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KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C30092 & UP) – PDF DOWNLOAD
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- KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:C30092 & UP
- PUBLICATION NUMBER:SEAM023800PT
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Description
KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C30092 & UP)
KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C30092 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C30092 & UP)
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. if this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners.
- 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 Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.
TABLE OF CONTENTS:
KOMATSU PC200-6 PC200LC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C30092 & UP)
MAIN MENU............................................................................................................................ 0 COVER................................................................................................................................ 2 CONTENTS............................................................................................................................. 9 1. FOREWORD.......................................................................................................................... 5 2. SAFETY INFORMATION................................................................................................................ 6 3. INTRODUCTION...................................................................................................................... 7 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR..................................................................... 8 SAFETY............................................................................................................................... 13 6. GENERAL PRECAUTIONS........................................................................................................... 14 7. PRECAUTIONS DURING OPERATION.................................................................................................. 21 7.1 BEFORE STARTING ENGINE................................................................................................... 21 7.2 AFTER STARTING ENGINE.................................................................................................... 23 7-3 TRANSPORTATION........................................................................................................... 30 7-4 BATTERY.................................................................................................................. 31 7.5 TOWING................................................................................................................... 33 7.6 LIFTING OPERATIONS....................................................................................................... 33 8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 34 8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................................................... 34 8.2 DURING MAINTENANCE....................................................................................................... 38 9. POSITION FOR ATTACHING SAFETY LABELS.......................................................................................... 44 OPERATION............................................................................................................................ 51 10. GENERAL VIEW................................................................................................................. 52 10.1 GENERAL VIEW OF MACHINE................................................................................................. 52 10.2 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 53 11. EXPLANATION OF COMPONENTS ................................................................................................... 54 11.1 MACHINE MONITOR......................................................................................................... 54 11.2 SWITCHES................................................................................................................ 65 11.3 CONTROL LEVERS, PEDALS.................................................................................................. 69 11.4 CEILING WINDOW.......................................................................................................... 74 11.5 FRONT WINDOW............................................................................................................ 75 11.6 DOOR LOCK............................................................................................................... 77 11.7 CAP, COVER WITH LOCK.................................................................................................... 78 11.8 HOT/COOL BOX............................................................................................................ 79 11.9 LUGGAGE BOX............................................................................................................. 79 11.10 ASHTRAY................................................................................................................ 79 11.11 AIR CONDITIONER........................................................................................................ 80 11.12 CAR RADIO.............................................................................................................. 83 11.13 FUSE................................................................................................................... 88 11.14 FUSIBLE LINK........................................................................................................... 89 11.15 CONTROLLERS............................................................................................................ 89 11.16 TOOL BOX............................................................................................................... 89 11.17 GREASE PUMP HOLDER..................................................................................................... 89 11.18 HANDLING ACCUMULATOR................................................................................................... 90 12. OPERATION.................................................................................................................... 92 12.1 CHECK BEFORE STARTING ENGINE............................................................................................ 92 12.2 STARTING ENGINE.........................................................................................................102 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................................105 12.4 MOVING MACHINE OFF......................................................................................................111 12.5 STEERING MACHINE........................................................................................................114 12.6 STOPPING MACHINE........................................................................................................116 12.7 SWINGING................................................................................................................117 12.8 OPERATION OF WORK EQUIPMENT.............................................................................................118 12.9 HANDLING ACTIVE MODE....................................................................................................119 12.10 WORKING MODE SELECTION.................................................................................................121 12.11PROHIBITIONS FOR OPERATION..............................................................................................123 12.12 PRECAUTIONS FOR OPERATION..............................................................................................125 12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILL.............................................................................126 12.14 HOW TO EXCAOR FRON.....................................................................................................128 12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR................................................................................129 12.16 REPLACEMENT AND INVERSION OF BUCKET....................................................................................130 12.17 PARKING MACHINE........................................................................................................132 12.18 CHECK AFTER FINISHING WORK.............................................................................................133 12.19 STOPPING ENGINE........................................................................................................134 12.20 CHECK AFTER STOPPING ENGINE............................................................................................135 12.21 LOCKING................................................................................................................135 13. TRANSPORTATION...............................................................................................................136 13.1 LOADING, UNLOADING WORK.................................................................................................136 13.2 PRECAUTION..............................................................................................................138 13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................139 14. COLD WEATHER.................................................................................................................140 14.1 PRECAUTIONS FOR LOADING.................................................................................................140 14.2 PRECAUTIONS AFTER COMPLETION OF WORK....................................................................................142 14.3 AFTER COLD WEATHER......................................................................................................142 15. LONG-TERM STORAGE............................................................................................................143 15.1 BEFORE STORAGE..........................................................................................................143 15.2 DURING STORAGE..........................................................................................................144 15.3 AFTER STORAGE...........................................................................................................144 15.4 STARTING MACHINE AFTER LONG-TERM STORAGE................................................................................144 16. TROUBLESHOOTING..............................................................................................................145 16.1 PHENOMENA THAT ARE NOT FAILURES.........................................................................................145 16.2 METHOD OF TOWING MACHINE................................................................................................145 16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...............................................................................145 16.4 PRECAUTIONS ON PARTICULAR JOBSITES......................................................................................146 16.5 IF BATTERY IS DISCHARGED................................................................................................146 