Komatsu PC200LC-8 Install guide

CEBM025500
Shop
Manual
PC200LC -8
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC200LC-8 A90301 and up
ENGINE SAA6D107E-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
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 for information on the latest revision.
Copyright 2011 Komatsu
Printed in U.S.A.
Komatsu America Corp.
September 2011

FOREWORD CONTENTS
00-2 PC200LC-8
12
CONTENTS 00
01 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
90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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FOREWORD SAFETY
00-4 PC200LC-8
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
•When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be 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 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. 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.
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FOREWORD GENERAL
PC200LC-8 00-5
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
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.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
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FOREWORD HOW TO READ THE SHOP MANUAL
00-6 PC200LC-8
12
HOW TO READ THE SHOP MANUAL 00
Volumes 00
Shop manuals are issued as a guide to carrying out repairs.
They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model,
it is necessary that chassis, engine, electrical and attachment
be available.
Distribution And Updating 00
Any additions, amendments or other changes will be sent to
your distributors. Get the most up-to-date information before
you start any work.
Filing Method 00
1. See the page number on the bottom of the page. File the
pages in correct order.
2. Following examples show how to read the page number:
Example:
10 - 3
Item number (10. Structure and Function)
Consecutive page number 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 (bcd…) 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 manual can be of ample practical use,
important places for safety and quality are marked with the
following symbols.
10-4
10-4-1 Added pages
10-4-2
10-5
Symbol Item Remarks
Safety Special safety precautions are necessary when performing the
work.
★Caution
Special technical precautions or
other precautions for preserving
standards are necessary when per-
forming the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special
attention for tightening torque
during assembly.
Coat Places to be coated with adhesives
and lubricants etc.
Oil, water Places where oil, water or fuel
must be added, and the capacity.
Drain Places where oil or water must be drained, and quantity to be
drained.
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FOREWORD HOISTING INSTRUCTIONS
PC200LC-8 00-7
12
HOISTING INSTRUCTIONS 00
Hoisting 00
●If a part cannot be smoothly removed from the machine
by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the
relative parts.
2. Check for existence of another part causing interface
with the part to be removed.
Wire Ropes 00
1. Use adequate ropes depending on the weight of parts to
be hoisted, referring to the table below:
★The allowable load value is estimated to be 1/6 or 1/7 of
the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
can result. Hooks have maximum strength at the middle
portion.
3. Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load 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 hoist-
ing 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 ropes make a 120° hanging angle. On
the other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing25 kg or more is
indicated clearly with the sym-
bol.
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load
mm kN tons
10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
rope, or slipping of the rope
from its original winding posi-
tion on the load, which can
result in a dangerous accident
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FOREWORD PUSH PULL COUPLER
00-8 PC200LC-8
12
PUSH PULL COUPLER 00
Type 1 00
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
Connection 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in 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. This does not
indicate an abnormality.
WARNING! Before carrying out the following work,
release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual pres-
sure from hydraulic tank.
WARNING! Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Accord-
ingly, prepare an oil receiving container.
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FOREWORD PUSH PULL COUPLER
PC200LC-8 00-9
Type 2 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface aof
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
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 mouthpiece 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.
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FOREWORD PUSH PULL COUPLER
00-10 PC200LC-8
12
Type 3 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface aof the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface aof 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 mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface aof the
hexagonal portion at the male end to connect it.
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FOREWORD COATING MATERIALS
PC200LC-8 00-11
12
COATING MATERIALS 00
★The recommended coating materials prescribed in the shop manuals are listed below.
Cate-
gory Komatsu code Part No. Qty Container Main features and applications
Adhesive
LT-1A 790-129-9030 150 g Tube • Used to prevent rubber gaskets, rubber cushions, and
cork plugs from coming out.
LT-1B 790-129-9050 20 g
(2 pcs.) Polyethylene container
• Used for plastic (except polyethylene, polypropylene, tet-
rafluoroethylene and vinyl chloride), rubber, metal, and
non-metal parts which require immediate and strong
adhesion.
LT-2 09940-00030 50 g Polyethylene
container • Features: Resistance to heat and chemicals. • Used to fix and seal bolts and plugs.
LT-3
790-129-9060
(Set of
adhesive and
hardener)
Adhesive:
1 kg
Hardener:
500 g
Can • Used to stick and seal metal, glass, and plastics.
LT-4 790-129-9040 250 g Polyethylene
container • Used to seal plugs.
Holtz MH
705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
ThreeBond
1735 790-129-9140 50 g Polyethylene container
• Quick-setting adhesive.
• Setting time: Within 5 sec. to 3 min.
• Used mainly to stick metals, rubbers, plastics, and
woods.
Aron-alpha
201 790-129-9130 2 g Polyethylene container
• Quick-setting adhesive.
• Quick-setting type.
(max. strength is obtained after 30 minutes)
• Used mainly to stick rubbers, plastics, and metals.
Loctite 648-
50 79A-129-9110 50 cc Polyethylene
container • Features: Resistance to heat and chemicals. • Used for fitted portions used at high temperatures.
Gasket sealant
LG-1 790-129-9010 200 g Tube • Used to stick or seal gaskets and packings of power train
case, etc.
LG-3 790-129-9070 1 kg Can
• Features: Resistance to heat
• Used as sealant for flange surfaces and bolts at high tem-
perature locations; used to prevent seizure.
• Used as sealant for heat-resistant gasket for high temper-
ature locations such as engine pre-combustion chamber,
exhaust pipe.
LG-5 790-129-9080 1 kg Polyethylene
container
• Used to seal various threaded portions, pipe joints, and
flanges.
• Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
LG-6 790-129-9020 200 g Tube • Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
LG-7 790-129-9170 1 kg Tube • Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
ThreeBond
1211 790-129-9090 100 g Tube • Gasket sealant used to repair engine.
ThreeBond
1207B 419-15-18131 100 g Tube • Features: Silicon-based, heat and cold-resistant, vibra-
tion-resistant, impact-resistant sealant.
• Used to seal transfer case, etc.

