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Komatsu PC200LL-8 Shop Manual

Hydraulic excavator
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Manual
PC200LL
PC220LL
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
ENGINE
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.
November 2012
PC200LL-8 A87001
PC220LL-8 A87001
6D107E-1
Copyright 2012 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM001505
-8
-8
and up
and up

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  • Page 1 6D107E-1 ENGINE 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.
  • Page 2 FOREWORD CONTENTS CONTENTS FOREWORD ............00-1 GENERAL .
  • Page 3 FOREWORD The affected pages are indicated by using the following Mark Indication Action marks. It is requested that necessary actions be taken to ❍ New page to be added these pages according to the table below. ● Page to be replaced Replace Page to be deleted Discard...
  • Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-47 10-80 10-113 10-146 10-48 10-81 10-114 10-147 10-49 10-82 10-115 10-148 10-50 10-83 10-116 10-149 10-51 10-84 10-117 10-150 10-52 10-85 10-118 10-151 10-53 10-86 10-119 10-152 10-54 10-87 10-120 10-153 10-55 10-88...
  • Page 5 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-179 10-212 10-245 10-278 10-180 10-213 10-246 10-279 10-181 10-214 10-247 10-280 10-182 10-215 10-248 10-183 10-216 10-249 20-1 10-184 10-217 10-250 20-2 10-185 10-218 10-251 20-3 10-186 10-219 10-252 20-4 10-187 10-220 10-253...
  • Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-7 30-40 30-73 30-106 30-8 30-41 30-74 30-107 30-9 30-42 30-75 30-108 30-10 30-43 30-76 30-109 30-11 30-44 30-77 30-110 30-12 30-45 30-78 30-111 30-13 30-46 30-79 30-112 30-14 30-47 30-80 30-113 30-15 30-48...
  • Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-139 40-7 40-40 40-73 30-140 40-8 40-41 40-74 30-141 40-9 40-42 40-75 30-142 40-10 40-43 40-76 30-143 40-11 40-44 40-77 30-144 40-12 40-45 40-78 30-145 40-13 40-46 40-79 30-146 40-14 40-47 40-80 30-147 40-15...
  • Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-106 40-139 40-172 40-205 40-107 40-140 40-173 40-206 40-108 40-141 40-174 40-207 40-109 40-142 40-175 40-208 40-110 40-143 40-176 40-209 40-111 40-144 40-177 40-210 40-112 40-145 40-178 40-211 40-113 40-146 40-179 40-212 40-114 40-147...
  • Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-238 40-271 40-304 40-337 40-239 40-272 40-305 40-338 40-240 40-273 40-306 40-339 40-241 40-274 40-307 40-340 40-242 40-275 40-308 40-341 40-243 40-276 40-309 40-342 40-244 40-277 40-310 40-343 40-245 40-278 40-311 40-344 40-246 40-279...
  • Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-370 40-403 50-7 50-40 40-371 40-404 50-8 50-41 40-372 40-405 50-9 50-42 40-373 40-406 50-10 50-43 40-374 40-407 50-11 50-44 40-375 40-408 50-12 50-45 40-376 40-409 50-13 50-46 40-377 40-410 50-14 50-47 40-378 40-411...
  • Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-73 50-106 50-139 50-172 50-74 50-107 50-140 50-173 50-75 50-108 50-141 50-174 50-76 50-109 50-142 50-175 50-77 50-110 50-143 50-176 50-78 50-111 50-144 50-177 50-79 50-112 50-145 50-178 50-80 50-113 50-146 50-179 50-81 50-114...
  • Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-205 50-238 60-10 60-43 50-206 50-239 60-11 60-44 50-207 50-240 60-12 60-45 50-208 50-241 60-13 60-46 50-209 50-242 60-14 60-47 50-210 50-243 60-15 60-48 50-211 50-244 60-16 60-49 50-212 50-245 60-17 60-50 50-213 50-246...
  • Page 13 FOREWORD Mark Page Mark Page Mark Page Mark Page 60-76 60-77 60-78 60-79 60-80 60-81 60-82 60-83 60-84 60-85 60-86 90-1 90-2 90-3 90-4 90-5 90-6 90-7 90-8 90-9 90-10 90-11 90-12 90-13 90-14 90-15 00-2-11 f PC200/220LL-8...
  • Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page 00-2-12 PC200/220LL-8...

  • Page 15: Safety Notice

    FOREWORD SAFETY SAFETY Safety Notice Important Safety Notice 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.
  • Page 16 FOREWORD SAFETY 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.
  • Page 17 FOREWORD SAFETY ★ Example of O-ring (Fitted to every joint of hoses and tubes) ★ For tightening torque, see the precautions for installation in each sec- tion of "Disassembly and assembly". 16. 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.
  • Page 18 FOREWORD GENERAL GENERAL 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.

