KOMATSU AVANCE PC200LL-6 PC220LL-6 LOGGING EXCAVATOR Operation & Maintenance Manual (SN:A85001 and UP) – PDF DOWNLOAD

Description

KOMATSU AVANCE PC200LL-6 PC220LL-6 LOGGING EXCAVATOR Operation & Maintenance Manual (SN:A85001 and UP)

KOMATSU AVANCE PC200LL-6 PC220LL-6 LOGGING EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A85001 AND UP) – PDF DOWNLOAD:

IMAGE PREVIEW:

DESCRIPTION:

KOMATSU AVANCE PC200LL-6 PC220LL-6 LOGGING EXCAVATOR Operation & Maintenance Manual (SN:A85001 and UP)

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
• If this manual is lost or becomes dirty and can not be read, request a replacement manual from Komatsu or your local distributor. If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult Komatsu or your local distributor for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

KOMATSU AVANCE PC200LL-6 PC220LL-6 LOGGING EXCAVATOR Operation & Maintenance Manual (SN:A85001 and UP)

MAIN MENU.......................................................................................................  0
COVER...........................................................................................................  1
INTRODUCTION....................................................................................................  7
	FOREWORD....................................................................................................  8
	SAFETY INFORMATION..........................................................................................  8
	INTRODUCTION................................................................................................  9
		INTENDED USE............................................................................................  9
		FEATURES................................................................................................  9
		BREAKING IN THE MACHINE.................................................................................  9
	LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR................................................... 10
		P.I.N. PLATE LOCATION................................................................................... 10
		ENGINE SERIAL NO. PLATE LOCATION........................................................................ 10
		TABLE TO ENTER NUMBERS AND DISTRIBUTOR.................................................................. 10
	TABLE OF CONTENTS........................................................................................... 11
SAFETY.......................................................................................................... 17
	WARNING LABELS.............................................................................................. 18
	GENERAL PRECAUTIONS......................................................................................... 24
		SAFETY RULES............................................................................................ 24
		SAFETY FEATURES......................................................................................... 24
		UNAUTHORIZED MODIFICATION............................................................................... 24
		INSIDE OPERATOR’S COMPARTMENT........................................................................... 25
		CLOTHING AND PERSONAL PROTECTIVE ITEMS.................................................................. 25
		ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT.......................................................... 25
		MOUNTING AND DISMOUNTING................................................................................ 26
		INJURY FROM WORK EQUIPMENT.............................................................................. 26
		FIRE PREVENTION FOR FUEL AND OIL........................................................................ 26
		PRECAUTIONS AT HIGH TEMPERATURES........................................................................ 27
		ASBESTOS DUST HAZARD PREVENTION......................................................................... 27
		FIRE EXTINGUISHER AND FIRST AID KIT..................................................................... 27
		CAB GLASS............................................................................................... 28
		WINDOW WASHER FLUID..................................................................................... 28
		ESCAPE FROM FIRE........................................................................................ 28
		PROTECTION AGAINST FALLING OR FLYING OBJECTS............................................................ 28
		MACHINES WITH ACCUMULATOR............................................................................... 29
		PRECAUTIONS FOR ATTACHMENTS............................................................................. 29
		INDOOR VENTILATION...................................................................................... 29
		EMERGENCY EXIT FROM OPERATORS CAB....................................................................... 29
	PRECAUTIONS DURING OPERATION................................................................................ 30
		BEFORE STARTING ENGINE.................................................................................. 30
			SAFETY AT WORK SITE................................................................................. 30
			FIRE PREVENTION..................................................................................... 30
			VENTILATION FOR ENCLOSED AREAS...................................................................... 30
			IN OPERATOR’S CAB................................................................................... 30
			PRECAUTIONS FOR MIRROR AND LIGHTS................................................................... 31
			WHEN STARTING ENGINE................................................................................ 31
		OPERATING MACHINE....................................................................................... 32
			WHEN STARTING ENGINE................................................................................ 32
			CHECK DIRECTION BEFORE STARTING MACHINE............................................................. 32
			CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE................................ 32
			NEVER LET ANYONE RIDE ON ATTACHMENT................................................................. 32
			PRECAUTIONS WHEN TRAVELING.......................................................................... 33
			OPERATE CAREFULLY ON SNOW........................................................................... 33
			TRAVELING ON SLOPES................................................................................. 34
			PROHIBITED OPERATIONS............................................................................... 34
			PRECAUTIONS FOR OPERATION........................................................................... 35
			DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.............................................................. 35
			WORKING ON LOOSE GROUND............................................................................. 36
			OPERATING ON SLOPES................................................................................. 36
			PARKING THE MACHINE................................................................................. 36
