Komatsu A87001, Shop Manual

Page 1: ...rp 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...

Page 2: ... GENERAL 01 1 10 STRUCTURE FUNCTION AND MAINTENANCE STANDARD 10 1 20 STANDARD VALUE TABLES 20 1 30 TESTING AND ADJUSTING 30 1 40 TROUBLESHOOTING 40 1 50 DISASSEMBLY AND ASSEMBLY 50 1 60 AIR CONDITIONER 60 1 90 DIAGRAMS AND DRAWINGS 90 1 Find manuals at https best manuals com ...

Page 3: ... 00 19 b 00 20 b 00 21 b 00 22 b 00 23 b 00 24 b 00 25 b 00 26 b 00 27 b 00 28 b 00 29 e 00 30 b 00 31 b 00 32 b 00 33 b 00 34 b 00 35 b 00 36 b 01 1 b 01 2 b 01 3 b 01 4 b 01 5 b 01 6 b 01 7 b 01 8 b 01 9 b Mark Page Rev 01 10 b 01 11 b 01 12 b 01 13 b 01 14 b 01 15 b 01 16 b 01 17 b 01 18 e 01 19 e 01 20 e 10 1 b 10 2 b 10 3 b 10 4 b 10 5 b 10 6 e 10 7 e 10 8 b 10 9 b 10 10 b 10 11 e 10 12 b 10 ...

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Page 14: ...FOREWORD 00 2 12 f PC200 220LL 8 Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev ...

Page 15: ...g 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 provid...

Page 16: ... 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...

Page 17: ... 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 Carefully review the safety and procedures for jump starting the machine ...

Page 18: ...rds when inspecting disassembled parts 20 STANDARD VALUE TABLE This section explains the standard values for new machine and judgement criteria for testing adjusting and troubleshooting This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting 30 TESTING AND ADJUSTING This section explains checks to be made before and after perfor...

Page 19: ...for each item 3 Additional pages Additional pages are indicated by a hyphen and numbered after the page number File as in the example Example Revised Edition Mark 00 When a manual is revised an edition mark 123 is recorded on the bottom outside corner of the pages Revisions 00 Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page Symbols 00 So that the shop ma...

Page 20: ...d with two or more ropes the force subjected to each rope will increase with the hanging angles The table below shows the variation of allowable load kg when hoisting is made with two ropes each of which is allowed to sling up to 1000 kg vertically at various hanging angles When two ropes sling a load vertically up to 2000 kg of total weight can be suspended This weight becomes 1000 kg when two ro...

Page 21: ...rotecting the wiring Compared with other electrical components fitted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful whe...

Page 22: ...the same time if water does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short circuited by the water so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it E Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the...

Page 23: ... connectors apart Never pull with one hand B When removing from clips Both of the connector and clip have stoppers which are engaged with each other when the connector is installed When removing a connector from a clip pull connector in a parallel direction to the clip for removing stoppers If the connector is twisted up and down or to the left or right the housing may break C Action to take after...

Page 24: ... securely Align the position of the connector correctly and then insert it securely For connectors with lock stopper push in the connector until the stopper clicks into position C Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots correct any protrusion of the boot In addition if the wiring harness is misaligned or the clamp is out of pos...

Page 25: ...r to dry the connector Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related parts too hot as this will cause deformation or damage to the connector Perform a continuity test on the connector After drying leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused b...

Page 26: ...FF before disconnecting or connecting connectors B Before performing troubleshooting check that all the related connectors are properly inserted Disconnect and connect the related connectors several times to check C Always connect any disconnected connectors before going on to the next step If the power is turned ON with the connectors still disconnected unnecessary abnormality displays will be ge...

Page 27: ...aled with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening is left open or is blocked with a rag there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this Do not simply drain oil out onto the ground but collect it and ask the customer to dispose of it or take it back with you for disposal 4 Do not let any dirt or d...

Page 28: ...primary flushing is performed with flushing oil and secondary flushing is performed with the specified hydraulic oil 7 Cleaning operations After repairing the hydraulic equipment pump control valve etc or when running the machine perform oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit The oil cleaning equipment is used to remove the ultra fine about 3 m 10 ft particl...

Page 29: ...flows out prepare an oil receiving container Connection 00 1 Hold hose adapter 1 or hose 5 and insert it into mating adapter 3 aligning them with each other Do not hold rubber cap portion 4 2 After inserting the hose into the mating adapter pull it back to check its connecting condition When the hose is pulled back the rubber cap portion moves toward the hose about 3 5 mm 0 138 This does not indic...

Page 30: ...surface a of hexagonal portion at the male end 2 Hold in the condition in Step 1 and turn lever 4 clockwise to the right 3 Hold in the condition in Steps 1 and 2 and pull out body 2 to disconnect Connection 00 1 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 to connect it ...

Page 31: ...ortion at the male end 2 Hold in the condition in Step 1 and push until cover 3 contacts surface a of the hexagonal portion at the male end 3 Hold in the condition in Steps 1 and 2 and pull out the whole body 2 to disconnect it Connection 00 1 Hold the connector of the tightening portion and push body 2 in straight until the slide prevention ring 1 contacts surface a of the hexagonal portion at th...

Page 32: ...on of size of rotating shaft and hole and relationship drawing of them 2 Standard Clearance And Standard Value The clearance made when new parts are assembled is called the standard clearance which is indicated by the range from the minimum clearance to the maximum clearance When some parts are repaired the clearance is generally adjusted to the standard clearance A value of performance and functi...

Page 33: ...e is estimated from various tests or experiences in most cases however it must be judged after considering the operating condition and customer s requirement 5 Clearance Limit Parts can be used until the clearance between them is increased to a certain limit The limit at which those parts cannot be used is called the clearance limit If the clearance between the parts exceeds the clearance limit th...

