Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC200Z-6LE, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC200Z-6LE workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM001700 – Hydraulic Excavator PC200Z-6LE Shop Manual.pdf
CEAM001800 – Hydraulic Excavator PC200Z-6LE Operation & Maintenance Manual.pdf
SEAM021700 – Hydraulic Excavator PC200Z-6 Operation & Maintenance Manual.pdf
Total Pages: 948 pages
File Format: PDF
Language: English
CEAM001800 – Hydraulic Excavator PC200Z-6LE Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…5
1. FORWARD…6
2. SAFETY INFORMATION…7
3. INTRODUCTION…8
3.1 INTENDED USE…8
3.2 FEATURES…8
3.3 BREAKING IN A NEW MACHINE…8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…9
4.1 MACHINE SERIAL NO. PLATE POSITION…9
4.2 ENGINE SERIAL NO. PLATE POSITION…9
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…9
5. TABLE OF CONTENTS…10
SAFETY…15
6. GENERAL PRECAUTIONS…16
7. PRECAUTIONS DURING OPERATION…23
7.1 BEFORE STARTING ENGINE…23
7.2 OPERATING MACHINE…25
7.3 TRANSPORTATION…31
7.4 BATTERY…33
7.5 TOWING…35
7.6 BUCKET WITH HOOK…36
7.6.1 GENERAL PRECAUTIONS…36
7.6.2 PRECAUTIONS FOR LIFTING OPERATION…37
8. PRECAUTIONS FOR MAINTENANCE…38
8.1 BEFORE CARRYING OUT MAINTENANCE…38
8.2 DURING MAINTENANCE…41
9. POSITION FOR ATTACHING SAFETY LABELS…46
OPERATION…50
10. GENERAL VIEW…51
10.1 GENERAL VIEW OF MACHINE…51
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…52
11. EXPLANATION OF COMPONENTS…53
11.1 MACHINE MONITOR…53
11.1.1 A. CAUTION ITEMS…54
11.1.2 B. EMERGENCY STOP ITEMS…54
11.1.3 C. METER DISPLAY PORTION…55
11.2 SWITCHES…56
11.3 CONTROL LEVERS, PEDALS…59
11.4 CEILING WINDOW…63
11.5 FRONT WINDOW…63
11.6 DOOR LOCK…66
11.7 ASHTRAY…66
11.8 CAP, COVER WITH LOCK…66
11.8.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)…66
11.8.2 METHOD OF OPENING AND CLOSING COVER WITH LOCK…67
11.9 CAB HEATER…67
11.9.1 PREPARING CAB HEATER…68
11.10 FUSE…68
11.11 FUSIBLE LINK…68
11.12 TOOL BOX…69
11.13 GREASE PUMP HOLDER…69
11.14 HANDLING ACCUMULATOR…69
11.14.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…70
12. OPERATION…71
12.1 CHECK BEFORE STARTING ENGINE…71
12.1.1 WALK-AROUND CHECK…71
12.1.2 CHECK BEFORE STARTING…72
12.1.3 ADJUSTMENT BEFORE OPERATION…72
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…74
12.2 STARTING ENGINE…75
12.2.1 NORMAL STARTING…75
12.2.2 STARTING IN COLD WEATHER…76
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…77
12.4 MOVING MACHINE…79
12.4.1 MOVING MACHINE FORWARD…79
12.4.2 MOVING MACHINE BACKWARD…80
12.5 STEERING MACHINE…82
12.6 STOPPING MACHINE…84
12.7 SWINGING…85
12.8 OPERATION OF WORK EQUIPMENT…86
12.9 PROHIBITIONS FOR OPERATION…87
12.10 PRECAUTIONS FOR OPERATION…89
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…90
12.12 HOW TO ESCAPE FROM MUD…92
12.12.1 WHEN ONE SIDE IS STUCK…92
12.12.2 WHEN BOTH SIDES ARE STUCK…92
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…93
12.13.1 BACKHOE WORK…93
12.13.2 SHOVEL WORK…93
12.13.3 DITCHING WORK…93
12.13.4 LOADING WORK…93
12.14 REPLACEMENT AND INVERSION OF BUCKET…94
12.14.1 REPLACEMENT…94
12.14.2 INVERSION…95
12.15 PARKING MACHINE…96
12.16 CHECK AFTER FINISHING WORK…97
12.17 STOPPING ENGINE…98
12.18 CHECK AFTER STOPPING ENGINE…98
12.19 LOCKING AND SECURING MACHINE…99
13. TRANSPORTATION…100
13.1 LOADING, UNLOADING WORK…100
13.2 PRECAUTIONS FOR LOADING…102
13.3 PRECAUTIONS FOR TRANSPORTATION…102
14. COLD WEATHER OPERATION…103
14.1 PRECAUTIONS FOR LOW TEMPERATURE…103
14.1.1 FUEL AND LUBRICANTS…103
14.1.2 COOLANT…103