FOREWORD COATING MATERIALS
00-12 PC200LC-8
Classi-
fication Komatsu code Part number Content Container Main feature, application
Lubricant with
molybdenum disulfide
LM-G 09940-00051 60g Can • To be used as lubricant (anti squeaking) for sliding
part.
LM-P 09940-00040 200g Tube
• To be used for press fit, shrink fit and preventing
scratching or seizure of thread.
• To be used as lubricant for linkage and bearing
etc..
Grease
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Various
kinds Various kinds • Versatile type
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
kinds Various kinds • To be used for the place where the bearing
designed for normal temperature and low load
condition is used and contacts water and steam.
Grease with
molybdenum
disulphide LM-
G(G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400gx10
400gx20
16kg
Bellows type
Can • To be used for heavy load places.
Hyper white
grease
G2-T GO-T(*)
*: For cold
region
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
400g
16kg Bellows type Can
• Higher anti seizure and heat resistance than
grease with molybdenum disulphide
• Body dirt is not distinctive due to white color.
Biological
grease G2-B
G2-BT(*)
*: For heat
resistance and
heavy load
SYG2-400B
SYGA-16CNB
SYG2-400BT
(*)
SYGA-16CNBT
(*)
400g
16kg Bellows type Can
• To be shortly dissolved by a bacteria in nature so
that the influence to microorganism and animals
and plants is suppressed to the minimum.
Primer
Sunstar primer
for painting
plane 580
super 417-926-3910
20ml
(0.7 oz) Glass container
For adhesion of cab glass
• To be used as primer for cab side.
(Term of validity: 4 months after
manufacturing)
Sunstar primer
for glass 580
super
20ml
(0.7 oz) Glass container
• To be used as primer for glass side.
(Term of validity: 4 months after
manufacturing)
Sunstar primer
for painting
plane 435-95 22M-54-27230 20ml
(0.7 oz) Glass container
• To be used as primer for painting plane of cab
side.
(Term of validity: 4 months after manufactur-
ing)
Sunstar primer
for glass
435-41 22M-54-27240 150ml
(5.1 oz) Can
• To be used as primer for black ceramic
coated plane of glass side and polycarbonate
hard coat plane.
(Term of validity: 4 months after
manufacturing)
Sunstar primer
for sash
GP-402 22M-54-27250 20ml
(0.7 oz) Glass container
• To be used as primer for sash (Alumite
surface treatment)
(Term of validity: 4 months after
manufacturing)