			PRECAUTIONS IN COLD WEATHER......................................................................... 37
		TRANSPORTATION.......................................................................................... 38
			LOADING AND UNLOADING............................................................................... 38
			PRECAUTIONS WHEN LIFTING............................................................................ 38
			SHIPPING............................................................................................ 39
		BATTERY................................................................................................. 40
			BATTERY HAZARD PREVENTION........................................................................... 40
			STARTING WITH BOOSTER CABLES........................................................................ 40
			CHARGING BATTERY.................................................................................... 41
		TOWING.................................................................................................. 42
			PRECAUTIONS WHEN TOWING............................................................................. 42
	PRECAUTIONS FOR MAINTENANCE................................................................................. 43
		BEFORE CARRYING OUT MAINTENANCE......................................................................... 43
			CONTACT WHEN THERE IS FAILURE....................................................................... 43
			WARNING TAG......................................................................................... 43
			CLEAN BEFORE INSPECTION OR MAINTENANCE.............................................................. 43
			NEAT CLEAN WORK PLACE............................................................................... 43
			FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS...................................................... 43
			RADIATOR COOLANT LEVEL.............................................................................. 44
			PROPER TOOLS........................................................................................ 44
			STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE..................................................... 44
			SUPPORT FOR WORK EQUIPMENT.......................................................................... 44
			PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS....................................................... 45
			USE OF LIGHTING..................................................................................... 45
			FIRE PREVENTION..................................................................................... 45
			RULES TO FOLLOW WHEN ADDING FUEL OR OIL............................................................. 45
		DURING MAINTENANCE...................................................................................... 46
			PERSONNEL........................................................................................... 46
			REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS.................................................... 46
			WORK UNDER THE MACHINE.............................................................................. 46
			NOISE............................................................................................... 46
			WHEN WORKING ON MACHINE............................................................................. 46
			LOCK INSPECTION COVERS.............................................................................. 46
			TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.................................................. 47
			DO NOT DROP TOOLS OR PARTS INSIDE MACHINE........................................................... 47
			FLYING PIECES WITH HAMMER WORK...................................................................... 47
			KEEP THE MACHINE CLEAN.............................................................................. 47
			WELDING REPAIRS..................................................................................... 48
			REMOVE BATTERY TERMINALS............................................................................ 48
			ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION.................................................. 48
			RULES TO FOLLOW WHEN ADDING FUEL.................................................................... 48
			PRECAUTIONS WHEN ADJUSTING TRACK TENSION............................................................ 48
			HANDLING HIGH PRESSURE HOSES........................................................................ 49
			PRECAUTIONS WITH HIGH PRESSURE OIL.................................................................. 49
			PRECAUTIONS FOR MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE......................................... 49
			WASTE MATERIALS..................................................................................... 50
			CHECKS AFTER INSPECTION AND MAINTENANCE............................................................. 50
			MAINTENANCE FOR AIR CONDITIONER..................................................................... 50
OPERATION....................................................................................................... 51
	GENERAL..................................................................................................... 52
		VIEW OF MACHINE......................................................................................... 52
		GENERAL VIEW OF OPERATORS COMPARTMENT................................................................... 53
		GENERAL VIEW OF MONITOR PANEL........................................................................... 54
	EXPLANATION OF COMPONENTS................................................................................... 55
		MACHINE MONITOR......................................................................................... 55
			MONITOR LIGHT GROUP................................................................................. 57
			METER DISPLAY PORTION............................................................................... 59
			SWITCHES............................................................................................ 63
		SWITCHES................................................................................................ 66
		CONTROL LEVERS AND PEDALS............................................................................... 70
		OPERATOR’S SEAT AND SEAT BELT........................................................................... 73
			SEAT ADJUSTMENT..................................................................................... 73
			SEAT BELT........................................................................................... 74
		MONITOR PANEL........................................................................................... 75
			ADJUSTMENT ANGLE.................................................................................... 75
		ROOF VENT............................................................................................... 75
			WHEN OPENING........................................................................................ 75
			WHEN CLOSING........................................................................................ 75
		FRONT WINDOW............................................................................................ 76