14.1.3 BATTERY…104
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…105
14.3 AFTER COLD WEATHER…105
15. LONG-TERM STORAGE…106
15.1 BEFORE STORAGE…106
15.2 DURING STORAGE…107
15.3 AFTER STORAGE…107
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…107
16. TROUBLESHOOTING…108
16.1 PHENOMENA THAT ARE NOT FAILURES…108
16.2 METHOD OF TOWING MACHINE…108
16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE…108
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…109
16.5 IF BATTERY IS DISCHARGED…109
16.5.1 STARTING ENGINE WITH BOOSTER CABLE…110
16.5.2 REMOVAL AND INSTALLATION OF BATTERY…112
16.6 OTHER TROUBLE…113
16.6.1 ELECTRICAL SYSTEM…113
16.6.2 CHASSIS…114
16.6.3 ENGINE…115
MAINTENANCE…117
17. GUIDES TO MAINTENANCE…118
18. OUTLINES OF SERVICE…121
18.1 OUTLINE OF OIL, FUEL, COOLANT…121
18.1.1 OIL…121
18.1.2 FUEL…122
18.1.3 COOLANT…122
18.1.4 GREASE…123
18.1.5 STORING OIL AND FUEL…123
18.1.6 FILTERS…123
18.2 OUTLINE OF ELECTRICAL SYSTEM…124
18.3 OUTLINE OF HYDRAULIC SYSTEM…125
19. WEAR PARTS LIST…126
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…128
20.1 ENGINE OIL SPECIFICATION…129
20.1.1 NORMAL OPERATION…129
20.1.2 ARCTIC OPERATION…129
20.2 DIESEL FUEL SPECIFICATIONS…130
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…131
21.1 INTRODUCTION OF NECESSARY TOOLS…131
21.2 TORQUE LIST…132
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…133
23. MAINTENANCE SCHEDULE…136
23.1 MAINTENANCE SCHEDULE CHART…136
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…139
24. SERVICE PROCEDURE…140
24.1 INITIAL 250 HOURS SERVICE…140
24.2 WHEN REQUIRED…141
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…141
24.2.2 CLEAN INSIDE OF COOLING SYSTEM (2 years or 2000 hours whichever occurs first)…143
24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS…147
24.2.4 CHECK AND ADJUST TRACK TENSION…148
24.2.5 CHECK ENGINE INTAKE AIR HEATER (ELECTRICAL)…150
24.2.6 INSTALLATION OF BUCKET TEETH (ESCO SUPERV ® TYPE)…151
24.2.7 REMOVAL OF BUCKET TEETH (ESCO SUPERV ® TYPE)…153
24.2.8 ADJUST BUCKET CLEARANCE…155
24.2.9 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…156
24.2.10 CHECK AND ADJUST AIR CONDITIONER…157
24.2.11 REPLACE ADDITIONAL BREAKER FILTER ELEMENT…158
24.2.12 CLEAN INLINE FILTER (RECTANGULAR HOUSING)…159
24.3 CHECK BEFORE STARTING…160
24.3.1 CHECK COOLANT LEVEL, ADD COOLANT…160
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…160
24.3.3 CHECK FUEL LEVEL, ADD FUEL…161
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…162
24.3.5 CHECK DUST INDICATOR…163
24.3.6 CHECK ELECTRIC WIRING…163
24.3.7 CHECK FOR WATER AND SEDIMENT IN FUEL-WATER SEPERATOR…164
24.4 EVERY 100 HOURS SERVICE…164
24.4.1 LUBRICATING…164
24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…166
24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK…166
24.5 EVERY 250 HOURS SERVICE…167
24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…167
24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE…168
24.5.3 LUBRICATE SWING CIRCLE (2 POINTS)…169
24.5.4 CHECK FAN BELT TENSION, ADJUST…169
24.5.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…170
24.5.6 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…171
24.6 EVERY 500 HOURS SERVICE…172
24.6.1 REPLACE HYDRAULIC FILTER ELEMENT…172
24.6.2 REPLACE FUEL FILTER CARTRIDGE AND FUEL-WATER SEPERATOR…173
24.6.3 CHECK SWING PINION GREASE LEVEL, ADD GREASE…175
24.6.4 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AC…175
24.6.5 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AC)…176
