HYDRAULICEXCAVATOR
ThismaterialisproprietarytoKomatsuAmericaCorp.andisnottobereproduced,used,ordisclosedexceptinaccordance withwrittenauthorizationfromKomatsuAmericaCorp.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomakechangesor addimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssoldpreviously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itisrecommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
10STRUCTUREANDFUNCTION.
20TESTING,ADJUSTINGANDTROUBLESHOOTING.
30DISASSEMBLYANDASSEMBLY.
PRODUCTPUBLICATIONSINFORMATION
VariousproductPartsandServicePublicationsareavailabletoallKOMATSUconstructionequipment owners,includingoperationandmaintenancemanuals,partsbooksandservicemanuals.
Specialpublications,suchasservicetool,airconditioningandturbochargerservicemanualsarealso availableaswellasselectedOperationandServicemanualsinforeignlanguages.
ThePublicationslistedbelowareavailableforthisparticularmachine(s).
DESCRIPTIONFORMNUMBER
PARTSBOOK-PAPER:
ChassisandEngine(PC200LL-7L).............................BEPB041500
ChassisandEngine(PC220LL-7L).............................BEPB041600
OPERATIONANDMAINTENANCEMANUAL: ChassisandEngine.........................................CEAM014400
SHOPMANUAL Chassis..................................................CEAM014300 Engine....................................................SEBM010019
SAFETYMANUAL
Machinespecific.................................................HE03-2
PartsandServicePublicationscanonlybeacquiredbyauthorizedKOMATSUdistributorsusingthe KomatsuAmericaCorp.ExtranetLiteratureOrderingSystem.
IftheExtranetLiteratureOrderingSystemisnotavailableatthedistributorlocation,thenthefollowing RequisitionforTechnicalServicePublicationsandServiceFormscanbeused.FormKDC91Eisshown onthereversesideofthispage.KomatsuAmericaCorp.reservestherighttoaddasurchargetoallfax orders.
COMPLETEFORM ANDRETURNTO
DataKomPublicationsandTrainingDivision
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:ServicePublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
TYPEorPRINT ONLY ATTN. STREETADDRESSORDERDATE CITY,STATE,ZIPCODE COUNTRY
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERAND MACHINESERIALNUMBERMUSTBESHOWN.
QTY.PUBLICATIONFORMNO.PARTSBOOKPUBLICATION DESCRIPTION
P-Paper M-Microfiche
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepairtechniques recommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperations requiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsareusedtomarksafetyprecautionsinthismanual.Thecautions accompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise, firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
Mistakesinoperationareextremelydangerous.Readthe OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
1.Beforecarryingoutanygreasingorrepairs,readallthe precautionsgivenonthedecalswhicharefixedtothe machine.
2.Whencarryingoutanyoperation,alwayswearsafety shoesandhelmet.Donotwearlooseworkclothes,or clotheswithbuttonsmissing.
Alwayswearsafetyglasseswhenhittingpartswitha hammer.
Alwayswearsafetyglasseswhengrindingpartswitha grinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.Whencarrying outweldingwork,alwayswearweldinggloves,apron, glasses,capandotherclothessuitedforweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Beforestarting work,hangUNDERREPAIRsignsonthecontrolsin theoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptoolsand removedparts.Alwayskeepthetoolsandpartsintheir correctplaces.Alwayskeeptheworkareacleanand makesurethatthereisnodirtoroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Neversmoke whileworking.
PREPARATIONSFORWORK
1.Beforeaddingoilormakingrepairs,parkthemachine onhard,levelground,andblockthewheelsortracksto preventthemachinefrommoving.
2.Beforestartingwork,lowerblade,ripper,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,besureto lockallthecontrolleversandhangwarningsignson them.
3.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
4.Removeallmudandoilfromthestepsorotherplaces usedtogetonandoffthemachine.Alwaysusethe handrails,laddersorstepswhengettingonoroffthe machine.Neverjumponoroffthemachine.Ifitis impossibletousethehandrails,laddersorsteps,usea standtoprovidesafefooting.
PRECAUTIONSDURINGWORK
1.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthemslowly topreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,water oraircircuits,firstremovethepressurecompletelyfrom thecircuit.
2.Thewaterandoilinthecircuitsarehotwhentheengine isstopped,sobecarefulnottogetburned.Waitforthe oilandwatertocoolbeforecarryingoutanyworkon theoilorwatercircuits.
3.Beforestartingwork,removetheleadsfromthebattery. ALWAYSremovetheleadfromthenegative(-) terminalfirst.
12 4.Whenraisingheavycomponents,useahoistorcrane.Checkthatthewirerope,chainsandhooksarefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrectplaces.Useahoistor craneandoperateslowlytopreventthecomponentfromhittinganyotherpart.Donotworkwithanypartstillraisedby thehoistorcraneandalwaysstandclearfromwhatyouareraising.