Page 34: ...m N m lbf ft 6 10 11 8 14 7 8 70 10 84 8 13 27 34 19 91 25 07 10 17 59 74 43 51 54 57 12 19 98 123 72 28 90 72 14 22 153 190 112 84 140 13 16 24 235 285 173 32 210 20 18 27 320 400 236 02 295 02 20 30 455 565 335 59 416 72 22 32 610 765 449 91 564 23 24 36 785 980 578 98 722 81 27 41 1150 1440 848 19 1062 09 30 46 1520 1910 1121 09 1408 74 33 50 1960 2450 1445 62 1807 02 36 55 2450 3040 1807 02 22...

Page 35: ...7 50 6 04 22 27 58 9 98 1 44 4 72 4 05 24 32 107 9 166 7 79 6 123 0 06 30 36 147 1 205 9 108 5 151 9 10 33 41 147 1 245 1 108 5 180 8 12 36 46 196 2 294 2 144 7 217 0 14 42 55 245 2 343 2 180 9 253 1 Thread diameter Width across flat Tightening torque mm mm N m lbf ft 10 14 59 74 43 51 54 57 12 17 98 123 72 28 90 72 16 22 235 285 173 32 210 20 Thread diameter Width across flat Tightening torque mm...

Page 36: ...ge Target 08 08 14 5 88 8 82 4 33 6 50 7 35 5 42 10 10 17 9 8 12 74 7 22 9 39 11 27 8 31 12 12 19 14 7 19 6 10 84 14 45 17 64 13 01 14 14 22 19 6 24 5 14 45 18 07 22 54 16 62 16 16 24 24 5 34 3 18 07 25 29 29 4 21 68 18 18 27 34 3 44 1 25 29 32 52 39 2 28 91 20 20 30 44 1 53 9 32 52 39 75 49 0 36 14 24 24 32 58 8 78 4 43 36 57 82 68 6 50 59 30 30 32 93 1 122 5 68 66 90 35 107 8 79 50 33 33 _ 107 8...

Page 37: ...gnal etc 5 65 0 32 5 23 4 6 37 Charging and signal 15 84 0 45 13 36 7 0 59 Starting Glow plug 40 85 0 80 42 73 11 4 135 Starting 60 127 0 80 63 84 13 6 178 Starting 100 217 0 80 109 1 17 6 230 Starting Priority Circuits Classification Charging Ground Starting Lighting Instrument Signal Other 1 Primary Code W B B R Y G L Color White Black Black Red Yellow Green Blue 2 Auxiliary Code WR BW RW YR GW ...

Page 38: ...tes color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV and AVS are classified by size nominal No they are not indicated Table 1 Type Symbol Material Using temperature range C F Example of use Low voltage wire for automobi...

Page 39: ...0 5 23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cover D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diameter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 109 1 d approx 3 7 ...

Page 40: ... White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White GR Green Red RY Red Yellow GW Green White Sb Sky Blue GY Green Yellow Y Yellow L Blue YB Yellow Black LB Blue Black YG Yellow Green Lg Light green YL Yellow Blue LgB Light green Black YR Yellow Red LgR...

Page 41: ...r in the table so divide by 10 move the decimal one place to the left to convert it to 55 mm B Carry out the same procedure as above to convert 55 mm to 2 165 inches C The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal one place to the right to return to the original value This gives 550 mm 21 65 inches c Millimeters to inches 1 mm 0 03937 in 0 1 2 3 4 5 6 ...

Page 42: ...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 Kilogram to Pound 1 kg 2 2046 lb 0 1 2 3 4 5 6 7 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...

Page 43: ...8 21 662 21 926 22 190 22 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 361 25 625 25 889 26 153 Liter to U K Gallon 1 L 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 25...

Page 44: ...1 600 3 607 6 614 8 622 0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 1005 4 140 1012 6 1019 9 1027 1 1034 3 1041...

Page 45: ...280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977 140 1991 2005 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 23...

Page 46: ... 19 66 2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 20...

Page 47: ... 790 129 9040 250 g Polyethylene container Used as sealant for machined holes Holtz MH 705 790 126 9120 75 g Tube Used as heat resisting sealant for repairing engine Three bond 1735 179 129 9140 2 g Polyethylene container Quick hardening type adhesive Cure time within 5 sec to 3 min Used mainly for adhesion of metals rubbers plastics and woods Aronalpha 201 790 129 9130 50 g Polyethylene container...

Page 48: ...ning type Used as sealant for flywheel housing intake manifold oil pan thermostat housing etc Three bond 1211 790 129 9090 100 g Tube Used as heat resisting sealant for repairing engines Molybdenum disulphide lubricant LM G 09940 00051 60 g Can Used as lubricant for sliding parts to prevent squeaking LM P 09940 00040 200 g Tube Used to prevent seizure or scuffing of the thread when press fitting o...

Page 49: ...Front 01 4 Working Ranges 01 6 Road Builder 01 6 PC200LL 8 Log Loader 36 Ft Komatsu Forest Front 01 7 PC220LL 8 Log Loader 38 Ft Komatsu Forest Front 01 7 Specifications PC200LL 8 01 8 Specifications PC220LL 8 01 10 WEIGHT TABLE 01 13 PC200LL 8 01 13 PC220LL 8 01 15 FUEL COOLANT AND LUBRICANTS 01 17 Recommended Brands Recommended Quality for Products Other Than Komatsu Genuine Oil 01 19 PC200 220L...

Page 50: ...GENERAL SPECIFICATIONS 01 2 1 PC200 220LL 8 12 SPECIFICATIONS Dimensions PC200LL 8 Road Builder Log Loader 36 Ft Komatsu Forest Front ...

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