Komatsu Hydraulic Excavator Pc200 250lc 6 Shop Manual

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CEBMOOOI 02

Shop
Manual

Pc2002001c4
PC21OLC=li
PC22OlLli
PC25Olbi
HYDRAULIC EXCAVATOR
PC200-6 - A82001
PC2OOLC-6 - A82001
PC21OLC-6 n A82001
SERIAL NUMBERS PC22OLC-6 n A82001 andup
PC25OLC-6 - A82001
This material is proprietary to Komatsu America lnternational Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.

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 add 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, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

00-l
October 1996 Copyright 1996 Komatsu America International Company 0

This is the cut pages sample. Download all 711 page(s) at: ManualPlace.com
 CONTENTS

01 GENERAL ............................................. 01-I

IO STRUCTURE AND FUNCTION ............................ IO-I

20 TESTING AND ADJUSTMENT ............................. 20-I

30 DISASSEMBLY AND ASSEMBLY .......................... 30-I

40 MAINTENANCE STANDARD .............................. 40-I

00-2
The affected pages are indicated by using the following
Mark Indication Action
marks. It is requested that necessary actions be taken
to these pages according to the table below. 0 New page to be added Add

l Page to be replaced Replace

( 1 Page to be deleted Discard

Pages without marks were previous additions or revised
pages.

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SAFETY SAFETY NOTICE

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.

To prevent injury to workers, the symbols A and *$ 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 clean and make sure that there is no dirt or oil on the
floor. Smoke only in the areas provided for smoking.
Mistakes in operation are extremely dangerous. Read the Never smoke while working.
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine. PREPARATIONS FOR WORK

1. 3efore carrying out any greasing or repairs, read all 7. Before adding oil or making repairs, park the ma-
:he precautions given on the decals which are fixed to chine on hard, level ground, and block the wheels or
:he machine. tracks to prevent the machine from moving.

2. When carrying out any operation, always wear safety 8. Before starting work, lower blade, ripper, bucket or
shoes and helmet. Do not wear loose work clothes, any otherwork equipment to the ground. If this is not
)r clothes with buttons missing. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure
l Always wear safety glasses when hitting parts with
to lock all the control levers and hang warning signs
a hammer.
on them.
l Always wear safety glasses when grinding parts
with a grinder, etc. 9. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
3. f welding repairs are needed, always have a trained, work.
experienced welder carry out the work. When carry-
ng out welding work, always wear welding gloves, 10, Remove all mud and oil from the steps or other
apron, glasses, cap and other clothes suited for places used to get on and off the machine. Always
Melding work. use the handrails, ladders or steps when getting on or
off the machine. Never jump on or off the machine.
4. JVhen carrying out any operation with two or more If it is impossible to use the handrails, ladders or
Norkers, always agree on the operating procedure steps, use a stand to provide safe footing.
oefore starting. Always inform your fellow workers
sefore starting any step of the operation. Before PRECAUTIONS DURING WORK
starting work, hang UNDER REPAIR signs on the
zontrols in the operator’s compartment. 11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
5. I<eep all tools in good condition and learn the correct slowly to prevent the oil from spurting out. Before
Nay to use them. disconnecting or removing components of the oil,
water or air circuits, first remove the pressure com-
6. IDecide a place in the repair workshop to keep tools pletely from the circuit.
and removed parts. Always keep the tools and parts
i n their correct places. Always keep the work area 12. The water and oil in the circuits are hot when the

00-3
SAFETY SAFETY NOTICE

engine is stopped, so be careful not to get burned. washing electrical parts.

Wait for the oil and water to cool before carrying out
any work on the oil or water circuits. 19. Be sure to assemble all parts again in their original
places. Replace any damaged part with new parts.
13. Before starting work, remove the leads from the
l When installing hoses and wires, be sure that
battery. ALWAYS remove the lead from the negative
they will not be damaged by contact with other
(-) terminal first.
parts when the machine is being operated.

