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