Komatsu Hydraulic Excavator PC200,PC250LC-6 PC210Lc-6 PC220-6 PC250LC-6 Operator Manual – DOWNLOAD

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Komatsu Hydraulic Excavator PC200,PC250LC-6 PC210Lc-6 PC220-6 PC250LC-6 Operator Manual

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Komatsu Hydraulic Excavator PC200,PC250LC-6 PC210Lc-6 PC220-6 PC250LC-6 Operator Manual

Size : 3.68 MB
Format : PDF
Language : English
Number of Pages : 257 Pages

KOMATSU HYDRAULIC EXCAVATOR PC200,PC250LC-6 PC210LC-6 PC220-6 PC250LC-6 OPERATOR MANUAL – DOWNLOAD:

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DESCRIPTION:

Komatsu Hydraulic Excavator PC200,PC250LC-6 PC210Lc-6 PC220-6 PC250LC-6 Operator Manual

FOREWORD:

• 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 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 your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC200,PC250LC-6 PC210Lc-6 PC220-6 PC250LC-6 Operator Manual

MAIN MENU...................................................................................................................................  0
COVER.......................................................................................................................................  1
1. FORWARD..................................................................................................................................  3
2. SAFETY INFORMATION.......................................................................................................................  4
3. INTRODUCTION.............................................................................................................................  5
	3.1 INTENDED USE........................................................................................................................  5
	3.2 FEATURES............................................................................................................................  5
	3.3 BREAKING IN A NEW MACHINE...........................................................................................................  5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................................  6
	4.1 MACHINE SERIAL NO. PLATE POSITION...................................................................................................  6
	4.2 ENGINE SERIAL NO. PLATE POSITION....................................................................................................  6
	4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...........................................................................................  6
5. CONTENTS.................................................................................................................................  7
6. GENERAL PRECAUTIONS...................................................................................................................... 13
7. PRECAUTIONS DURING OPERATIONS............................................................................................................ 20
	7.1 BEFORE STARTING ENGINE.............................................................................................................. 20
	7.2 OPERATING MACHINE................................................................................................................... 22
	7.3 TRANSPORTATION...................................................................................................................... 30
	7.4 BATTERY............................................................................................................................. 31
	7.5 TOWING.............................................................................................................................. 33
	7.6 BUCKET WITH HOOK.................................................................................................................... 34
		7.6.1 GENERAL PRECAUTIONS........................................................................................................... 34
		7.6.2 PRECAUTIONS FOR LIFTING OPERATION............................................................................................. 35
8. PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 36
	8.1 BEFORE CARRYING OUT MAINTENANCE..................................................................................................... 36
	8.2 DURING MAINTENANCE.................................................................................................................. 39
9. POSITION FOR ATTACHING SAFETY LABELS..................................................................................................... 44
10. GENERAL VIEW............................................................................................................................ 49
	10.1 GENERAL VIEW OF MACHINE............................................................................................................ 49
	10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................................................................ 50
11. EXPLANATION OF COMPONENTS............................................................................................................... 51
	11.1 MACHINE MONITOR.................................................................................................................... 51
		11.1.1 A. BASIC CHECK ITEMS......................................................................................................... 51
		11.1.2 B. CAUTION ITEMS............................................................................................................. 53
		11.1.3 C. EMERGENCY STOP ITEMS...................................................................................................... 54
		11.1.4 D. METER DISPLAY PORTION..................................................................................................... 55
		11.1.5 E: SWITCHES.................................................................................................................. 59
	11.2 SWITCHES........................................................................................................................... 62
	11.3 CONTROL LEVERS, PEDALS............................................................................................................. 66
	11.4 CEILING WINDOW..................................................................................................................... 71
	11.5 FRONT WINDOW....................................................................................................................... 72
	11.6 DOOR LOCK.......................................................................................................................... 74
	11.7 CAP, COVER WITH LOCK............................................................................................................... 75
		11.7.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................. 75
		11.7.2 METHOD OF OPENING AND CLOSING COVER WITH LOCK................................................................................ 75
	11.8 HOT/COOL BOX....................................................................................................................... 76
	11.9 LUGGAGE BOX........................................................................................................................ 76
	11.10 ASHTRAY........................................................................................................................... 76
	11.11 CAB HEATER........................................................................................................................ 77
	11.12 CAR RADIO......................................................................................................................... 79
		11.12.1 EXPLANATION OF COMPONENTS................................................................................................... 79
		11.12.2 LOCATION AND FUNCTION OF CONTROLS........................................................................................... 79
		11.12.3 METHOD OF OPERATION......................................................................................................... 82
		11.12.4 PRECAUTIONS WHEN USING...................................................................................................... 83
		11.12.5 SPECIFICATIONS.............................................................................................................. 83
	11.13 FUSE.............................................................................................................................. 84
	11.14 FUSIBLE LINK...................................................................................................................... 85