14. When raising heavy components, use a hoist or

20. When installing high pressure hoses, make sure that
crane. Check that the wire rope, chains and hooks
they are nottwisted. Damaged tubes are dangerous,
are free from damage. Always use lifting equipment
so be extremely careful when installing tubes for high
which has ample capacity. Install the lifting equip
pressure circuits. Also check that connecting parts
ment at the correct places. Use a hoist or crane and
are correctly installed.
operate slowly to prevent the component from hitting
any other part. Do not work with any part still raised
21. When assembling or installing parts, always use the
by the hoist or crane.
specified tightening torques. When installing protec-
tive parts such as guards, or parts which vibrate
15. When removing covers which are under internal
violently or rotate at high speed, be particularly
pressure or under pressure from a spring, always
careful to check that they are installed correctly.
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
22. When aligning two holes, never insert your fingers or
remove.
hand. Be careful not to get your fingers caught in a
hole.
16. When removing components, be careful not to break
or damage the wiring, Damaged wiring may cause
23. When measuring hydraulic pressure, check that the
electrical fires.
measuring tool is correctly assembled before taking
any measurements.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, wipe
24. Take care when removing or installing the tracks of
it up immediately. Fuel or oil on the floor can cause
track-type machines. When removing the track, the
you to slip, or can even start fires.
track separates suddenly, so never let anyone stand
at either end of the track.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when

00-4
FOREWARD GENERAL

FOREWARD

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.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further divided into each
main group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of
the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made
at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also
included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.

00-5
FOREWARD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out When a manual is revised, an edition mark (000 ....) is
repairs. They are divided as follows: recorded on the bottom outside corner of the pages.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series REVISIONS
Electrical volume: Each issued as one to cover all
models Revised pages are shown at the LIST OF REVISED
Attachment volume: Each issued as one to cover all PAGES between the title page and SAFETY page.
models
SYMBOLS
These various volumes are designed to avoid duplication
of information. Therefore to deal with all repairs for any So that the shop manual can be of ample practical use,
model, it is necessary that chassis, engine electrical and important places for safety and quality are marked with
attachment be available. the following symbols.

DISTRIBUTION AND UPDATING

Symbol Item Remarks

Any additions, amendments or other changes will be sent Special safety precautions are nec-
Safety
to your distributors. Get the most up-to-date information A essary when performing the work.
before you start any work.
Special technical precautions or
other precautions for preserving
FILING METHOD Caution
* standards are necessary when
performing the work.
1. See the page number on the bottom of the page. File
the pages in correct order. Weight of parts or systems. Cau-
tion necessary when selecting
2. Following examples show how to read the page
number:
el b Weight
hoisting wire or when working pos-
ture is important, etc.
Example 1 (Chassis volume):
Places that require special atten-
Tightening
tion for tightening torque during
torque
assembly.
Item number (10. Structure and
Places to be coated with adhesives
Function) Coat
and lubricants etc.
Y Consecutive page number for
Places where oil, water or fuel
each item Oil, water
must be added, and the capacity.

Example 2 (Engine volume): Places where oil or water must be

Refer to the pertinent engine manual. Drain drained, and quantity to be
.t.
drained.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File
as in the example.
Example:
1o-4
1o-4-1
Added pages
1O-4-2 I
1o-5

00-6
FOREWARD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Heavy parts (25 kg or more) must be lifted with

&i a hoist etc. In the DISASSEMBLY AND AS-
SEMBLY section, every part weighing 25 kg or more
is indicated clearly with the symbol
100% 88% 79% 71% 41%
6 kg
FSO064

3) Do not sling a heavy load with one rope alone, but

l If a part cannot be smoothly removed from the
sling with two or more ropes symmetrically wound
machine by hoisting, the following checks should be
on to the load.
made:
1) Check for removal of all bolts fastening the part

