Related Manuals for Komatsu PC220 -8
Summarization of Contents
Index and Foreword
Index
Alphabetical listing of topics within the manual for quick reference.
Shop Manual Composition
Explains the structure and organization of the shop manual into different volumes and sections.
Table of Contents Overview
Outlines the main sections and their respective page numbers within the manual.
Foreword and General Information
Provides introductory details, safety notices, and guidance on using the shop manual effectively.
Safety Notice
Important safety precautions to prevent injury and ensure safe machine operation and repair.
How to Read the Shop Manual
Guidance on understanding the manual's layout, symbols, and terminology for effective use.
Maintenance Standard Terms
Defines key terms and concepts used in maintenance standards for part replacement and repair.
Handling Electric and Hydraulic Components
Procedures and precautions for safely handling electrical wiring and hydraulic systems.
Handling New Engine Connectors
Specific instructions for connecting and disconnecting various types of new engine connectors.
Reading Electric Wire Codes
Explains the coding system used for electric wires to understand circuit diagrams.
Operational Precautions
General safety guidelines and procedures to follow during machine operation and maintenance.
Push-Pull Coupler Disassembly/Connection
Step-by-step instructions for safely disconnecting and connecting push-pull type hydraulic couplers.
Standard Tightening Torque Tables
Tables providing specified torque values for bolts, nuts, and various fittings used in the machine.
Preparations for Work
General preparations and safety checks required before starting any maintenance or repair work.
Precautions during work
Safety guidelines and precautions to follow while performing various maintenance and repair tasks.
Sling Work and Sign Making Precautions
Safety measures for sling work and the role of appointed sign makers.
Precautions for using mobile crane
Safety guidelines for operating mobile cranes.
Selecting wire ropes
Criteria and recommendations for selecting appropriate wire ropes for lifting operations.
Air Conditioner Hose Precautions
Guidelines for safely disconnecting and connecting air conditioner hoses and tubes.
Shop Manual Filing Method
Instructions on how to organize and file the shop manual brochures correctly.
Symbols Used in Manual
Explanation of symbols used to highlight important safety and quality information.
Units of Measurement
Information on the units of measurement used in the manual (SI and Gravitational).
Standard Clearance and Value
Defines standard clearance, standard value, and their importance in part assessment.
Standard Interference
Explains standard interference between parts and how to measure it.
Repair Limit and Allowable Value
Defines repair limit and allowable values for parts based on wear and deformation.
Clearance Limit
Specifies the maximum allowable clearance for parts before replacement is needed.
Interference Limit
Defines the maximum allowable interference between assembled parts.
Electric Equipment Handling Points
Key considerations for handling electrical components and wiring harnesses safely.
Wiring Harness Failures
Common failures encountered in wiring harnesses, such as defective contact and crimping.
Wiring Harness Issues
Common problems with wiring, including disconnections, water ingress, and contamination.
Connector/Harness Removal and Installation
Procedures for safely removing, installing, and drying electrical connectors and wiring harnesses.
Connecting Electrical Connectors
Steps for properly aligning and connecting electrical connectors securely.
Heavy Duty Connector Handling
Specific instructions for disconnecting and connecting heavy-duty DT type connectors.
Wiring Harness Drying Procedures
Methods for drying wiring harnesses and connectors after exposure to moisture.
Controller Handling Precautions
Careful handling procedures for electronic controllers to prevent damage.
Hydraulic Equipment Handling
Key precautions for maintaining hydraulic systems, focusing on cleanliness and proper fluid management.
Hydraulic Oil Change Procedures
Guidance on changing hydraulic oil, emphasizing draining warm oil and flushing.
Hydraulic System Flushing
Procedures for flushing hydraulic circuits to remove contaminants and sludge.
Hydraulic Oil Cleaning Operations
Methods for cleaning hydraulic oil to remove ultra-fine particles using specialized equipment.
Slide Lock Connector Types
Details on slide lock type connectors used for various sensors and switches.
Pull Lock Connector Types
Information on pull lock type connectors for temperature and pressure sensors.
Push Lock Connector Types
Instructions for handling push lock type connectors on different engine models.
Turn-Housing Connector Types
Procedures for disconnecting and connecting turn-housing type connectors.
Wire Type, Symbol, and Material
Details on wire types, their symbols, materials, and temperature ratings.
Wire Dimensions and Specifications
Table of dimensions and specifications for various electrical wire types.
Electric Wire Color Codes
Table listing color codes used for electrical wires and their meanings.
Circuit Types and Wire Colors
Cross-reference table showing circuit types and their corresponding wire color codes.
Removal Work Precautions
Safety measures and procedures to follow when removing machine components.
Piping Disassembly Precautions
Guidelines for handling piping during disassembly, including plug usage.