			WHEN OPENING........................................................................................ 76
			WHEN CLOSING........................................................................................ 77
			FRONT BOTTOM WINDOW................................................................................. 78
		DOOR LOCK............................................................................................... 78
		CAP, COVER WITH LOCK.................................................................................... 79
			METHOD OF OPENING AND CLOSING LOCK CAP.............................................................. 79
			METHOD OF OPENING AND CLOSING COVER LOCK............................................................ 79
		OPERATOR EASE........................................................................................... 80
			HOT AND COOL BOX.................................................................................... 80
			STORAGE BOX......................................................................................... 80
			ASHTRAY............................................................................................. 80
		AIR CONDITIONER......................................................................................... 81
			GENERAL LOCATIONS ON CONTROL PANEL.................................................................. 81
			PRECAUTIONS WHEN USING AIR CONDITIONER.............................................................. 83
			CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER........................................................ 83
		AM/FM RADIO............................................................................................. 84
			EXPLANATION OF COMPONENTS........................................................................... 84
			METHOD OF OPERATION................................................................................. 86
			PRECAUTIONS WHEN USING.............................................................................. 88
			SPECIFICATIONS...................................................................................... 88
		FUSE.................................................................................................... 89
		FUSIBLE LINK............................................................................................ 90
		CONTROLLERS............................................................................................. 90
		TOOL BOX................................................................................................ 90
		GREASE GUN HOLDER....................................................................................... 90
		HANDLING ACCUMULATOR.................................................................................... 91
			RELEASING PRESSURE.................................................................................. 91
	OPERATION................................................................................................... 92
		CHECK BEFORE STARTING ENGINE............................................................................ 92
			WALK AROUND CHECK................................................................................... 92
			CHECK BEFORE STARTING............................................................................... 94
			ADJUST OPERATOR’S SEAT.............................................................................. 97
			ADJUST SEAT BELT.................................................................................... 97
			ADJUST ARM RESTS.................................................................................... 97
			ADJUST MONITOR PANEL................................................................................ 97
			OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................................ 98
		STARTING ENGINE.........................................................................................100
			NORMAL STARTING.....................................................................................100
			STARTING IN COLD WEATHER............................................................................101
		OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................103
			WHEN NORMAL.........................................................................................103
			AUTOMATIC WARM UP OPERATION.........................................................................106
		MOVING MACHINE..........................................................................................109
			MOVING MACHINE FORWARD..............................................................................109
			MOVING MACHINE REARWARD.............................................................................111
		STEERING MACHINE........................................................................................113
			STEERING (CHANGING DIRECTION).......................................................................113
		STOPPING MACHINE........................................................................................114
		SWINGING................................................................................................115
		OPERATION OF WORK EQUIPMENT.............................................................................116
		ACTIVE MODE.............................................................................................117
		WORKING MODES...........................................................................................118
			WORKING MODE........................................................................................118
			POWER MAX, SWIFT SLOW DOWN..........................................................................118
		PRECAUTIONS FOR OPERATION...............................................................................120
			PRECAUTIONS WHEN TRAVELING..........................................................................120
			PRECAUTIONS AT HI SPEED TRAVEL......................................................................120
			PERMISSIBLE WATER DEPTH.............................................................................120
		PRECAUTIONS WHEN TRAVELING ON HILLS.....................................................................121
			BRAKING WHEN TRAVELING DOWNHILL.....................................................................121
			IF SHOES SLIP.......................................................................................121
			IF ENGINE STOPS.....................................................................................121
			PRECAUTIONS ON SLOPES...............................................................................121
		HOW TO ESCAPE FROM MUD..................................................................................122
			WHEN ONE SIDE IS STUCK..............................................................................122
			WHEN BOTH SIDES ARE STUCK...........................................................................122
		PARKING MACHINE.........................................................................................123
		CHECK AFTER FINISHING WORK..............................................................................125
		STOPPING ENGINE.........................................................................................125
		CHECK AFTER STOPPING ENGINE.............................................................................125