A
to the relative parts. Slinging with one rope may cause turning of
2) Check for existence of another part causing the load during hoisting, untwisting of the rope,
interface with the part to be removed. or slipping of the rope from its original winding posi-
tion on the load, which can result in a dangerous
WIRE ROPES accident.
1) Use adequate ropes depending on the weight of
parts to be hoisted, referring to the table below:
4) Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load
Wire ropes
with two or more ropes, the force subjected to each
(Standard “Z” or “S”twist ropes without galvanizing
rope will increase with the hanging angles. The
table below shows the variation of allowable load
Rope diameter (mm) Allowable load (tons)
(kg) when hoisting is made with two ropes, each of
10.0 1.0 which is allowed to sling up to 1000 kg vertically, at
11.2 1.4 various hanging angles. When two ropes sling a
12.5 1.6 load vertically, up to 2000 kg of total weight can be
14.0 2.2 suspended. This weight becomes 1000 kg when
16.0 2.8 two ropes make a 120” hanging angle. On the
18.0 3.6 other hand, two ropes are subject to an excessive
20.0 4.4 force as large as 4000 kg if they sling a 2000 kg
22.4 5.6 load at a lifting angle of 150”.
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0

The allowable load value is estimated to be 116 or

*
I/7 of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoisting,
and a serious accident can result. Hooks have
60’ 900 120” 150”
maximum strength at the middle portion.
Lifting angle : ct
FSO065

00-7
FOREWARD COATING MATERIALS

COATING MATERIALS

The recommended coating materials prescribed in the shop manuals are listed below.

Category 1 Code 1 Part No. Qty Container Main aoolicationsfeatures

l Used to prevent rubber gaskets, rubber cushions and cork plugs from
LT-IA 790-I 29-9030 150g Tube
I coming out
l Used in places requiring an immediately effective, strong adhesive.
Plastic
LT-1 B 790-I29-9050 20 9 ca container
Used for plastics (except polyethylene. polypropylene,
tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
Plastic l Features: Resistance to heat, chemicals
50 g
container l Used for anti-loosenina and sealant ourooses for bolts and oluas.
Adhesive 790-I29-9060
Adh 1 kg
Set of adhesive
Hard agt Can l Used as adhesive or sealant for metal, glass or plastic.
and hardening
500 kg
agent
Plastic
790-I 29-9040 250 g l Used as sealant for machined holes.
container
l Features: Resistance to heat, chemicals
50 cc ___
l Used at joint portions subject to high temperature.
l Used as adhesive or sealant for gaskets and packing of power train
LG-1 790-l29-9010 200 g Tube
case, etc.
l Features: Resistance to heat
t l Used as sealant for flange surfaces and bolts at high temperature
LG-3 790-I29-9070 1 kg Can locations; used to prevent seizure.
l Used as sealant for heat resistant gasket for at high temperature
locations such as engine pre-combustion chamber, exhaust pipe.
l Features: Resistance towater, oil
l Used as sealant for flange surface, thread.
LG-4 790-I29-9020 200 g Tube l Also possible to use as sealant for flanges with large clearance.
Gasket sealant l Used as sealant for mating surfaces of final drive case, transmission
case.
l Used as sealant for various threads, pipe joints, flanges.
Plastic
790-I29-9080 1 kg l Used as sealant for tapered plugs, elbows, nipples of hydraulic
container
piping.
l Features: Silicon based, resistant to heat, cold.
09940-00011 250 g Tube l Used as sealant for flange surface, thread.
l Used as sealant for oil pan, final drive case, etc.
l Features: Silicon based, quick hardening type.
LG-7 09920-00150 1509 Tube l Used as sealant for flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
I

Rust oreven- I 09940-00051 Can l Used as lubricant for sliding parts (to prevent squeaking).
60 g

l Used to prevent seizure or scuffing of the thread when press fitting or

09940-00040 200 g Tube shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG-35OLI
SYG-400LI
Lithium grease G2-Ll SYG-400LI-A Various Various l General purpose type
SYG-160LI
SYGA-1 GOCNLI
SSG2-400CA
SYG2-350CA
l Used for normal temperature, light load bearing at places in contact
Calcium grease G2-CA SYG2-400CA-A Various Various
with water or steam.
SYGZ-I 60CA
+ I
SYGA-1 GCNCA

Molybdenum 400 g
SYG2-400M Bellows type l Used for places with heavy load.
disultide grease --- (1 O/case)

00-8
FOREWARD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of
DISASSEMBLY AND ASSEMBLY.

