembledparts.

STANDARDVALUETABLE

Thissectionexplainsthestandardvaluesfornewmachineandjudgementcriteriafortesting,adjustingand troubleshooting.Thisstandardvaluetableisusedtocheckthestandardvaluesintestingandadjustingandtojudgeparts introubleshooting.

TESTINGANDADJUSTING

Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.

TROUBLESHOOTING

Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthissection.

DISASSEMBLYANDASSEMBLY

Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.

DIAGRAMSANDSCHEMATICS

Thissectionhasthefoldoutdrawingsforthemachine.

NOTICE

Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvancenotice.Contact yourdistributorforthelatestinformation.

12 HOWTOREADTHESHOPMANUAL

Volumes

Shopmanualsareissuedasaguidetocarryingoutrepairs. Theyaredividedasfollows:

Chassisvolume:Issuedforeverymachinemodel

Enginevolume:Issuedforeachengineseries

Electricalvolume:Eachissuedasonetocoverallmodels

Attachmentvolume:Eachissuedasonetocoverallmodels

Thesevariousvolumesaredesignedtoavoidduplicationof information.Thereforetodealwithallrepairsforanymodel, itisnecessarythatchassis,engine,electricalandattachment beavailable.

DistributionAndUpdating

Anyadditions,amendmentsorotherchangeswillbesentto yourdistributors.Getthemostup-to-dateinformationbefore youstartanywork.

FilingMethod

1.Seethepagenumberonthebottomofthepage.Filethe pagesincorrectorder.

2.Followingexamplesshowhowtoreadthepagenumber: Example: 10-3

Itemnumber(10.StructureandFunction)

Consecutivepagenumberforeachitem

3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.Fileas intheexample. Example:

Revisions

RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.

Symbols

Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.

SymbolItemRemarks

Safety

Caution

Weight

Tightening torque

Specialsafetyprecautionsare necessarywhenperformingthe work.

Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhenperformingthework.

Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.

Placesthatrequirespecial attentionfortighteningtorque duringassembly.

CoatPlacestobecoatedwithadhesives andlubricantsetc.

Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.

Drain

Placeswhereoilorwatermustbe drained,andquantitytobe drained.

Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.

12 HOISTINGINSTRUCTIONS

Hoisting

WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc. IntheDISASSEMBLYAND ASSEMBLYsection,every partweighing25kgormoreis indicatedclearlywiththesymbol.

Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:

1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.

2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.

WireRopes

1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:

Wireropes (Standard“Z”or“S”twistropeswithoutgalvanizing)

Theallowableloadvalueisestimatedtobe1/6or1/7of thebreakingstrengthoftheropeused.

2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident

canresult.Hookshavemaximumstrengthatthemiddle portion.

3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.

WARNING!Slingingwithoneropemay causeturningoftheloadduringhoisting,untwistingofthe rope,orslippingoftherope fromitsoriginalwindingpositionontheload,whichcan resultinadangerousaccident

4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)whenhoistingismadewithtworopes,eachofwhichisallowedto slingupto1000kgvertically,atvarioushangingangles. Whentworopesslingaloadvertically,upto2000kgof totalweightcanbesuspended.Thisweightbecomes 1000kgwhentworopesmakea120°hangingangle.On theotherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kgloadata liftingangleof150°.

12 PUSHPULLCOUPLER

WARNING!Beforecarryingoutthefollowingwork, releasetheresidualpressurefromthe hydraulictank.Fordetails,seeTESTING ANDADJUSTING,Releasingresidualpressurefromhydraulictank.

WARNING!Eveniftheresidualpressureisreleasedfrom thehydraulictank,somehydraulicoilflows outwhenthehoseisdisconnected.Accordingly,prepareanoilreceivingcontainer.

Type1

Disconnection

1.Releasetheresidualpressurefromthehydraulictank.Fordetails, seeTESTINGANDADJUSTING,Releasingresidualpressurefrom hydraulictank.

2.Holdtheadapter(1)andpushthehosejoint(2)intothemating adapter(3).Theadaptercanbepushedinabout3.5mm.Donothold therubbercapportion(4).

3.Afterthehosejoint(2)ispushedintotheadapter(3),pressthe rubbercapportion(4)againsttheadapteruntilitclicks.

4.Holdthehoseadapter(1)orhose(5)andpullitout.Sincesome hydraulicoilflowsout,prepareanoilreceivingcontainer.

Connection

1.Holdthehoseadapter(1)orhose(5)andinsertitinthemating adapter(3),aligningthemwitheachother.Donotholdtherubber capportion(4).

2.Afterinsertingthehoseinthematingadapter,pullitbacktocheck itsconnectingcondition.Whenthehoseispulledback,therubber capportionmovestowardthehoseabout3.5mm.Thisdoesnot indicateanabnormality.

Type2

Disconnection

1.Holdthemouthpieceofthetighteningportionandpushbody(2)in straightuntilslidingpreventionring(1)contactscontactsurfaceaof thehexagonalportionatthemaleend.