		LOCKING.................................................................................................126
	TRANSPORTATION..............................................................................................127
		TRANSPORTATION PROCEDURE................................................................................127
		LOADING, UNLOADING WORK ON TRAILERS.....................................................................127
			LOADING.............................................................................................128
			SECURING MACHINE....................................................................................129
			UNLOADING...........................................................................................131
	COLD WEATHER OPERATION......................................................................................134
		PRECAUTIONS FOR LOW TEMPERATURE.........................................................................134
			FUEL AND LUBRICANTS.................................................................................134
			COOLANT.............................................................................................134
			BATTERY.............................................................................................135
		PRECAUTIONS AFTER COMPLETION OF WORK....................................................................136
		AFTER COLD WEATHER......................................................................................136
	LONG TERM STORAGE...........................................................................................137
		BEFORE STORAGE..........................................................................................137
		DURING STORAGE..........................................................................................137
		AFTER STORAGE...........................................................................................137
		MACHINE START AFTER LONG TERM STORAGE...................................................................138
	TROUBLESHOOTING.............................................................................................139
		PHENOMENA THAT ARE NOT FAILURES.........................................................................139
		METHOD OF TOWING DISABLED MACHINE.......................................................................139
		USING MACHINE FOR LIGHT WEIGHT TOWING...................................................................139
		PRECAUTIONS ON PARTICULAR JOB SITES.....................................................................139
		DISCHARGED BATTERY......................................................................................140
			REMOVING AND INSTALLING BATTERY.....................................................................140
			PRECAUTIONS FOR CHARGING BATTERY....................................................................140
			STARTING ENGINE WITH BOOSTER CABLE..................................................................141
		OTHER TROUBLE...........................................................................................143
			ELECTRICAL SYSTEM...................................................................................143
			CHASSIS.............................................................................................144
			ENGINE..............................................................................................145
			ELECTRONIC CONTROL SYSTEM...........................................................................146
MAINTENANCE.....................................................................................................147
	GUIDES TO MAINTENANCE.......................................................................................148
	OUTLINES OF SERVICE.........................................................................................150
		OUTLINE OF OIL, FUEL, COOLANT...........................................................................150
			OIL.................................................................................................150
			FUEL................................................................................................150
			COOLANT.............................................................................................151
			GREASE..............................................................................................151
			STORING OIL AND FUEL................................................................................151
			FILTERS.............................................................................................151
			RELATING TO ELECTRICAL SYSTEM.......................................................................151
		OUTLINE OF HYDRAULIC SYSTEM.............................................................................152
	WEAR PARTS LIST.............................................................................................153
	USE OF FUEL, COOLANT AND LUBRICANTS.........................................................................154
		PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................154
			ABBREVIATIONS.......................................................................................154
		ENGINE OIL SPECIFICATIONS...............................................................................155
			NORMAL OPERATION....................................................................................155
			ARCTIC OPERATION....................................................................................155
		DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYD.......156
		FINAL DRIVE OIL SPECIFICATIONS..........................................................................156
		FUEL SYSTEM.............................................................................................156
		COOLING SYSTEM..........................................................................................157
			GENERAL.............................................................................................157
			WATER...............................................................................................157
			ANTIFREEZE..........................................................................................157
			INHIBITORS/CONDITIONERS.............................................................................158
			SUPPLEMENTAL COOLANT ADDITIVES......................................................................158
	STANDARD TIGHTENING TORQUES.................................................................................162
		INTRODUCTION OF NECESSARY TOOLS.........................................................................162
		BOLT IDENTIFICATION CHART...............................................................................163
	PERIODIC REPLACEMENT OF CRITICAL PARTS......................................................................164
	MAINTENANCE SCHEDULE CHART..................................................................................165
	SERVICE PROCEDURE...........................................................................................167
		INITIAL 250 HOURS SERVICE...............................................................................167
			FUEL FILTER CARTRIDGE...............................................................................167
