This is a shop manual for the Komatsu PC200LL-8 and PC220LL-8 Hydraulic Excavators, specifically for models with serial numbers A87001 and up, powered by the 6D107E-1 engine. This manual provides comprehensive technical information for service and repair operations, aiming to improve repair quality by offering accurate understanding of the product and correct repair procedures.
Function Description:
The Komatsu PC200LL-8 and PC220LL-8 are hydraulic excavators designed for various heavy-duty applications. The manual covers configurations for both "Road Builder" and "Log Loader" (36 Ft and 38 Ft Komatsu Forest Front) setups, indicating their versatility in construction and forestry operations. As hydraulic excavators, their primary function involves digging, lifting, and moving materials using a hydraulic system that powers the boom, arm, and bucket (or other work equipment). The "LL" designation likely refers to "Log Loader," highlighting their specialized use in logging.
Important Technical Specifications:
The manual includes detailed sections on technical specifications, such as:
- Dimensions: Separate dimension charts are provided for PC200LL-8 and PC220LL-8 models, further broken down by "Road Builder" and "Log Loader" configurations. These charts include various measurements like overall length, width, height, and specific dimensions related to the work equipment.
- Working Ranges: Similar to dimensions, working range specifications are provided for both models and configurations, detailing the maximum digging depth, reach, and loading height, crucial for operational planning and efficiency.
- Weight Table: Comprehensive weight tables are included for both PC200LL-8 and PC220LL-8, listing the weights of various components and the overall machine. This information is vital for transportation, lifting, and ensuring safe handling during maintenance.
- Fuel, Coolant, and Lubricants: A dedicated section outlines the recommended types and qualities of fuel, coolant, and lubricants, including specific brands and Komatsu Genuine Oil recommendations. This ensures optimal performance and longevity of the engine and hydraulic systems.
- Engine: The specified engine for these models is the 6D107E-1, a key component influencing the machine's power and operational capabilities.
Usage Features:
While primarily a repair manual, the content implicitly highlights usage features through its focus on maintenance and troubleshooting:
- Versatile Configurations: The availability of "Road Builder" and "Log Loader" configurations suggests the machines are adaptable to different job requirements, from general excavation to specialized forestry tasks.
- Hydraulic System: The emphasis on handling hydraulic equipment, including precautions against dirt and proper oil changes, indicates the critical role of the hydraulic system in the machine's operation and the need for its precise functioning.
- Electrical System: Detailed instructions on handling electrical equipment, wiring harnesses, and connectors point to the machine's reliance on advanced electronic controls for its functions.
Maintenance Features:
The manual is a comprehensive guide for maintaining and repairing the hydraulic excavators, offering several key maintenance features:
- Structured Information: The manual is organized into logical sections:
- 00 FOREWORD: Introduces the manual, explains how to read it, and lists safety precautions.
- 01 GENERAL: Provides general machine dimensions, performance specifications, component weights, and fluid specifications.
- 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD: Explains component structure, function, and inspection standards for disassembled parts.
- 20 STANDARD VALUE TABLE: Lists standard values for new machines and judgment criteria for testing, adjusting, and troubleshooting.
- 30 TESTING AND ADJUSTING: Details checks and adjustments to be made before and after repairs.
- 40 TROUBLESHOOTING: Contains charts correlating problems to causes.
- 50 DISASSEMBLY AND ASSEMBLY: Outlines procedures for removing, installing, disassembling, and assembling components.
- 60 AIR CONDITIONER: Covers the air conditioning system's structure, function, testing, adjusting, troubleshooting, disassembly, and assembly.
- 90 DIAGRAMS AND DRAWINGS: Provides foldout drawings of the machine.
- Safety Precautions: Extensive safety warnings are provided, including general precautions, preparations for work, and precautions during work, emphasizing the use of personal protective equipment, proper lifting techniques, and safe handling of fluids and electrical components. Special warnings are given for handling refrigerant gas (R134a) in the air conditioner circuit.
- Handling Electric and Hydraulic Equipment: Dedicated sections provide detailed instructions on handling sensitive electrical and hydraulic components, including proper disconnection/connection of connectors, drying wiring harnesses, and preventing contamination in hydraulic circuits.
- Tightening Torques: Standard tightening torques for bolts, nuts, hose nuts, split flange bolts, and flared nuts are provided, ensuring correct assembly and preventing damage or loosening.
- Conversion Tables: Useful conversion tables for millimeters to inches, kilograms to pounds, liters to U.S. gallons, liters to U.K. gallons, kg/cm² to lb/in², and temperature conversions (Fahrenheit to Centigrade) are included for convenience.
- Electric Wire Code: A detailed explanation of the electric wire code, including classification by thickness and color, aids in understanding wiring diagrams for electrical troubleshooting and repair.
- Coating Materials: A list of recommended coating materials (adhesives, gasket sealants, greases, molybdenum disulphide lubricants) with their part numbers, quantities, containers, and main applications/features is provided for proper sealing and lubrication during repairs.
- Revision Tracking: The manual includes a system to track revisions, indicating new, replaced, or deleted pages, ensuring users always have the most up-to-date information.
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