	11.15 CONTROLLER........................................................................................................................ 85
	11.16 TOOL BOX.......................................................................................................................... 85
	11.17 GREASE PUMP HOLDER................................................................................................................ 85
	11.18 HANDLING ACCUMULATOR.............................................................................................................. 86
		11.18.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR........................................ 86
12. OPERATION............................................................................................................................... 87
	12.1 CHECK BEFORE STARTING ENGINE....................................................................................................... 87
		12.1.1 WALK-AROUND CHECK............................................................................................................ 87
		12.1.2 CHECK BEFORE STARTING........................................................................................................ 89
		12.1.3 ADJUSTMENT BEFORE OPERATION.................................................................................................. 93
		12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................................................. 95
	12.2 STARTING ENGINE.................................................................................................................... 96
		12.2.1 NORMAL STARTING.............................................................................................................. 96
		12.2.2 STARTING IN COLD WEATHER..................................................................................................... 97
	12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................................................ 99
		12.3.1 WHEN NORMAL.................................................................................................................. 99
		12.3.2 IN COLD AREAS................................................................................................................101
	12.4 MOVING MACHINE.....................................................................................................................104
		12.4.1 MOVING MACHINE FORWARD.......................................................................................................104
		12.4.2 MOVING MACHINE BACKWARD......................................................................................................105
	12.5 STEERING MACHINE...................................................................................................................107
	12.6 STOPPING MACHINE...................................................................................................................109
	12.7 SWINGING...........................................................................................................................110
	12.8 OPERATION OF WORK EQUIPMENT........................................................................................................111
	12.9 HANDLING ACTIVE MODE...............................................................................................................112
	12.10 WORKING MODE SELECTION............................................................................................................114
	12.11 PROHIBITIONS FOR OPERATION........................................................................................................116
	12.12 PRECAUTIONS FOR OPERATION.........................................................................................................118
	12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................................................119
	12.14 HOW TO ESCAPE FROM MUD............................................................................................................121
		12.14.1 WHEN ONE SIDE IS STUCK......................................................................................................121
		12.14.2 WHEN BOTH SIDES ARE STUCK...................................................................................................121
	12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................................................................................122
		12.15.1 BACKHOE WORK................................................................................................................122
		12.15.2 SHOVEL WORK.................................................................................................................122
		12.15.3 DITCHING WORK...............................................................................................................122
		12.15.4 LOADING WORK................................................................................................................122
	12.16 REPLACEMENT AND INVERSION OF BUCKET...............................................................................................123
		12.16.1 REPLACEMENT.................................................................................................................123
		12.16.2 INVERSION...................................................................................................................124
	12.17 PARKING MACHINE...................................................................................................................125
	12.18 CHECK AFTER FINISHING WORK........................................................................................................126
	12.19 STOPPING ENGINE...................................................................................................................127
	12.20 CHECK AFTER STOPPING ENGINE.......................................................................................................128
	12.21 LOCKING AND SECURING MACHINE......................................................................................................128
13. TRANSPORTATION..........................................................................................................................129
	13.1 LOADING, UNLOADING WORK............................................................................................................129
	13.2 PRECAUTIONS FOR LOADING............................................................................................................131
	13.3 PRECAUTIONS FOR TRANSPORTATION.....................................................................................................132
14. COLD WEATHER OPERATION..................................................................................................................133
	14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................................................................................133
		14.1.1 FUEL AND LUBRICANTS..........................................................................................................133
		14.1.2 COOLANT......................................................................................................................133
		14.1.3 BATTERY......................................................................................................................134
	14.2 PRECAUTIONS AFTER COMPLETION OF WORK...............................................................................................135
	14.3 AFTER COLD WEATHER.................................................................................................................135
15. LONG-TERM STORAGE.......................................................................................................................136
	15.1 BEFORE STORAGE.....................................................................................................................136
	15.2 DURING STORAGE.....................................................................................................................137
	15.3 AFTER STORAGE......................................................................................................................137
	15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...........................................................................................137
16. TROUBLESHOOTING.........................................................................................................................138
	16.1 PHENOMENA THAT ARE NOT FAILURES....................................................................................................138