  • Page 19: How To Read The Shop Manual

    FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL Volumes Revisions Shop manuals are issued as a guide to performing repairs. Revised pages are shown at the LIST OF REVISED PAGES They are divided as follows: between the title page and SAFETY page.

  • Page 20: Hoisting Instructions

    FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Hoisting can result. Hooks have maximum strength at the middle portion. 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.
  • Page 21 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs.
  • Page 22 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS C. Disconnections in wiring. • If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
  • Page 23 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Removing, installing, and drying connectors and wiring harnesses A. Disconnecting connectors. • Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, completely loosen the screw, then hold the male and female connectors in each hand and pull apart.
  • Page 24 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Connecting connectors A. Check the connector visually. • Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
  • Page 25 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS E. Drying wiring harness • If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 26 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS E. Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when performing arc welding. •...
  • Page 27 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Points To Remember When Handling Hydraulic Equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 28 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Flushing operations • After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is performed twice: primary flushing is performed with flushing oil, and secondary flushing is performed with the specified hydraulic oil.
  • Page 29 FOREWORD PUSH PULL COUPLER PUSH PULL COUPLER WARNING! Before performing the following work, release the residual pressure from the hydraulic tank. For details, see Section 30 - TESTING AND ADJUSTING, "RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT". WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 30 FOREWORD PUSH PULL COUPLER Type 2 Disconnection Hold mouthpiece of the tightening portion and push body (2) straight in until sliding prevention ring (1) contacts surface "a" of hexagonal portion at the male end. Hold in the condition in Step 1, and turn lever (4) clockwise to the right.
  • Page 31 FOREWORD PUSH PULL COUPLER Type 3 Disconnection Hold the connector 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. Hold in the condition in Step 1, and push until cover (3) contacts surface a of the hexagonal portion at the male end.
  • Page 32 FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS EXPLANATION OF MAINTENANCE STANDARD TERMS • The maintenance standard values necessary for judgment of products and parts are described by the following terms. Standard Size And Tolerance • To be accurate, the finishing size of parts is a little different from one to another.
  • Page 33 FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS Repair Limit And Allowable Value • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. • If a part is worn to the repair limit must be replaced or repaired. •...

  • Page 34: Standard Tightening Torque

    FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE Bolts And Nuts • Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) ★ The following table corresponds to the bolts in Figure A. Thread diameter of bolt Width across flats Tightning torque...
  • Page 35 FOREWORD STANDARD TIGHTENING TORQUE Tightening Torque Of Hose Nuts Use these torques for hose nuts. Thread diameter Width across flat Tightening torque Nominal No. N•m lbf ft 19.6 - 29.4 14.5 - 21.7 29.4 - 68.6 21.7 - 50.6 58.9 - 98.1 44.4 - 72.4 107.9 - 166.7 79.6 - 123.0...
  • Page 36 FOREWORD STANDARD TIGHTENING TORQUE Tightening Torques For O-ring Boss Piping Joints ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Thread diameter Width across flat Tightening torque N•m (lbf ft) Norminal No. Range Target 35 - 63 (25.81 - 46.46) 44 (32.45)
  • Page 37 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. Classification By Thickness Copper wire Nominal...

  • Page 38: How To Read Electric Wire Code

    FOREWORD ELECTRIC WIRE CODE How To Read Electric Wire Code ★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
  • Page 39 FOREWORD ELECTRIC WIRE CODE Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/ 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 Diameter of strand Conductor Sectional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
  • Page 40 FOREWORD ELECTRIC WIRE CODE Color Codes Table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...

  • Page 41: Conversion Tables

    FOREWORD CONVERSION TABLES CONVERSION TABLES Method Of Using The Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE •...
  • Page 42 FOREWORD CONVERSION TABLES Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 43 FOREWORD CONVERSION TABLES Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925...
  • Page 44 FOREWORD CONVERSION TABLES kgm to ft. lb. 1 kgm = 7.233 ft. lb. 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
  • Page 45 FOREWORD CONVERSION TABLES kg/cm to lb/in 1 kg/cm = 14.2233lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 46 FOREWORD CONVERSION TABLES Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.

  • Page 47: Coating Materials

    FOREWORD COATING MATERIALS COATING MATERIALS ★ The recommended coating materials prescribed in the shop manuals are listed below. Category Code Part No. Quantity Container Main applications, features • Used to prevent rubber gaskets, rubber cush- LT-1A 790-129-9030 150 g Tube ions and cork plugs from coming out •...
  • Page 48 FOREWORD COATING MATERIALS Category Code Part No. Quantity Container Main applications, features • Features: Resistance to water, oil • Used as sealant for flange surface, thread. • Also possible to use as sealant for flanges with LG-4 790-129-9020 200 g Tube large clearance.
  • Page 49 Log Loader – 36 Ft Komatsu Forest Front ....... . .

  • Page 50: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS Dimensions PC200LL-8 Road Builder Log Loader – 36 Ft Komatsu Forest Front 01-2 PC200/220LL-8...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Pc220ll-8A87001

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