5.Whenremovingcoverswhichareunderinternalpressureorunderpressurefromaspring,alwaysleavetwoboltsin positiononoppositesides.Slowlyreleasethepressure,thenslowlyloosentheboltstoremove.
6.Whenremovingcomponents,becarefulnottobreakordamagethewiring,Damagedwiringmaycauseelectricalfires.
7.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.Fueloroilonthefloorcancauseyoutoslip,orcanevenstartfires.
8.Neveruseflammableliquidstocleanparts,alwaysuseapprovednon-flammablesolventstocleanparts.
9.Besuretoassembleallpartsintheiroriginallocations.Replaceanydamagedpartwithnewparts.
•Wheninstallinghosesandwires,besurethattheywillnotbedamagedbycontactwithotherpartswhenthemachine isbeingoperated.
10.Wheninstallinghighpressurehoses,besurethattheyarenottwisted.Damagedtubbingdangerous,beextremelycareful wheninstallingtubesforhighpressurecircuits.Alsomakesurepartsarecorrectlyinstalled.
11.Whenassemblingorinstallingparts,alwaysusethespecifiedtighteningtorquesandsequences.Wheninstalling protectivepartssuchasguards,orpartsthatmayvibrateorrotateathighspeeds,beparticularlycarefultochecktheir installationcarefully.
12.Whenaligningtwoholes,neverinsertyourfingersorhand.Useappropriatetoolstoalignparts.
13.Whenmeasuringhydraulicpressure,besurethemeasuringtooliscorrectlyassembledbeforetakinganymeasurements.
14.Takecarewhenremovingorinstallingthetracksontrack-typemachines.Whenremovingthetrack,thetrackseparates suddenly,neverletanyonestandateitherendofthetrack.
15.Whenmakingrepairsoradjustmentsonelectronicallycontrolledengines,avoidanyphysicalcontactwiththeinjection systemswiringharnesswhiletheengineisrunning.Duetothehighvoltageandamperageinthissystem,seriousinjury mayoccur.
16.Whenremovingthetrack,thetrackseparatessuddenly,soneverletanyonestandateitherendofthetrack.
12 GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesureyou understandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.For easeofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeachmain groupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolantand lubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.Troubleshootingchartscorrelating“Problems”to“Causes”arealsoincludedinthis section.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeachcomponent, aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
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:
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark(…)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISEDPAGES betweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwiththe followingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhen selectinghoistingwireorwhen workingpostureisimportant, etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesivesandlubricantsetc. Oil,waterPlaceswhereoil,waterorfuel mustbeadded,andthecapacity.
Drain
Placeswhereoilorwatermust bedrained,andquantitytobe drained.
12 HOISTINGINSTRUCTIONS
HOISTING
WARNING!Heavyparts(25kgormore) mustbeliftedwithahoistetc.In theDISASSEMBLYAND ASSEMBLYsection,everypart weighing25kgormoreis indicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthemachine byhoisting,thefollowingchecksshouldbemade:
1.Checkforremovalofallboltsfasteningtheparttothe relativeparts.
2.Checkforexistenceofanotherpartcausinginterface withtheparttoberemoved.
WIREROPES
1.Useadequateropesdependingontheweightofpartsto behoisted,referringtothetablebelow:
Wireropes (Standard“Z”or“S”twistropeswithoutgalvanizing)
Theallowableloadvalueisestimatedtobe1/6or1/ 7ofthebreakingstrengthoftheropeused.
3.Donotslingaheavyloadwithoneropealone,butsling withtwoormoreropessymmetricallywoundontothe load.
WARNING!Slingingwithoneropemay causeturningoftheloadduring hoisting,untwistingoftherope, orslippingoftheropefromits originalwindingpositiononthe load,whichcanresultina dangerousaccident
4.Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaloadwith twoormoreropes,theforcesubjectedtoeachropewill increasewiththehangingangles.Thetablebelow showsthevariationofallowableload(kg)when hoistingismadewithtworopes,eachofwhichis allowedtoslingupto1000kgvertically,atvarious hangingangles.Whentworopesslingaloadvertically, upto2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentworopesmakea120° hangingangle.Ontheotherhand,tworopesaresubject toanexcessiveforceaslargeas4000kgiftheyslinga 2000kgloadataliftingangleof150°
2.Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausetheropeto slipoffthehookduringhoisting,andaseriousaccident canresult.Hookshavemaximumstrengthatthemiddle portion.
12 COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QuantityContainerMainapplications,features
LT-1A790-129-9030150gTubeUsedtopreventrubbergaskets,rubber cushionsandcorkplugsfromcomingout
LT-1B790-129-905020g(2pes.)
Polyethylene container
LT-209940-0003050gPolyethylene container
Usedinplacesrequiringanimmediately effective,strongadhesive. Usedforplastics(exceptpolyethylene, polypropylene,tetrafluoroethylene,and vinylchloride),rubber,metaland non-metal.
Features:Resistancetoheat,chemicals Usedforanti-looseningandsealant purposesforboltsandplugs.
