Shop Manual
PC200Z-6LE HYDRAULICEXCAVATOR
MACHINEMODELSERIALNUMBERS
PC200Z-6LEA83001andup
ThismaterialisproprietarytoKomatsuAmericaInternationalCompanyandisnottobereproduced,used,ordisclosed exceptinaccordancewithwrittenauthorizationfromKomatsuAmericaInternationalCompany.
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Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
PRODUCTPUBLICATIONSINFORMATION
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOP MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALS INFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
COMPLETEFORM ANDRETURNTOKomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications FaxNo.(847)970-4186 TelNo.(847)970-5887
COMPANYNAME
SHIPTO
TYPEorPRINT ONLY
ATTN.
STREETADDRESS
CITY,STATE,ZIPCODE
COUNTRY
PURCHASEORDERNO.
ORDERDATE
PHONENO.FAXNO.SHIPPINGMETHODDISTR/BRANCHCODE
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN. QTY.PUBLICATIONFORMNO.P-Paper MODELNUMBERSERIALNUMBER
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONSPREPARATIONSFORWORK
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthe OPERATION&MAINTENANCEMANUALcarefullymachineonhard,levelground,andblockthewheels BEFOREoperatingthemachine.ortrackstopreventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readall8.Beforestartingwork,lowerblade,ripper,bucketor theprecautionsgivenonthedecalswhicharefixedtoanyotherworkequipmenttotheground.Ifthisisnot themachine.possible,insertthesafetypinoruseblockstoprevent
2.Whencarryingoutanyoperation,alwayswearsafetytolockallthecontrolleversandhangwarningsigns shoesandhelmet.Donotwearlooseworkclothes,onthem. orclotheswithbuttonsmissing.
9.Whendisassemblingorassembling,supporttheAlwayswearsafetyglasseswhenhittingpartswith ahammer.
theworkequipmentfromfalling.Inaddition,besure machinewithblocks,jacksorstandsbeforestarting work.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.10.Removeallmudandoilfromthestepsorother
3.Ifweldingrepairsareneeded,alwayshaveatrained,usethehandrails,laddersorstepswhengettingonor experiencedweldercarryoutthework.Whenoffthemachine.Neverjumponoroffthemachine. carryingoutweldingwork,alwayswearweldingIfitisimpossibletousethehandrails,laddersor gloves,apron,glasses,capandotherclothessuitedsteps,useastandtoprovidesafefooting. forweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure11.Whenremovingtheoilfillercap,drainplugor beforestarting.Alwaysinformyourfellowworkershydraulicpressuremeasuringplugs,loosenthem beforestartinganystepoftheoperation.Beforeslowlytopreventtheoilfromspurtingout.Before startingwork,hangUNDERREPAIRsignsonthedisconnectingorremovingcomponentsoftheoil, controlsintheoperator'scompartment.wateroraircircuits,firstremovethepressure
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.12.Thewaterandoilinthecircuitsarehotwhenthe
placesusedtogetonandoffthemachine.Always PRECAUTIONSDURINGWORK completelyfromthecircuit. engineisstopped,sobecarefulnottogetburned.
6.DecideaplaceintherepairworkshoptokeeptoolsWaitfortheoilandwatertocoolbeforecarryingout andremovedparts.Alwayskeepthetoolsandpartsanyworkontheoilorwatercircuits. intheircorrectplaces.Alwayskeeptheworkarea cleanandmakesurethatthereisnodirtoroilonthe13.Beforestartingwork,removetheleadsfromthe floor.Smokeonlyintheareasprovidedforsmoking.battery.ALWAYSremovetheleadfromthenegative Neversmokewhileworking.(-)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistorcrane andoperateslowlytopreventthecomponentfrom hittinganyotherpart.Donotworkwithanypartstill raisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring,Damagedwiringmaycause electricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause youtoslip,orcanevenstartfires.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen washingelectricalparts.
19.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagedpartwithnewparts.
Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethat theyarenottwisted.Damagedtubesaredangerous, sobeextremelycarefulwheninstallingtubesforhigh pressurecircuits.Alsocheckthatconnectingparts arecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,beparticularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtina hole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyonestand ateitherendofthetrack.
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingof thestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemade atcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealso includedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engineelectricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributors.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberfor eachitem
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4 10-4-1Addedpages 10-4-2 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety Specialsafetyprecautionsare necessarywhenperformingthe work.
Caution
Weight
Tightening torque
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhenperformingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecialattention fortighteningtorqueduring assembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,waterPlaceswhereoil,waterorfuelmust beadded,andthecapacity.
DrainPlaceswhereoilorwatermustbe drained,andquantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYANDASSEMBLYsection,everypartweighing25kgormore isindicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepart totherelativeparts.
2)Checkforexistenceofanotherpartcausing interfacewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
Slingingwithoneropemaycauseturningof theloadduringhoisting,untwistingoftherope, orslippingoftheropefromitsoriginalwinding positionontheload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaload withtwoormoreropes,theforcesubjectedtoeach ropewillincreasewiththehangingangles.The tablebelowshowsthevariationofallowableload (kg)whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto1000kgvertically,at varioushangingangles.Whentworopesslinga loadvertically,upto2000kgoftotalweightcanbe suspended.Thisweightbecomes1000kgwhen tworopesmakea120hangingangle.Onthe otherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kg loadataliftingangleof150.
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthe hook.Slingingneartheedgeofthehookmay causetheropetoslipoffthehookduringhoisting, andaseriousaccidentcanresult.Hookshave maximumstrengthatthemiddleportion.
COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTubeUsedtopreventrubbergaskets,rubbercushionsandcorkplugsfrom comingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene,polypropylene, Plastic container
Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
LT-209940-0003050gPlasticFeatures:Resistancetoheat,chemicalscontainerUsedforanti-looseningandsealantpurposesforboltsandplugs.
Adhesive
Gasketsealant
LT-3HardagtCanUsedasadhesiveorsealantformetal,glassorplastic.
790-129-9060 Setofadhesive andhardening agent Adh1kg 500kg
LT-4790-129-9040250gUsedassealantformachinedholes. Plastic container
Loctite
79A-129-911050cc---
Features:Resistancetoheat,chemicals 648-50 Usedatjointportionssubjecttohightemperature.
LG-1790-129-9010200gTubeUsedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
Features:Resistancetoheat Usedassealantforflangesurfacesandboltsathightemperature Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
LG-4790-129-9020200gTubeAlsopossibletouseassealantforflangeswithlargeclearance.
Features:Resistancetowater,oil Usedassealantforflangesurface,thread. Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
LG-5790-129-90801kgcontainerPlasticUsedassealantfortaperedplugs,elbows,nipplesofhydraulic
Usedassealantforvariousthreads,pipejoints,flanges. piping.
Features:Siliconbased,resistanttoheat,cold.
LG-609940-00011250gTubeUsedassealantforflangesurface,thread.
Usedassealantforoilpan,finaldrivecase,etc.
LG-709920-00150150gTubeUsedassealantforflywheelhousing,intakemanifold,oilpan,
Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Rustpreventionlubricant---09940-0005160gCanUsedaslubricantforslidingparts(topreventsqueaking).
Molybdenum
Usedtopreventseizureorscuffingofthethreadwhenpressfittingor disulfide---09940-00040200gTubeshrinkfitting. lubricant Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVariousGeneralpurposetype
SYG-160Ll SYGA-160CNLl
SSG2-400CA
SYG2-350CA
CalciumgreaseG2-CASYG2-400CA-AVariousVarious
SYG2-160CA SYGA-16CNCA
Usedfornormaltemperature,lightloadbearingatplacesincontact withwaterorsteam.
Molybdenum400g disulfidegrease(10/case)---SYG2-400MBellowstypeUsedforplaceswithheavyload.
STANDARDTIGHTENINGTORQUE
STANDARDTIGHTENINGTORQUEOFBOLTSANDNUTS
Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts.Exceptionsaregiveninsectionsof DISASSEMBLYANDASSEMBLY
1kgm=9.806Nm
ThreaddiameterofboltWidthacrossflat
Thistorquetabledoesnotapplytotheboltswithwhichnylonpackingorothernon-ferrousmetalwashersareto beused,orwhichrequiretighteningtootherwisespecifiedtorque.
TIGHTENINGTORQUEOFSPLITFLANGEBOLTS
Usethesetorquesforsplitflangebolts.
ThreaddiameterofboltWidthacrossflatTighteningtorque mmmmkgmNm 10146.70±0.765.7±6.8 121711.5±1.0112±9.8 162228.5±3279±29
TIGHTENINGTORQUEFORFLAIREDNUTS
Usethesetorquesforflairedpartofnut.
ThreaddiameterofboltWidthacrossflatTighteningtorque mmmmkgmNm
ELECTRICWIRECODE
Inthewiringdiagrams,variouscolorsandsymbolsareemployedtoindicatethethicknessofwires.Thiswirecode tablewillhelpyouunderstandWIRINGDIAGRAMS. Example:05WBindicatesacablehavinganominalnumber05andwhitecoatingwithblackstripe.
CLASSIFICATIONBYTHICKNESS
NominalCableCurrentrating numberO.D.(mm)(A) Copperwire Applicablecircuit
NumberofDia.OfstrandCrosssecstrands(mm)tion(mm²)
0.85110.320.882.412Starting,lighting,signaletc. 2260.322.093.120Lighting,signaletc. 5650.325.234.637Chargingandsignal
CLASSIFICATIONBYCOLORANDCODE
CONVERSIONTABLES
METHODOFUSINGTHECONVERSIONTABLE
TheConversionTableinthissectionisprovidedtoenablesimpleconversionoffigures.Fordetailsofthemethodof usingtheConversionTable,seetheexamplegivenbelow.
EXAMPLE
MethodofusingtheConversionTabletoconvertfrommillimeterstoinches.
1.Convert55mmintoinches.
(1)Locatethenumber50intheverticalcolumnattheleftside,takethisasa,thendrawahorizontallinefrom a.
(2)Locatethenumber5intherowacrossthetop,takethisasb,thendrawaperpendicularlinedownfromb.
(3)Takethepointwherethetwolinescrossasc.Thispointcgivesthevaluewhenconvertingfrommillimeters toinches.Therefore,55millimeters=2.165inches.
2.Convert550mmintoinches.
(1)Thenumber550doesnotappearinthetable,sodivideby10(movethedecimaloneplacetotheleft)to convertitto55mm.
(2)Carryoutthesameprocedureasabovetoconvert55mmto2.165inches.
(3)Theoriginalvalue(550mm)wasdividedby10,somultiply2.165inchesby10(movethedecimaloneplace totheright)toreturntotheoriginalvalue.Thisgives550mm=21.65inches.
MillimeterstoInches
1mm=0.03937in
a501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
MillimeterstoInches
1mm=0.03937in mm0123456789
000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8742.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
KilogramtoPound
1kg=2.2046lb kg0123456789
002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93 3066.1468.3470.5572.7574.9677.1679.3781.5783.7885.98 4088.1890.3992.5994.8097.0099.21101.41103.62105.82108.03
50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26