Installation Work Precautions
Safety measures and procedures for installing machine components, including torque and material usage.
Post-Operation Precautions
Checks and procedures after completing operations, like refilling fluids and checking connections.
Type 1 Coupler Disconnection
Steps for disconnecting Type 1 push-pull hydraulic couplers.
Type 1 Coupler Connection
Steps for connecting Type 1 push-pull hydraulic couplers.
Type 2 Coupler Disconnection
Steps for disconnecting Type 2 push-pull hydraulic couplers.
Type 2 Coupler Connection
Steps for connecting Type 2 push-pull hydraulic couplers.
Type 3 Coupler Disconnection
Steps for disconnecting Type 3 push-pull hydraulic couplers.
Type 3 Coupler Connection
Steps for connecting Type 3 push-pull hydraulic couplers.
Bolts and Nuts Tightening Torque
Table of specified tightening torques for metric bolts and nuts based on thread size.
Split Flange Bolts Torque
Table of specified tightening torques for split flange bolts.
O-Ring Boss Piping Joints Torque
Table of specified tightening torques for O-ring boss piping joints.
O-Ring Boss Plugs Torque
Table of specified tightening torques for O-ring boss plugs.
Hose Tightening Torques (Taper/Face Seal)
Table of specified torques for tightening hoses with taper and face seal types.
Face Seal Joints Torque
Table of specified tightening torques for face seal joints used in engine applications.
Engine Series Bolt/Nut Torque (102/107/114)
Tightening torque specifications for bolts and nuts on 102, 107, and 114 engine series.
Engine Series Eye Joint Torque (102/107/114)
Tightening torque specifications for eye joints on 102, 107, and 114 engine series.
Engine Series Taper Screw Torque (102/107/114)
Tightening torque specifications for taper screws on 102, 107, and 114 engine series.
Troubleshooting
Failure Code and Fuse Locations
Lists failure codes and their corresponding fuse locations for diagnosing machine issues.
General Troubleshooting Information
Provides an overview and basic principles for effective troubleshooting of machine problems.
Troubleshooting by Failure Code (Part 1)
Detailed troubleshooting steps for specific failure codes related to engine and electrical systems.
Troubleshooting by Failure Code (Part 2)
Continues troubleshooting specific failure codes for various machine systems.
Troubleshooting by Failure Code (Part 3)
Further troubleshooting guides for additional failure codes across machine systems.
Electrical System Troubleshooting (E-mode)
Specific procedures for diagnosing and resolving electrical system faults using E-mode.
Hydraulic/Mechanical System Troubleshooting (H-mode)
Diagnostic steps for hydraulic and mechanical system failures identified through H-mode.
Engine Troubleshooting (S-mode)
Guides for troubleshooting engine-related issues using S-mode diagnostics.
Disassembly and Assembly
General information on disassembly and assembly
Provides overview and general precautions for performing disassembly and assembly of machine components.
Coating materials list
Lists the types and specifications of coating materials used during assembly procedures.
Special tools list
Lists specialized tools required for performing disassembly and assembly tasks.
Sketches of special tools
Illustrations and diagrams of specialized tools for disassembly and assembly.
Structure, Function, and Maintenance Standard
Engine and Cooling System
Details the components, structure, and maintenance standards for the engine and cooling system.
Power Train
Covers the structure, function, and maintenance of the power train components like final drive and swing machinery.
Undercarriage and Frame
Explains the structure, function, and maintenance of undercarriage parts and the main frame.
Hydraulic System
Details the structure, function, and maintenance of hydraulic system components, including pumps and valves.
Work Equipment
Describes the structure, function, and maintenance of the machine's work equipment.
Cab and its Attachments
Covers the structure, function, and maintenance of the operator's cab and related attachments.
Electrical System
Explains the structure, function, and maintenance of the machine's electrical system components.
Diagrams and Drawings
Hydraulic circuit diagram (PC200, 200LC-8)
Detailed hydraulic circuit diagram for PC200 and PC200LC-8 models.
Hydraulic circuit diagram (PC220, 220LC-8)
Detailed hydraulic circuit diagram for PC220 and PC220LC-8 models.
Hydraulic circuit diagram (PC200, 200LC-8, PC220, 220LC-8)
Combined hydraulic circuit diagram for PC200/200LC-8 and PC220/220LC-8 models.
Electrical circuit diagram
General electrical circuit diagram for the machine.
Connector arrangement diagram
Illustrates the layout and arrangement of electrical connectors on the machine.
Electrical circuit diagram for air conditioner
Specific electrical circuit diagram for the air conditioning system.
Conversion Table
Method of using the conversion table
Explanation and examples of how to use the conversion table for millimeters to inches.
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