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Procedure Manual
for
Visual Machine Check
【PC200-7, 8】

June 2011
Parts Dept.
Product Support Div.
Kltd.
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Safety Precautions
Preparation
Check that the clothes are proper first.
Check the chin strap of the helmet, work clothes, work gloves,
safety boots, and so forth. Start work in the proper clothes.

Keep this tag hanging on the

control lever on the right to prevent
other personnel from moving the
machine during checks.

Move the lock lever down before

leaving the seat.
Refer to the operation and maintenance
manual for details.
 Page3

Check procedure of PC200-7,8 ③

②
④
⑬ ⑭

⑪ ⑯ ⑮ ⑤
①
⑫
⑩
⑨ ⑦
⑧
⑥

1 Model, Type and Machine Serial Number 9 Around the operator cabin
2 Right side 10 Inside the cabin
3 Right side undercarriage 11 Work equipment
4 Inside the right cover 12 Bucket
5 Rear of the machine 13 Battery
6 Left undercarriage 14 Fuel tank cap
7 Inside the left cover 15 Around the engine
8 Left side 16 Swing machinery
Difference in check procedure of PC300/400 from PC200 4
Page

PC200-7,8 PC300-7,8
4 Inside the right cover 4 Inside the right cover
1） Fuel Pre-filter/Water separatｏｒ（Model 7） 1） Fuel Pre-filter/Water separatｏｒ（Model 7）
2） Drain ｗater and sediment from ｆuel ｔank 2） Drain ｗater and sediment from ｆuel ｔank
3） Hydraulic oil ｌevel 4） Air element
4） Engine oil ｆilter 5） Radiator Sub-tank
5） Around main pump 6） Cooling core
6） Around main pump of hydraulic hose 7） Grease gun
7 Inside the left cover 7 Inside the left cover
1） Air element 1） Window washier tank
2） Window washier tank 2） Engine oil ｆilter
3） Radiator Sub-tank 3） Hydraulic oil ｌevel
4） Cooling core 4） Around main pump
5） Grease gun 5） Around main pump of hydraulic hose

PC200-7,8 PC400-7,8
4 Inside the right cover 4 Inside the right cover
1） Fuel Pre-filter/Water separatｏｒ（Model 7） 1） Drain ｗater and sediment from ｆuel ｔank
2） Drain ｗater and sediment from ｆuel ｔank 2） Air element
3） Engine oil ｆilter 3） Cooling core
4） Around main pump 4） Grease gun
5） Around main pump of hydraulic hose
6） Hydraulic oil ｌevel
7 Inside the left cover 7 Inside the left cover
1） Air element 1） Window washier tank
2） Window washier tank 2） Hydraulic oil ｌevel
3） Radiator Sub-tank 3） Around main pump
4） Cooling core 4） Around main pump of hydraulic hose
5） Grease gun
15 Around the engine 15 Around the engine
1） Fan belt 1） Fan belt
2） Tensioner 2） Tensioner
3） Air conditioner belt 3） Air conditioner belt
4） Supply pump 4） Supply pump
5） Fuel main filter 5） Fuel Pre-filter
6） Muffler 6） Fuel main filter
7） Air hose 7） Engine oil ｆilter
8） Engine oil level 8） Muffler
9） Radiator cap 9） Air hose
10） Radiator hose 10） Engine oil level
11） Radiator Sub-tank
12） Radiator cap
13) Radiator hose
1. Model, type and serial number 3. Right side Undercarriage Page 5
1)Model, type and machine serial number Carrier Roller Track Shoe
Assembly

2-1)Service meter (PC200-7)

Idler
Final Drive
Track Roller
Sprocket
Page 17
1)Track shoe assembly (Item5-21)
2-2)Replacement history (1)KOMATSU logo mark
Check the replacement If non genuine is used, recommend Komatsu genuine.
history of each part on the (2)Loose track link tension
maintenance list of the Adjust tension.
monitor.
(3)Kink of track link
(4)Shoe bolt
Tighten loose Bolt.
2. Right side of the machine Recommend to install new bolts if it’s lost.
1)Mirror (Item4) PC200-7 (5)Cracked or bent Shoe plates
Recommend to install new shoe plates.
Loose
Tighten
2) Idler (Item5-8)
Damageｄ
Exchange

2)Side cover (Item1)