LT-3
790-129-9060 (Setofadhesive andhardening agent)
Adhesive: 1kg Hardening agent: 500g CanUsedasadhesiveorsealantformetal,glass orplastic.
LT-4790-129-9040250gPolyethylenecontainerUsedassealantformachinedholes.
Holtz MH705790-126-912075gTubeUsedasheat-resistingsealantforrepairing engine.
Threebond 1735179-129-91402gPolyethylene container
Gasket sealant
Aron-alpha 201790-129-913050gPolyethylene container
Loctite 648-5079A-129-911050ccPolyethylene container
Quickhardeningtypeadhesive. Curetime:within5sec.to3min. Usedmainlyforadhesionofmetals, rubbers,plasticsandwoods.
Quickhardeningtypeadhesive. Quickcuretype(max.strengthafter 30minutes).
Usedmainlyforadhesionofrubbers, plasticsandmetals.
Features:Resistancetoheat,chemicals Usedatjointportionssubjecttohigh temperature.
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsand packingofpowertraincase,etc.
Features:Resistancetoheat
LG-3790-129-90701kgCan
Usedassealantforflangesurfacesandbolts athightemperaturelocations;usedto preventseizure.
Usedassealantforheatresistantgasketfor athightemperaturelocationssuchasengine pre-combustionchamber,exhaustpipe.
CategoryCodePartNo.QuantityContainerMainapplications,features
Features:Resistancetowater,oil
Gasket sealant
LG-4790-129-9020200gTube
LG-5790-129-90801kgPolyethylene container
Usedassealantforflangesurface,thread. Alsopossibletouseassealantforflanges withlargeclearance.
Usedassealantformatingsurfacesoffinal drivecase,transmissioncase.
Usedassealantforvariousthreads,pipe joints,flanges.
Usedassealantfortaperedplugs,elbows, nipplesofhydraulicpiping.
Features:Siliconbased,resistanttoheat, cold.
LG-609940-00011250gTube
LG-709920-00150150gTube
Usedassealantforflangesurface,thread. Usedassealantforoilpan,finaldrivecase, etc.
Features:Siliconbased,quickhardening type.
Usedassealantforflywheelhousing,intake manifold,oilpan,thermostathousing,etc.
Threebond 1211790-129-9090100gTubeUsedasheat-resistingsealantforrepairing engines.
MolybdenumdisulphidelubricantLM-G09940-0005160gCanUsedaslubricantforslidingparts (topreventsqueaking).
LM-P09940-00040200gTube
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
G2-CA
SYG2-160CA
SYG2160CNCA
Usedtopreventseizureorscuffingofthe threadwhenpressfittingorshrinkfitting. Usedaslubricantforlinkage,bearings,etc.
VariousVariousGeneralpurposetype
VariousVarious
Usedfornormaltemperature,lightload bearingatplacesincontactwithwateror steam.
MolybdenumdisulphidelubricantSYG2-400M400g(10percase)BelowstypeUsedforplaceswithheavyload.
Grease
STANDARDTIGHTENINGTORQUE
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts.ExceptionsaregiveninDISASSEMBLYAND ASSEMBLY.
ThreaddiameterofboltWidthacrossflats mmmmNmkgm
ThreaddiameterofboltWidthacrossflats
12 HOSENUTSTIGHTENINGTORQUE
Usethesetorquesforhosenuts.
NominalNo.
SPLITFLANGEBOLTSTIGHTENINGTORQUE
Usethesetorquesforsplitflangebolts.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmkgm 101465.7±6.86.7±0.7 1217112±9.811.5±1 1622279±2928.5±3
FLAREDNUTSTIGHTENINGTORQUE
Usethesetorquesforflaredpartofnut.
ThreaddiameterWidthacrossflatTighteningtorque mmmmNmkgm 141924.5±4.92.5±0.5 182449±19.65±2 222778.5±19.68±2 2432137.3±29.414±3 3036176.5±29.418±3 3341196.1±4920±5 3646245.2±4925±5 4255294.2±4930±5
O-RINGBOSSPIPINGJOINTSTIGHTENINGTORQUE
Unlesstherearespecialinstructions,tightentheO-ringbosspipingjointstothetorquebelow.
Variesdepending ontypeof connector.
O-RINGBOSSPLUGSTIGHTENINGTORQUE
Unlesstherearespecialinstructions,tightentheO-ringbossplugstothetorquebelow.
12 ENGINESERIESTIGHTENINGTORQUE
1)BOLTANDNUTS
Usethesetorquesforboltsandnuts(unit:mm)ofCumminsEngine.
2)EYEJOINTS
Usethesetorquesforeyejoints(unit:mm)ofCumminsEngine. Threaddiameter
3)TAPEREDSCREWS
Usethesetorquesfortaperedscrews(unit:inch)ofCumminsEngine.
1/16 1/8 1/4 3/8 1/2 3/4 1 3±1
1.22±0.20 1.53±0.41 2.45±0.41 3.67±0.51 6.12±0.92