	16.2 METHOD OF TOWING MACHINE...........................................................................................................138
	16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE..........................................................................................138
	16.4 PRECAUTIONS ON PARTICULAR JOBSITES.................................................................................................139
	16.5 IF BATTERY IS DISCHARGED...........................................................................................................139
	16.6 OTHER TROUBLE......................................................................................................................143
		16.6.1 ELECTRICAL SYSTEM............................................................................................................143
		16.6.2 CHASSIS......................................................................................................................144
		16.6.3 ENGINE.......................................................................................................................145
		16.6.4 ELECTRONIC CONTROL SYSTEM....................................................................................................147
17. GUIDES TO MAINTENANCE...................................................................................................................149
18. OUTLINES OF SERVICE.....................................................................................................................152
	18.1 OUTLINE OF OIL, FUEL, COOLANT......................................................................................................152
		18.1.1 OIL..........................................................................................................................152
		18.1.2 FUEL.........................................................................................................................153
		18.1.3 COOLANT......................................................................................................................153
		18.1.4 GREASE.......................................................................................................................154
		18.1.5 STORING OIL AND FUEL.........................................................................................................154
		18.1.6 FILTERS......................................................................................................................154
	18.2 OUTLINE OF ELECTRICAL SYSTEM.......................................................................................................155
	18.3 OUTLINE OF HYDRAULIC SYSTEM........................................................................................................156
19. WEAR PARTS LIST.........................................................................................................................157
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................................................................159
	20.1 ENGINE OIL SPECIFICATION...........................................................................................................160
		20.1.1 NORMAL OPERATION.............................................................................................................160
		20.1.2 ARCTIC OPERATION.............................................................................................................160
	20.2 DIESEL FUEL SPECIFICATIONS.........................................................................................................161
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................................................................................162
	21.1 INTRODUCTION OF NECESSARY TOOLS....................................................................................................162
	21.2 TORQUE LIST........................................................................................................................163
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................................................................................164
23. MAINTENANCE SCHEDULE CHART..............................................................................................................167
	23.1 MAINTENANCE SCHEDULE CHART.........................................................................................................167
	23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER..................................................................................170
24. SERVICE PROCEDURE.......................................................................................................................171
	24.1 INITIAL 250 HOURS SERVICE..........................................................................................................171
	24.2 WHEN REQUIRED......................................................................................................................172
		24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.................................................................................172
		24.2.2 CLEAN INSIDE OF COOLING SYSTEM...............................................................................................174
		24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS...........................................................................................178
		24.2.4 CHECK AND ADJUST TRACK TENSION...............................................................................................179
		24.2.5 CHECK ENGINE INTAKE AIR HEATER (ELECTRICAL)..................................................................................181
		24.2.6 INSTALLATION OF BUCKET TEETH.................................................................................................182
		24.2.7 REMOVAL OF BUCKET TEETH......................................................................................................184
		24.2.8 ADJUST BUCKET CLEARANCE......................................................................................................186
		24.2.9 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...................................................................................187
		24.2.10 CHECK AND ADJUST AIR CONDITIONER............................................................................................188
		24.2.11 REPLACE ADDITIONAL BREAKER FILTER ELEMENT...................................................................................188
		24.2.12 CLEAN INLINE FILTER (RECTANGULAR HOUSING)...................................................................................189
	24.3 CHECK BEFORE STARTING..............................................................................................................190
		24.3.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................................................................190
		24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...................................................................................190
		24.3.3 CHECK FUEL LEVEL, ADD FUEL...................................................................................................191
		24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...................................................................................192
		24.3.5 CHECK AIR CLEANER FOR CLOGGING...............................................................................................192
		24.3.6 CHECK ELECTRIC WIRING........................................................................................................193
		24.3.7 CHECK FOR WATER AND SEDIMENT IN FUEL-WATER SEPERATOR.........................................................................193
	24.4 EVERY 100 HOURS SERVICE............................................................................................................194
		24.4.1 LUBRICATING..................................................................................................................194
		24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.............................................................................196
		24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK......................................................................................196
	24.5 EVERY 250 HOURS SERVICE............................................................................................................197
		24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................197
		24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE...........................................................................................198