2.HoldintheconditioninStep1,andturnthelever(4)totherightclockwise.

3.HoldintheconditioninSteps1and2,andpulloutthewholebody (2)todisconnectit.

1.Holdthemouthpieceofthetighteningportionandpushbody(2)in straightuntilslidingpreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleendtoconnectit.

12 Type3

Disconnection

1.Holdthemouthpieceofthetighteningportionandpushthebody(2) instraightuntilslidingpreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleend.

2.HoldintheconditioninStep1,andpushuntilthecover(3)contacts surfaceaofthehexagonalportionatthemaleend.

3.HoldintheconditioninSteps1and2,andpulloutthewholebody (2)todisconnectit.

Connection

1.Holdthemouthpieceofthetighteningportionandpushthebody(2) instraightuntiltheslidepreventionring(1)contactssurfaceaofthe hexagonalportionatthemaleendtoconnectit.

12 COATINGMATERIALS

Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.

Category KomatsucodePartNo.QtyContainerMainfeaturesandapplications

LT-1A790-129-9030150gTube•Usedtopreventrubbergaskets,rubbercushions,and corkplugsfromcomingout.

LT-1B790-129-905020g(2pcs.) Polyethylene container

LT-209940-0003050gPolyethylene container

LT-3

•Usedforplastic(exceptpolyethylene,polypropylene,tetrafluoroethyleneandvinylchloride),rubber,metal,and non-metalpartswhichrequireimmediateandstrong adhesion.

•Features:Resistancetoheatandchemicals. •Usedtofixandsealboltsandplugs.

790-129-9060 (Setof adhesiveand hardener) Adhesive: 1kg Hardener: 500g Can•Usedtostickandsealmetal,glass,andplastics.

LT-4790-129-9040250gPolyethylenecontainer•Usedtosealplugs.

HoltzMH705790-129-912075gTube•Heat-resistantsealusedtorepairengines.

ThreeBond1735790-129-914050gPolyethylene container

Aron-alpha201790-129-91302gPolyethylene container

Loctite648-5079A-129-911050ccPolyethylene container

•Quick-settingadhesive.

•Settingtime:Within5sec.to3min.

•Usedmainlytostickmetals,rubbers,plastics,and woods.

•Quick-settingadhesive.

•Quick-settingtype. (max.strengthisobtainedafter30minutes)

•Usedmainlytostickrubbers,plastics,andmetals.

•Features:Resistancetoheatandchemicals.

•Usedforfittedportionsusedathightemperatures.

LG-1790-129-9010200gTube•Usedtostickorsealgasketsandpackingsofpowertrain case,etc.

•Features:Resistancetoheat

•Usedassealantforflangesurfacesandboltsathightemperaturelocations;usedtopreventseizure.

LG-3790-129-90701kgCan

LG-5790-129-90801kgPolyethylene container

LG-6790-129-9020200gTube

LG-7790-129-91701kgTube

•Usedassealantforheat-resistantgasketforhightemperaturelocationssuchasenginepre-combustionchamber, exhaustpipe.

•Usedtosealvariousthreadedportions,pipejoints,and flanges.

•Usedtosealtaperedplugs,elbows,andnipplesof hydraulicpiping.

•Features:Silicon-basedheatandcold-resistantsealant. •Usedtosealflangesurfacesandthreadedportions. •Usedtosealoilpan,finaldrivecase,etc.

•Features:Silicon-basedquick-settingsealant.

•Usedtosealflywheelhousing,intakemanifold,oilpan, thermostathousing,etc.

ThreeBond1211790-129-9090100gTube•Gasketsealantusedtorepairengine.

ThreeBond1207B419-15-18131100gTube

•Features:Silicon-based,heatandcold-resistant,vibration-resistant,impact-resistantsealant. •Usedtosealtransfercase,etc.

ClassificationKomatsucodePartnumberContentContainerMainfeature,application

Lubricant with molybdenum disulfideLM-G09940-0005160gCan•Tobeusedaslubricant(antisqueaking)forsliding part.

LM-P09940-00040200gTube

SYG2-400LI

SYG2-350LI

G2-LI

SYG2-400LI-A

SYG2-160LI

SYGA-160CNLI

SYG2-400CA

SYG2-350CA

G2-CA

Greasewith molybdenum disulphideLMG(G2-M)

Hyperwhite grease

G2-TGO-T(*) *:Forcold region

Biological greaseG2-B

G2-BT(*) *:Forheat resistanceand heavyload

SYG2-400CA-A

SYG2-160CA

SYGA-160CNCA

SYG2-400M

SYG2-400M-A

SYGA-16CNM

SYG2-400T-A

SYG2-16CNT

SYG0-400T-A(*)

SYG0-16CNT(*)

SYG2-400B

SYGA-16CNB

SYG2-400BT (*)

SYGA-16CNBT (*)

Sunstarprimer forpainting plane580 super417-926-3910

Sunstarprimer forglass580 super

Sunstarprimer forpainting plane435-95

Sunstarprimer forglass 435-41

Sunstarprimer forsash GP-402

•Tobeusedforpressfit,shrinkfitandpreventing scratchingorseizureofthread. •Tobeusedaslubricantforlinkageandbearing etc..

