Download Komatsu Pc200 210 220 250lc 6le Excavator Manual

CEBM001002

Shop Manual

PC200LC-6LE PC210LC-6LE PC220LC-6LE PC250LC-6LE HYDRAULIC EXCAVATOR

SERIAL NUMBERS

PC200LC-6LE PC210LC-6LE PC220LC-6LE PC250LC-6LE

A83001 A83001 A83001 A83001

and UP

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 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.

June 2005 Printed in USA PC200/210/220/250LC-6LE

Copyright 2005 Komatsu DataKom Publishing Division 00-1 c

FOREWORD 12

CONTENTS

CONTENTS

00

01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20

TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90

OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 c

PC200/210/220/250LC-6LE

PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION PARTS BOOK - PAPER: Chassis and Engine PC200LC-6LE Chassis and Engine PC210LC-6LE Chassis and Engine PC220LC-6LE Chassis and Engine PC250LC-6LE

FORM NUMBER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB001703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB001800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB001902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB002001

OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM001200 SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001002 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEBM010020 SAFETY MANUAL: Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE03-02 STANDARD MAN-HOUR GUIDE: GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CEKQ000300

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If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders.

PC200/210/220/250LC-6LE Pubinfo.fm

6/23/05

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PC200/210/220/250LC-6LE

FOREWORD

SAFETY

12

SAFETY SAFETY NOTICE

00

00

IMPORTANT SAFETY NOTICE

00

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 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

00

PREPARATIONS FOR WORK

00

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1.

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.

1.

Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

2.

2.

When carrying out 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.

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.

3.

When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

4.

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.

â—? â—?

3.

If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4.

When carrying out any operation with two or more workers, always agree on the operating procedure 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.

5.

6.

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 make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PC200/210/220/250LC-6LE

PRECAUTIONS DURING WORK

00

1.

When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

2.

The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.

3.

Before starting work, remove the leads from the battery.

ALWAYS remove the lead from the negative (-) terminal first.

00-3 c

FOREWORD

SAFETY

12 4. 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. Do not work with any part still raised by the hoist or crane.

5.

When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6.

When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.

7.

When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.

Fuel or oil on the floor can cause you to slip, or can even start fires.

8.

Gasoline or other fuels should never be used to clean parts. Clean part with apropriate solvents.

9.

Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.

When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.

â—?

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.

14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

15. 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. Carefully review the safety and procedures for jump starting the machine.

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PC200/210/220/250LC-6LE

FOREWORD

GENERAL

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GENERAL

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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. This section also inlcudes material for the maintenance standards.

TESTING, ADJUSTING AND TROUBLESHOOTING 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.

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.

PC200/210/220/250LC-6LE

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FOREWORD

HOW TO READ THE SHOP MANUAL

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HOW TO READ THE SHOP MANUAL VOLUMES

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REVISIONS

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Shop manuals are issued as a guide to carrying out repairs.

They are divided as follows:

Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.

Chassis volume: Engine volume:

SYMBOLS

Issued for every machine model Issued for each engine series

Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.

DISTRIBUTION AND UPDATING

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2.

So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.

Tightening torque

Places that require special attention for tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

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Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.

FILING METHOD

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See the page number on the bottom of the page. File the pages in correct order.

Following examples show how to read the page number: Example: 10 - 3

★

Item number (10. Structure and Function) Consecutive page number for each item 3.

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Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example.

Example:

10-4 10-4-1 Added pages 10-4-2 10-5

REVISED EDITION MARK

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When a manual is revised, an edition mark (bcd‌) is recorded on the bottom outside corner of the pages.

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PC200/210/220/250LC-6LE

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