24.6.6 REPLACE HYDRAULIC TANK BREATHER ELEMENT…176
24.6.7 REPLACE IN-LINE FUEL STRAINER…177
24.7 EVERY 1000 HOURS SERVICE…178
24.7.1 CHANGE OIL IN SWING MACHINERY CASE…178
24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…179
24.7.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…179
24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR…179
24.7.5 CHECK ALTERNATOR BELT TENSIONER BEARING, BELT AND FAN HUB…180
24.8 EVERY 2000 HOURS SERVICE…181
24.8.1 CHANGE OIL IN FINAL DRIVE CASE…181
24.8.2 CLEAN HYDRAULIC TANK STRAINER…182
24.8.3 CLEAN, CHECK TURBOCHARGER…182
24.8.4 CHECK ALTERNATOR, STARTING MOTOR…182
24.8.5 CHECK VIBRATION DAMPER…182
24.8.6 CHANGE ANTIFREEZE…182
24.8.7 CHECK AND ADJUST VALVE CLEARANCE…183
24.9 EVERY 5000 HOURS SERVICE…184
24.9.1 CHANGE OIL IN HYDRAULIC TANK…184
SPECIFICATIONS…188
25. SPECIFICATIONS…189
25.1 Standard specifications…189
25.2 Static dimensions…190
25.3 Working dimensions…191
25.4 Lifting capacity…192
OPTIONS, ATTACHMENTS…194
26. GENERAL PRECAUTIONS…195
26.1 PRECAUTIONS RELATED TO SAFETY…195
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…196
27. HANDLING BUCKET WITH HOOK…197
27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK…197
27.2 PROHIBITED OPERATIONS…197
27.3 PRECAUTIONS DURING OPERATIONS…197
28. HANDLING AIR CONDITIONER…198
28.1 GENERAL LOCATIONS ON CONTROL PANEL…198
28.2 PRECAUTIONS WHEN USING AIR CONDITIONER…200
29. MACHINES READY FOR ATTACHMENTS…201
29.1 EXPLANATION OF COMPONENTS…201
29.2 HYDRAULIC CIRCUIT…203
29.2.1 CONNECTING HYDRAULIC CIRCUIT…204
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…205
29.4 OPERATION…206
29.5 LONG-TERM STORAGE…207
29.6 SPECIFICATIONS…207
30. INTRODUCTION OF ATTACHMENTS…208
30.1 BUCKET SELECTION…208
30.2 BUCKET INSTALLATION COMBINATIONS…208
30.3 SELECTION OF TRACK SHOES…210
30.4 BACKHOE CONTROL PATTERN CONVERSION…211
31. EXTENDING MACHINE SERVICE LIFE…212
31.1 HYDRAULIC BREAKER…212
31.2 CRUSHER…215
31.3 GRAPPLE…216
31.4 BUCKET WITH THUMB GRAPPLE…217
31.5 ROTATING GRAPPLE…218
31.6 SHEAR…219
31.7 HYDRAULIC PILE DRIVER…220
CEBM001700 – Hydraulic Excavator PC200Z-6LE Shop Manual…221
SEAM021700 – Hydraulic Excavator PC200Z-6 Operation & Maintenance Manual…706
1. FOREWORD…707
2. SAFETY INFORMATION…708
3. INTRODUCTION…709
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…710
5. CONTENTS…711
SAFETY…715
6. GENERAL PRECAUTIONS …716
7. PRECAUTIONS DURING OPERATION …724
7.1 BEFORE STARTING ENGINE …724
7.2 AFTER STARTING ENGINE …726
7.3 TRANSPORTATION …733
7.4 BATTERY …734
7.5 TOWING …736
7.6 LIFTING OPERATIONS …736
7.7 BUCKET WITH HOOK…737
8. PRECAUTIONS FOR MAINTENANCE …739
8.1 BEFORE CARRYING OUT MAINTENANCE …739
8.2 DURING MAINTENANCE …743
9. POSITION FOR ATTACHING SAFETY LABELS …749
OPERATION…753
10. GENERAL VIEW …754
10.1 GENERAL VIEW OF MACHINE …754
10.2 GENERAL VIEW OF CONTROLS AND GAUGES …755
11. EXPLANATION OF COMPONENTS …756
11.1 MACHINE MONITOR …756
11.2 SWITCHES …761
11.3 CONTROL LEVERS AND PEDALS …765
11.4 CEILING WINDOW …770
11.5 FRONT WINDOW …771
11.6 DOOR LOCK …773
11.7 ASHTRAY …773
11.8 CAP, COVER WITH LOCK …774
11.9 HANDLING CAR HEATER …775
11.10 FUSE …776
11.11 FUSIBLE LINK …777
11.12 TOOL BOX …777
11.13 GREASE PUMP HOLDER …777
11.14 HANDLING ACCUMULATOR …778
12. OPERATION …779
12.1 CHECK BEFORE STARTING ENGINE …779
12.2 STARTING ENGINE …789
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE …791
12.4 MOVING MACHINE OFF …793
12.5 STEERING MACHINE …796
12.6 STOPPING MACHINE …798
12.7 SWINGING…799