Take a picture if you find a Wear of the idler
defect and report to an Recommend to replace or
experienced serviceperson repair the idler if it is worn
about it. out like this.
3. Right side Undercarriage
3)Carrier roller (Item5-25)
Page 18
Recommend customer to
replace the carrier rollers if oil
leaks or wear of the rollers are
found.
4)Sprocket (Item5-25)
Page 19
Wear of Sprocket.
Recommend to replace it if it
is worn out.
5)Final drive (Item5-7)
Sprocket is wet by oil,
Check from the inside, too.
Oil leaks from lubrication plug.
Recommend to replace O-ring
if oil leaks from it.
Take a picture and report to
an experienced serviceperson
about it.
6)Track roller (Item5-8)
Page 20
Oil leaks and wear.
Lost Bolt.
Recommend to replace the
track rollers if oil leak or wear
of the rollers are found.
How to use the wear gauge Page6
The wear of shoe plate grouser
To check wear of the shoe plate
The gauge does not touch the bottom of the
shoe plate, though it touches the top of the
grouser. Thus, the wear limit is not reached
yet.
Recommend the customer to replace
the shoe plate if the gauge touches the
bottom of the shoe plate.
The wear of link height
To check wear of the link height
The gauge does not touch the bottom of the
shoe plate, though it touches the tread of
the link. Thus, the wear limit is not reached
yet.
Recommend the customer to replace
the link assembly if the gauge touches
the bottom of the shoe plate.
The wear of the bush
To check wear of the bush
The gauge does not touch the bottom of the
shoe plate, though it touches the bush.
Thus, the wear limit is not reached yet.
Recommend the customer to replace the
link assembly if the gauge touches the
bottom of the shoe plate.
7)Swing circle area
Check that there are no grease leaks
and that the grease tube is not
broken.
Check Oil leaks mark
4. Inside the right cover Page7
3)Check Engine Oil Filter (Item5-18)
Oil leaks from the engine oil filter.
Oil leaks or damage of the remote
hose.

Non genuine filter is used.

Be sure to recommend to use
Komatsu genuine filters.

1)Pre-Filter (Item5-14) (PC200-7)

4)Check the Hydraulic Oil Level (Item5-9)
Water Separator

Water and sediment in

Machine position
the bowl. to check oil Level

Clean the fuel pre-filter.

2)Fuel Tank Drain (Item5-14) If the level is low, recommend to add hydraulic oil.
Drain water and sediment from
the fuel tank.

Page 21

Check Oil leaks mark

4. Inside the right cover 8
Page

6)Check the Main Pump Area (Item2) 7)Check the hoses Around the Main Pump (Item2)
Front side
(PC200-7)

Left side

(PC200-7)

Right side

Oil leaks or the spread of oil from the mating surface of the case. Oil leaks or damage.
Take a picture and report to an experienced serviceperson Tighten necessary parts or recommend the customer to
about it. replace them, depending on its conditions.

Check Oil leaks mark

5. Rear of the Machine Page9

1)Counter weight (Item1) 1)Air element (Item5-16)

Installation condition, no Evacuator valve.
loose bolts.
If a hardening or damage is found,
recommend to replace the parts.

2)Around of the underbody (Item1)

oil or water under of the machine.
Obtain the customer’s approval
and take a picture of the Air element cap and air
defective position, and report to suction port ｉs dirty.
an experienced serviceperson Clean then.
about it.

6. Left side Undercarriage

Same manner as check item number 3, right side
undercarriage. Do not remove the inner element
during cleaning the outer element.
7. Inside of the left cover
(PC200-7) After the outer element ｉｓ cleaned
six times or used for a year, be
sure to recommend to replace the
air element assembly, outer and
inner elements together.

Check the Komatsu genuine logo

marks.

Check Oil leaks mark

7. Inside of the left cover 10
Page

2)Level of window washer liquid (Item6-3) 5)Grease gun

The level is low. If grease gun is not found,
Recommend to fill the tank with the greasing may not be done
proper window washer liquid. properly.

3)Check the level of radiator sub-tank (Item5-3) 8. Left side of the machine
Radiator coolant level is low. 1)Whole cover (Item1)
Recommend to fill the sub-tank with
Whole cover,
genuine coolant if the level is low.
Catch of the cover door.
Make sure that the radiator is cool.

4)Damaged cooling core (Item5-17)

Damages of Radiator,
2)Mirror (Item4)
Hydraulic oil cooler,
After-cooler,
Air conditioner condenser,
Fuel cooler.
Take a picture and report to
an experienced service
person about it.
9. Around the operator cabin
1)Glass trim (Item1)
Glass trim is deformed.
Take a picture of it, and report to
an experienced service person
about it.
2)Door (Item1)
Door opens, closes and locks properly.
Any problems are found, correct
them if they can be adjustable.
If replacement is required, take a
picture of it, and report to an
experienced service person about it.
10. Inside the cabin
1)Lights(Item6-3)
6)Bucket mount (Item6-9)
Lights are not on properly.
Recommend to repair or replace it, depending
on the conditions.
2)Wiper (Item6-3) Page11
Raise the wiper blade in order
not to damage the glass.
Blade rubber is cracked or cut.
Recommend to replace it.
3)Horn (Item6-3)
Horn is sounding abnormally.
Recommend to repair or replace
the necessary parts.
4)Operator seat (Item3)
Recommend to replace it,
depending on the condition.
5)Filter of air conditioner
Recommend to clean or replace it,
depending on the conditions.
move it horizontally and make sure it is not
fluctuated.
After checking, pull out the key again, put a
tag, lower the safety lock lever and then
leave the seat.
Check the safety around the machine, alert by the
horn, and move the work equipment.
11. Work equipment Page12
3)Boom cylinder head (Item6-9)
Oil leaks from the boom cylinder rod head.
The boom cylinder rod end pins are
dislocated.
The locks are broken and the parts are
greased properly.