VariouskindsVariouskinds•Versatiletype

VariouskindsVariouskinds

400gx10

•Tobeusedfortheplacewherethebearing designedfornormaltemperatureandlowload conditionisusedandcontactswaterandsteam.

400gx20 16kg Bellowstype Can •Tobeusedforheavyloadplaces.

400g 16kg Bellowstype Can

400g 16kg Bellowstype Can

20ml (0.7oz)

20ml (0.7oz)

22M-54-2723020ml (0.7oz)

Glass container

Glass container

Glass container

22M-54-27240150ml (5.1oz)Can

22M-54-2725020ml (0.7oz)

Glass container

•Higherantiseizureandheatresistancethan greasewithmolybdenumdisulphide •Bodydirtisnotdistinctiveduetowhitecolor.

•Tobeshortlydissolvedbyabacteriainnatureso thattheinfluencetomicroorganismandanimals andplantsissuppressedtotheminimum.

•Tobeusedasprimerforcabside. (Termofvalidity:4monthsafter manufacturing)

For adhesion of cab glass

•Tobeusedasprimerforglassside. (Termofvalidity:4monthsafter manufacturing)

•Tobeusedasprimerforpaintingplaneofcab side.

(Termofvalidity:4monthsaftermanufacturing)

•Tobeusedasprimerforblackceramic coatedplaneofglasssideandpolycarbonate hardcoatplane.

(Termofvalidity:4monthsafter manufacturing)

•Tobeusedasprimerforsash(Alumite surfacetreatment)

(Termofvalidity:4monthsafter manufacturing)

ClassificationKomatsucodePartnumberContentContainerMainfeature,application

Adhesive compound

Sunstarpenguineseal580 super"S"or "W"

SikaLtd, JapanSika Flex256HV

Sunstarpenguinesuper 560

Caulking compound

SunstarpenguinesealNo. 2505

417-926-3910320ml (10.8oz)

20Y-54-39850310ml (10.5oz)

22M-54-27210320ml (10.8oz)

417-926-3920320ml (10.8oz)

Sekisuisiliconesealant20Y-54-55130333ml (11.3oz)

GEToshiba SiliconesTosseal381

Polyethylene container

Polyethylene container

ECOCART (special container)

Polyethylene container

Polyethylene container

22M-54-27220333ml (11.3oz)Cartridge

For adhesion of cab glass

•"S"and"W"areusedasglassadhesive compoundinhightemperature(April-October)andinlowtemperature(October-April) respectively. (Termofvalidity:4monthsafter manufacturing)

•Tobeusedasglassadhesivecompound. (Termofvalidity:6monthsafter manufacturing)

•Tobeusedasglassadhesivecompound. (Termofvalidity:6monthsafter manufacturing)

•Tobeusedassealforjointsofglass. (Termofvalidity:4monthsafter manufacturing)

•Tobeusedforsealoffrontwindow. (Termofvalidity:6monthsafter manufacturing)

•Tobeusedassealforjointsofglass. semi-transparentwhiteseal (Termofvalidity:12monthsafter manufacturing)

StandardTighteningTorqueOfBoltsAndNuts

ThreaddiameterofboltWidthacrossflats

ThreaddiameterofboltWidthacrossflats

12 TighteningTorqueOfHoseNuts

00 Usethesetorquesforhosenuts.

NominalNo. ThreaddiameterWidthacrossflatTighteningtorque mmmmN•mlbfft 02141919.6-29.414.5-21.7 03182429.4-68.621.7-50.6 04222758.9-98.144.4-72.4 052432107.9-166.779.6-123.0 063036147.1-205.9108.5-151.9 103341147.1-245.1108.5-180.8 123646196.2-294.2144.7-217.0 144255245.2-343.2180.9-253.1

TighteningTorqueOfSplitFlangeBolts

00 Usethesetorquesforsplitflangebolts.

ThreaddiameterWidthacrossflatTighteningtorque mmmmN•mlbfft 1014 59-7443.51-54.57 1217 98-12372.28-90.72 1622 235-285173.32-210.20

TighteningTorqueForFlaredNuts 00

Usethesetorquesforflaredpartofnut.

ThreaddiameterWidthacrossflatTighteningtorque mmmmN•mlbfft 1419 24.5±4.918.0±3.6 1824 49±19.636.1±14.4 2227 78.5±19.657.8±14.4 2432 137.3±29.4101.2±21.6 3036 176.5±29.4130.1±21.6 3341 196.1±49144.6±36.1 3646 245.2±49180.8±36.1 4255 294.2±49216.9±36.1