12.8 OPERATION OF WORK EQUIPMENT …800
12.9 PROHIBITIONS FOR OPERATION …801
12.10 PRECAUTIONS FOR OPERATION …803
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS …804
12.12 HOW TO ESCAPE FROM MUD …806
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR …807
12.14 REPLACEMENT AND INVERSION OF BUCKET …808
12.15 PARKING MACHINE …810
12.16 CHECK AFTER FINISHING WORK…811
12.17 STOPPING ENGINE …812
12.18 CHECK AFTER STOPPING ENGINE …813
12.19 LOCKING …813
13. TRANSPORTATION …814
13.1 LOADING, UNLOADING WORK …814
13.2 PRECAUTIONS FOR LOADING …816
13.3 PRECAUTIONS FOR TRANSPORTATION …817
14. COLD WEATHER OPERATION …818
14.1 PRECAUTIONS FOR LOW TEMPERATURE …818
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…820
14.3 AFTER COLD WEATHER …820
15. LONG-TERM STORAGE …821
15.1 BEFORE STORAGE …821
15.2 DURING STORAGE …822
15.3 AFTER STORAGE …822
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE …822
16. TROUBLESHOOTING …823
16.1 PHENOMENA THAT ARE NOT FAILURES …823
16.2 METHOD OF TOWING MACHINE…823
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE …823
16.4 PRECAUTIONS ON PARTICULAR JOBSITES …824
16.5 IF BATTERY IS DISCHARGED …824
16.6 OTHER TROUBLE …828
MAINTENANCE…832
17. GUIDES TO MAINTENANCE …833
18. OUTLINES OF SERVICE …836
18.1 OUTLINE OF OIL, FUEL, COOLANT …836
18.2 OUTLINE OF ELECTRIC SYSTEM …839
18.3 OUTLINE OF HYDRAULIC SYSTEM …840
19. WEAR PARTS LIST …841
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE …842
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…847
21.1 INTRODUCTION OF NECESSARY TOOLS …847
21.2 TORQUE LIST…848
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS …849
23. MAINTENANCE SCHEDULE CHART …853
23.1 MAINTENANCE SCHEDULE CHART …853
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER …855
24. SERVICE PROCEDURE …856
24.1 INITIAL 250 HOURS SERVICE …856
24.2 WHEN REQUIRED …857
24.3 CHECK BEFORE STARTING …876
24.4 EVERY 100 HOURS SERVICE …881
24.5 EVERY 250 HOURS SERVICE …884
24.6 EVERY 500 HOURS SERVICE …890
24.7 EVERY 1000 HOURS SERVICE …895
24.8 EVERY 2000 HOURS SERVICE …898
24.9 EVERY 4000 HOURS SERVICE …901
24.10 EVERY 5000 HOURS SERVICE …902
SPECIFICATIONS…907
25. SPECIFICATIONS …908
OPTIONS, ATTACHMENTS…913
26. GENERAL PRECAUTIONS …914
26.1 PRECAUTIONS RELATED TO SAFETY …914
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS …915
27. HANDLING BUCKET WITH HOOK …916
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…916
27.2 PROHIBITED OPERATIONS …916
27.3 PRECAUTIONS DURING OPERATIONS …916
28. AIR CONDITIONER (MACHINES EQUIPPED WITH AIR CONDITIONER) …917
28.1 AIR CONDITIONER …917
29. MACHINES READY FOR ATTACHMENTS …920
29.1 EXPLANATION OF COMPONENTS …920
29.2 HYDRAULIC CIRCUIT …922
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE …924
29.4 OPERATION …926
29.5 LONG-TERM STORAGE …927
29.6 SPECIFICATIONS …927
30. INTRODUCTION OF ATTACHMENTS …928
30.1 BUCKET SELECTION …928
30.2 BUCKET INSTALLATION COMBINATIONS …928
30.3 BACKHOE CONTROL PATTERN CONVERSION …930
30.4 SELECTION OF TRACK SHOES …931
30.5 HANDLING RUBBER PAD SHOE …932
30.6 HANDLING TRAPEZOIDAL BUCKET …934
30.7 HANDLING EXTENSION ARM …935
30.8 HANDLING CLAMSHELL BUCKET …936
31. EXTENDING MACHINE SERVICE LIFE …937
31.1 HYDRAULIC BREAKER …937
31.2 POWER RIPPER …940
31.3 FORK GRAB …941
31.4 GRAPPLE BUCKET …942
31.5 SCRAP GRAPPLE …943
31.6 CRUSHER & CUTTER …944
31.7 HYDRAULIC PILE DRIVER …945
31.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE …946
Komatsu Hydraulic Excavator PC200Z-6LE Repair Service Manuals