CEBM001505
Shop Manual
HYDRAULIC EXCAVATOR SERIAL NUMBERS
PC200LL-8 A87001 and up PC220LL-8 A87001 and up
ENGINE
6D107E-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 2012 Komatsu Printed in U.S.A. Komatsu America Corp. November 2012
FOREWORD
CONTENTS
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00
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
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STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
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TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
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TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
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AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
90
DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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Important Safety Notice
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Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
General Precautions WARNING! Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1.
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Before performing any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc. If welding repairs are needed, always have a trained, experienced welder perform the work. When performing welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation
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When performing any operation with two or more workers, always agree on operating procedures before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and
PC200/220LL-8
make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
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Preparations For Work 1.
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Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
Precautions During Work 1.
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When removing oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent oil from spurting out. Before disconnecting or removing components of the oil, cooling, or air circuits, first completely remove pressure from the circuit. The coolant and oil in the circuits is hot when the engine is stopped, so be careful not to get burned. Wait for the oil and coolant to cool down before performing any work on the oil or cooling circuits. Before starting work, remove the leads from the battery. ALWAYS remove lead from the negative (-) terminal first.
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