FOREWORD COATING MATERIALS
PC200LC-8 00-13
Adhesive compound
Sunstar pen-
guine seal 580
super "S" or
"W"
417-926-3910 320ml
(10.8 oz) Polyethylene container
For adhesion of cab glass
• "S" and "W" are used as glass adhesive
compound in high temperature (April -Octo-
ber) and in low temperature (October -April)
respectively.
(Term of validity: 4 months after
manufacturing)
Sika Ltd,
Japan Sika
Flex 256HV 20Y-54-39850 310ml
(10.5 oz) Polyethylene container
• To be used as glass adhesive compound.
(Term of validity: 6 months after
manufacturing)
Sunstar pen-
guine super
560 22M-54-27210 320ml
(10.8 oz)
ECOCART
(special
container)
• To be used as glass adhesive compound.
(Term of validity: 6 months after
manufacturing)
Caulking compound
Sunstar pen-
guine seal No.
2505 417-926-3920 320ml
(10.8 oz) Polyethylene container
• To be used as seal for joints of glass.
(Term of validity: 4 months after
manufacturing)
Sekisui sili-
cone sealant 20Y-54-55130 333ml (11.3 oz) Polyethylene container
• To be used for seal of front window.
(Term of validity: 6 months after
manufacturing)
GE Toshiba
Silicones Tos-
seal 381 22M-54-27220 333ml
(11.3 oz) Cartridge
• To be used as seal for joints of glass.
semi-transparent white seal
(Term of validity: 12 months after
manufacturing)
Classi-
fication Komatsu code Part number Content Container Main feature, application

FOREWORD STANDARD TIGHTENING TORQUE
00-14 PC200LC-8
12
STANDARD TIGHTENING TORQUE 00
Standard Tightening Torque Of Bolts And Nuts 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm N•m lbf ft
610
11.8 - 14.7 8.70 - 10.84
813
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 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm N•m lbf ft
610
5.9 - 9.8 4.35 - 7.22
813
13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52

FOREWORD STANDARD TIGHTENING TORQUE
PC200LC-8 00-15
12
Tightening Torque Of Hose Nuts 00
Use these torques for hose nuts.
Tightening Torque Of Split Flange Bolts 00
Use these torques for split flange bolts.
Tightening Torque For Flared Nuts 00
Use these torques for flared part of nut.
Nominal No. Thread diameter Width across flat Tightening torque
mm mm N•m lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 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 mm N•m lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1

FOREWORD STANDARD TIGHTENING TORQUE
00-16 PC200LC-8
12
Table Of Tightening Torques For O-ring Boss Piping Joints 00
★Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Table Of Tightening Torques For O-ring Boss Plugs 00
★Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type) 00
★Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★Apply the following torque when the threads are coated (wet) with engine oil.
Norminal No. Thread diameter Width across flat Tightening torque N•m {lbf ft}
mm mm Range Target
02 14
Varies depending on
type of connector.
35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
Norminal No. Thread diameter Width across flat Tightening torque N•m {lbf lb}
mm mm Range 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 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
Nominal
size of hose Width across flats
Tightening torque N•m {lbf ft} Taper seal
type Face seal type
Range Target Thread size
(mm)
Nominal thread
size - Threads per
inch, Thread series
Root diameter (mm)
(Reference)
02 19 34 - 54 {25.0 - 39.8} 44 {32.4} -9/16 - 18 UN 14.3
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
03 22 54 - 93 {39.8 - 68.5} 74 {54.5} -11/16 -16 UN 17.5
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16 UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14 UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12 UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -

FOREWORD ELECTRIC WIRE CODE
PC200LC-8 00-17
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
Classification By Thickness 00
Classification By Color And Code 00
Nominal num-
ber
Copper wire Cable O.D.
(mm) Current rat- ing (A) Applicable circuit
Number of
strands Dia. Of strand (mm) Cross section (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal 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 Classi-
fication 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 LW
Color White &
Red —Black &
White Red & White Yellow & Red Green & White Blue & White
3
Code WB — BY RB YB GR LR
Color White &
Black —Black &
Yellow Red & Black Yellow &
Black Green & Red Blue & Red
4
Code WL — BR RY YG GY LY
Color White &
Blue — Black & Red Red &
Yellow Yellow & Green Green & Yellow Blue & Yellow
5
Code WG — — RG YL GB LB
Color White &
Green ——
Red &
Green Yellow & Blue Green & Black Blue & Black
6
Code — — — RL YW GL —
Color — — — Red & Blue Yellow &
White Green & Blue —

FOREWORD CONVERSION TABLES
00-18 PC200LC-8
12
CONVERSION TABLES 00
Method Of Using The Conversion Table 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
●Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point dgives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
A. The number 550 does not appear 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
0123456789
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
b50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 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

FOREWORD CONVERSION TABLES
PC200LC-8 00-19
12
Millimeters to Inches 1 mm = 0.03937 in
0123456789
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 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
0123456789
0 0 2.204.416.618.8211.0213.2315.4317.6419.84
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
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

FOREWORD CONVERSION TABLES
00-20 PC200LC-8
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal
0123456789
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 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
0123456789
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 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777