		WHEN REQUIRED...........................................................................................168
			CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT.........................................................168
			DRAIN, FLUSH AND REFILL COOLING SYSTEM..............................................................170
			CHECK AND TIGHTEN TRACK SHOE BOLTS..................................................................173
			CHECK AND ADJUST TRACK TENSION......................................................................173
			CHECK ELECTRICAL INTAKE AIR HEATER..................................................................175
			CHECK WINDOW WASHER FLUID, ADD FLUID................................................................175
			CHECK, MAINTAIN AIR CONDITIONER.....................................................................176
			CLEAN IN LINE FILTERS...............................................................................177
		CHECK BEFORE STARTING...................................................................................178
			CHECK COOLANT LEVEL, ADD COOLANT....................................................................178
			CHECK ENGINE OIL LEVEL, ADD OIL.....................................................................178
			CHECK FUEL LEVEL, ADD FUEL..........................................................................179
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..........................................................179
			CHECK AIR CLEANER FOR CLOGGING......................................................................180
			CHECK ELECTRIC WIRING...............................................................................180
			DRAIN WATER FROM FUEL WATER SEPARATOR...............................................................181
		EVERY 100 HOURS SERVICE.................................................................................182
			GREASE LUBRICATION..................................................................................182
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....................................................182
			DRAIN WATER AND SEDIMENT FROM FUEL TANK.............................................................182
		EVERY 250 HOURS SERVICE.................................................................................183
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL........................................................183
			CHECK LEVEL OF BATTERY ELECTROLYTE..................................................................183
			REPLACE HYDRAULIC FILTER ELEMENT....................................................................184
			LUBRICATE SWING CIRCLE (2 POINTS)...................................................................184
			CHECK BELT TENSION, ADJUST..........................................................................185
		EVERY 500 HOURS SERVICE.................................................................................186
			PREVIOUS MAINTENANCE................................................................................186
			REPLACE FUEL FILTER CARTRIDGE.......................................................................186
			CHECK SWING PINION GREASE LEVEL, ADD GREASE.........................................................188
			CLEAN AND INSPECT RADIATOR AND OIL COOLER...........................................................188
			CLEAN AIR CONDITIONER FILTERS.......................................................................189
			REPLACE HYDRAULIC TANK BREATHER.....................................................................189
			CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE.........................................................190
			REPLACE IN LINE FUEL STRAINER.......................................................................191
		EVERY 1000 HOURS SERVICE................................................................................192
			PREVIOUS MAINTENANCE................................................................................192
			CHANGE OIL IN SWING MACHINERY CASE..................................................................192
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.............................................................192
			CHECK TIGHTENING PARTS OF TURBOCHARGER..............................................................193
			CHECK PLAY OF TURBOCHARGER ROTOR....................................................................193
			CHECK ALTERNATOR BELT TENSIONER.....................................................................193
		EVERY 2000 HOURS SERVICE................................................................................194
			PREVIOUS MAINTENANCE................................................................................194
			CHANGE OIL IN FINAL DRIVE CASE......................................................................194
			CLEAN HYDRAULIC TANK STRAINER.......................................................................194
			CLEAN, CHECK TURBOCHARGER...........................................................................195
			CHECK ALTERNATOR, STARTING MOTOR....................................................................195
			CHECK VIBRATION DAMPER..............................................................................195
			CHECK ENGINE VALVE CLEARANCE, ADJUST................................................................196
		EVERY 4000 HOURS SERVICE................................................................................198
			PREVIOUS MAINTENANCE................................................................................198
			CHECK WATER PUMP....................................................................................198
		EVERY 5000 HOURS SERVICE................................................................................199
			PREVIOUS MAINTENANCE................................................................................199
			CHANGE OIL IN HYDRAULIC TANK........................................................................199
			PROCEDURE FOR BLEEDING AIR..........................................................................200
SPECIFICATIONS..................................................................................................203
	SPECIFICATIONS AND DIMENSIONS...............................................................................204
		SPECIFICATIONS..........................................................................................204
		DIMENSIONS..............................................................................................206
			PC200LL-6...........................................................................................206
			PC220LL-6...........................................................................................208
OPTIONS, ATTACHMENTS............................................................................................211
	GENERAL PRECAUTIONS.........................................................................................212
		PRECAUTIONS RELATED TO SAFETY...........................................................................212
		SELECTION OF TRACK SHOES................................................................................213

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.