		24.5.3 REPLACE HYDRAULIC FILTER ELEMENT.............................................................................................199
		24.5.4 LUBRICATE SWING CIRCLE PC200, 200LC, 210LC, 220LC: 2 POINTS PC250: 3 POINTS..................................................200
		24.5.5 CHECK FAN BELT TENSION, ADJUST...............................................................................................201
		24.5.6 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST........................................................................202
	24.6 EVERY 500 HOURS SERVICE............................................................................................................203
		24.6.1 REPLACE FUEL FILTER CARTRIDGE AND FUEL-WATER SEPERATOR.......................................................................203
		24.6.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE..................................................................................205
		24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS(ONLY FOR MACHINES EQUIPPED WITH AC)....206
		24.6.4 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)..........207
		24.6.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT......................................................................................207
		24.6.6 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE............................................................208
		24.6.7 REPLACE IN-LINE FUEL STRAINER................................................................................................209
	24.7 EVERY 1000 HOURS SERVICE...........................................................................................................210
		24.7.1 CHANGE OIL IN SWING MACHINERY CASE...........................................................................................210
		24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................................211
		24.7.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...................................................................................211
		24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR.............................................................................................211
		24.7.5 CHECK ALTERNATOR BELT TENSIONER BEARING, BELT AND FAN HUB....................................................................212
	24.8 EVERY 2000 HOURS SERVICE...........................................................................................................213
		24.8.1 CHANGE OIL IN FINAL DRIVE CASE...............................................................................................213
		24.8.2 CLEAN HYDRAULIC TANK STRAINER................................................................................................214
		24.8.3 CLEAN, CHECK TURBOCHARGER....................................................................................................214
		24.8.4 CHECK ALTERNATOR, STARTING MOTOR.............................................................................................214
		24.8.5 CHECK VIBRATION DAMPER.......................................................................................................214
		24.8.6 CHANGE ANTIFREEZE............................................................................................................214
		24.8.7 CHECK AND ADJUST VALVE CLEARANCE.............................................................................................215
	24.9 EVERY 4000 HOURS SERVICE...........................................................................................................216
		24.9.1 CHECK WATER PUMP.............................................................................................................216
	24.10 EVERY 5000 HOURS SERVICE..........................................................................................................217
		24.10.1 CHANGE OIL IN HYDRAULIC TANK................................................................................................217
25. SPECIFICATIONS..........................................................................................................................222
26. GENERAL PRECAUTIONS.....................................................................................................................230
	26.1 PRECAUTIONS RELATED TO SAFETY......................................................................................................230
	26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS............................................................................................231
27. HANDLING BUCKET WITH HOOK...............................................................................................................232
	27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK...............................................................................................232
	27.2 PROHIBITED OPERATIONS..............................................................................................................232
	27.3 PRECAUTIONS DURING OPERATIONS......................................................................................................232
28. HANDLING AIR CONDITIONER................................................................................................................233
	28.1 GENERAL LOCATIONS ON CONTROL PANEL.................................................................................................233
	28.2 PRECAUTIONS WHEN USING AIR CONDITIONER.............................................................................................235
29. MACHINES READY FOR ATTACHMENTS..........................................................................................................236
	29.1 EXPLANATION OF COMPONENTS..........................................................................................................236
	29.2 HYDRAULIC CIRCUIT..................................................................................................................238
		29.2.1 CONNECTING HYDRAULIC CIRCUIT.................................................................................................239
	29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE..........................................................................................240
	29.4 OPERATION..........................................................................................................................242
	29.5 LONG-TERM STORAGE..................................................................................................................243
	29.6 SPECIFICATIONS.....................................................................................................................243
30. INTRODUCTION OF ATTACHMENTS.............................................................................................................244
	30.1 BUCKET SELECTION...................................................................................................................244
	30.2 BUCKET INSTALLATION COMBINATIONS...................................................................................................244
	30.3 SELECTION OF TRACK SHOES...........................................................................................................247
	30.4 BACKHOE CONTROL PATTERN CONVERSION.................................................................................................248
31. EXTENDING MACHINE SERVICE LIFE..........................................................................................................249
	31.1 HYDRAULIC BREAKER..................................................................................................................249
	31.2 CRUSHER............................................................................................................................252
	31.3 GRAPPLE............................................................................................................................253
	31.4 BUCKET WITH THUMB GRAPPLE..........................................................................................................254
	31.5 ROTATING GRAPPLE...................................................................................................................255
	31.6 SHEAR..............................................................................................................................256
	31.7 HYDRAULIC PILE DRIVER..............................................................................................................257

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