4)Arm cylinder head (Item6-9)

Oil is leaks from the arm cylinder hose
and arm cylinder rod head.
Arm cylinder rod end pins and the boom
and arm connection pins are dislocated.
The locks are broken.

1)Boom cylinder (Item6-9) The parts are greased properly.

Check whether the boom fixing pins

5)Bucket cylinder head (Item6-9)
and the fixing pins on the boom cylinder
bottom side are dislocated, and Oil leaks from the bucket cylinder hose
the locks are broken and the parts are and bucket cylinder rod head.
greased properly. Four bucket fixing pins are dislocated.
The locks are broken.
2)Boom cylinder hose (Item6-9) The parts are greased properly.
Crack
Abrasion wound
Page 22 Check the right side in the same manner.
Recommend the
customer to replace it.
12. Bucket 13. Battery (Item 5-2) Page13
1)Bucket (Item5-22) Hａｒｎｅｓｓ.
Bucket corners.
Base edge. Loose terminals.
Adapter joints. Tighten Them.
Side plates.
Arm connection bracket.
Liquid level is low.
Bottom wear plates.
Side cutters or side shrouds.
2)Tooth (Item5-22) Dilute sulfuric acid are inside. Be
Page 23 very careful not to splash sulfuric
acid on your clothes or skin during
refilling distilled water.
When your clothes or skin are
exposed to sulfuric acid, rinse
thoroughly with plenty of flowing
water.
How to use the wear gauge of the tooth
14. Fuel tank cap (Item5-18)
Sound of sucking air is heard when
The shape of new tooth is like left picture. the cap is opened,

Clean the cap.

Packing of the cap.
The tooth shape is like left picture as it wars.
Installation of the strainer.
Measure the distance from the edge of the Dirt or clogging of the strainer.
horizontal pin hole to the top of wear with
the tooth wear gauge.
Recommend to replace the tooth earlier
to avoid increasing resistance force of
digging works.
15. Around the engine 3)Air conditioner belt (Item5-15) Page14
Wear or damage of the air conditioner belt.
Recommend to replace if the belt is
defective.

4)Fuel supply pump

Fuel or oil leaks from the
supply pump. （PC200-7）
Take a picture and report
to an experienced
1)Fan belt (Item5-15) serviceperson about it.

Wear or damage of the fan belt.

5)Fuel main filter (Item5-18)

Fuel main filter is genuine.
Recommend to replace it.

2)Tension (Item5-15)
Fan belt is worn unevenly.
6)Muffler (Item5-18)
Open the fan guard and check it in detail.
If the inside of the engine room is
blackened by exhaust gas, gas may leak
from the muffler or turbocharger.
Belt tension is defective.
Take a picture of the blackest sooty part
Recommend to replace the tension
with loose mounting or holes caused by
assembly and fan belt.
corrosion and report to an experienced
serviceperson about it.
 Page15
7)Air hose (Item5-16)
Deterioration, hardening or breakage of the
air hose.
16. Swing machinery (Item5-10, 6-9)
Recommend the customer to replace Oil leaks or damage of the hoses
the hose if it is deteriorated or hardened. between the control valve and the work
Loose fixing band. equipment circuit.
Tighten it.
Recommend to replace defective
8)Engine oil level （Item5-4） hoses.
Oil level gauge.
Color and quantity of oil

If oil level is low, recommend to add oil.

Oil level is low.

Good Add oil level
Add oil.
9)Radiator hose
Loose band.
Tighten it.
Hardening or deterioration of the hose.
Recommend to replace the hose.

10)Radiator cap (Item5-3)

Cracks of the radiator cap seal.
Recommend to replace the radiator cap
assembly.
When the cap is opening during a
hot, the coolant may spray out and
you may get a burn. Be very careful.
 Page 16
KOMTRAX - Maximize Product Support activity -
Be sure to reset remaining time in the maintenance list on the monitor
panel if filter or oil are changed.

The next replacement timing is obtained in linkage with KOMTRAX.

The machine location is displayed in the KOMTRAX map.
It can be utilized for the effective machine touch planning.
KOMTRAX displays machines that reach the filter and oil change
timing and machine that are 30 hours before the change timing in red
and yellow flags for easy management.

With this management function, machines that require filter and oil
change are found at a glance. This function can be utilized for effective
maintenance service and parts sales.
By displaying applicable machines in the KOMTRAX map effective
machine touch can be planned easily.
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