1 kam = 9.806 Nm

Thread diameter of bolt Width across flat

0 0 0 0

mm mm km Nm

6 10 1.35 *0.15 13.2 *I .4

8 13 3.20 kO.3 31.4 *2.9
10 17 6.70 *0.7 65.7 56.8
12 19 11.5 *I .o 112 kg.8
14 22 18 k2.0 177 *I9
16 24 28.5 &3 279 *29
18 27 39 *4 383 *39
20 30 56 *6 549 i58
22 32 76 *8 745 *78
24 36 94.5 iI0 927 *98
27 41 135 *I5 1320 *I 40
30 46 175 *20 1720 *I 90
33 50 225 *25 2210 &240
36 55 280 *30 2750 i290
39 60 335 i35 3280 *340

k This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to
be used, or which require tightening to otherwise specified torque.

00-9
FOREWARD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter of bolt Width across flat Tightening torque

mm mm kgm Nm

10 14 6.70 *0.7 65.7 k6.8

12 17 11.5 &I .o 112 k9.8
16 22 28.5 k3 279 *29

TIGHTENING TORQUE FOR FLAIRED NUTS

cm483
Use these torques for flaired part of nut.

Thread diameter of bolt Width across flat Tightening torque

I

mm mm kgm Nm

14 19 2.5 k0.5 24.5 k4.9

18 24 5 *2 49 &I 9.6
22 27 8 *2 78.5 *I 9.6
24 32 14 i3 137.3 Q9.4
30 36 18k3 176.5 i29.4
33 41 20 zt5 196.1 zk49
36 46 25 k5 245.2 k49
42 55 30 *5 294.2 *49

00-l 0
FOREWARD 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 Cable Current rating
Number of Dia. Of strand Applicable circuit
number O.D. (mm) (A)
strands (mm)

0.85 11 0.32 Starting, lighting, signal etc.

2 26 0.32 Lighting, signal etc.

5 65 0.32 Charging and signal

15 1 84 1 0.45 13.36
I 7.0
159
Starting (Glow plug)

40 1 85 1 0.80 42.73 I 11.4 1’35 Starting

60 1 127 1 0.80 63.84 I 13.6 1178 Starting

100 1 217 I 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Priority Classification Circuits Charging Ground Starting Lighting Instruments Signal 1 Other

Code W B B R Y
1 Primary
Color White Black Black Red Yellow

Code WR ___ BW RW YR
2
Color White/Red -- Black/White Yellow/Red Green/White Bluewhite

Code WB ___ BY RB YB
3
Color White/Black --- BlXk/Yt?lOW Red/Black Yellow/Black

Code WL _- BR RY YG GY LY
I
4
Color I White/Blue I --- I Black/Red Red/Yellow Yellow/Green GreenNellow BlueNellow
I
RG YL

Red/Green Yellow/Blue

RL YW
6
Red/Blue Green/Blue I --

00-1 1
FOREWARD 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
l Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as 0, then draw a horizontal line from
0.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting from millimeters
to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by IO (move the decimal one place to the left) to
convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by IO, so multiply 2.165 inches by IO (move the decimal one place
to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to Inches
1 mm = 0.03937 in
mm 0 1 2 3 4 50 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

IO 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
0

3 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-l 2
Komatsu Hydraulic Excavator Pc200 250lc 6 Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc200-250lc-6-shop-manual/
FOREWARD CONVERSIONTABLES

Millimeterstolnches
1 mm=O.O3937in
mm 0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogramto Pound
1 kg = 2.2046 lb

kg 0 1 2 3 4 5 6 7
T 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-l 3
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