16.6 OTHER TROUBLE...........................................................................................................150 MAINTENANCE..........................................................................................................................155 17. GUIDES TO MAINTENANCE........................................................................................................156 18. OUTLINES OF SERVICE..........................................................................................................159 18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................159 18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................162 18.3 OUTLINE OF HYDRAULIC SYSTEM.............................................................................................163 19. WEAR PARTS LIST.............................................................................................................164 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................................166 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................170 21.1 INTRODUCTION OF NECESSARY TOOLS.........................................................................................170 21.2 TORQUE LIST.............................................................................................................171 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................172 23. MAINTENANCE SCHEDULE CHART...................................................................................................176 23.1 MAINTENANCE SCHEDULE CHART..............................................................................................176 23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER.......................................................................178 24. SERVICE PROCEDURE............................................................................................................179 24.1 INITIAL 250 HOURS SERVICE...............................................................................................179 REPLACE FUEL CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION)............................................................179 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................179 24.2 WHEN REQUIRED ..........................................................................................................180 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................180 CLEAN INSIDE OF COOLING SYSTEM...........................................................................................182 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................186 CHECK AND TIGHTEN TRACK TENSION..........................................................................................187 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................189 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)................................................................................190 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................193 ADJUST BUCKET CLEARANCE..................................................................................................194 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................195 CHECK AND ADJUST AIR CONDITIONER.........................................................................................196 REPLACE ADDITIONAL BREAKET FILTER ELEMENT................................................................................197 24.3 CHECK BEFORE STARTING...................................................................................................198 CHECK COOLANT LEVEL, ADD WATER...........................................................................................198 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...............................................................................198 CHECK FUEL LEVEL IN HYDRAULIC TANK, ADD OIL..............................................................................199 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................................200 CHECK AIR CLEANER FOR CLOGGING...........................................................................................201 CHECK ELECTRIC WIRINGS...................................................................................................201 LUBRICATE CLAMSHELL BUCKET (12 POINTS)...................................................................................202 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER (OPTION)....................................................202 24.4 EVERY 100 HOURS SERVICE.................................................................................................203 BOOM CYLINDER FOOT PIN (2 POINTS)........................................................................................203 BOOM FOOT PIN (2 POINTS).................................................................................................203 BOOM CYLINDER ROD END (2 POINTS).........................................................................................203 ARM CYLINDER FOOT PIN (1 POINT)..........................................................................................203 BOOM-ARM COUPLING PIN (1 POINT)..........................................................................................204 ARM CYLINDER ROD END (1 POINT)...........................................................................................204 BUCKET CYLINDER FOOT PIN (1 POINT).......................................................................................204 ARM-LINK COUPLING PIN (1 POINT)..........................................................................................204 ARM-BUCKET COUPLING PIN (1 POINT)........................................................................................204 LINK COUPLING PIN (2 POINT)..............................................................................................204 BUCKET CYLINDER ROD END (1 POINT)........................................................................................204 BUCKET-LINK COUPLING PIN (1 POINT).......................................................................................204 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.........................................................................204 DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................205 24.5 EVERY 250 HOURS SERVICE.................................................................................................206 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................206 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................207 CHANGE OIL ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................208 LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................209 CHECK FAN TENSION, ADJUST................................................................................................210 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................................................211 24.6 EVERY 500 HOURS SERVICE.................................................................................................212 REPLACE FUEL FILTER CARTRIDGE AND ADDITIONAL FUEL CARTRIDGE (OPTION).....................................................212 CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................213 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....214 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......215 REPLACE HYDRAULIC TANK BREAHER ELEMENT...................................................................................215 REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................216 24.7 EVERY 1000 HOURS SERVICE................................................................................................217 CHANGE OIL IN SWING MACHINERY CASE.......................................................................................217 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL..................................................................................218 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................218 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................218 CHECK ALTERNATOR BELT TENSION AND REPLACE ALTERNATOR BELT................................................................219 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................................219 24.8 EVERY 2000 HOURS SERVICE................................................................................................220 CHANGE OIL IN FINAL DRIVE CASE...........................................................................................220 CLEAN HYDRAULIC TANK STRAINER............................................................................................221 CLEAN, CHECK TURBOCHARGER................................................................................................221 CHECK ALTERNATOR, STARTING MOTOR.........................................................................................221 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................221 CHECK VIBRATION DAMPER...................................................................................................222 24.9 EVERY 4000 HOURS SERVICE...............................................................................................223 CHECK WATER PUMP.........................................................................................................223 24.10 EVERY 5000 HOURS SERVICE...............................................................................................224 CHANGE OIL IN HYDRAULIC TANK.............................................................................................224 SPECIFICATIONS.......................................................................................................................229 25. SPECIFICATIONS...............................................................................................................230 OPTIONS, ATTACHMENTS.................................................................................................................234 26. GENERAL PRECAUTIONS..........................................................................................................235 26.1 PRECAUTIONS RELATED TO SAFETY...........................................................................................235 26.2 PRECAUTIONS RELATED TO SAFETY...........................................................................................236 27. HANDLING BUCKET WITH HOOK....................................................................................................237 27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK.................................................................................237 27.2 PROHIBITED OPERATIONS...................................................................................................237 27.3 PRECAUTIONS DURING OPERATIONS...........................................................................................237 28. USING SEAT BELT..............................................................................................................238 28.1 SEAT BELT...............................................................................................................238 29. HANDLING CAR HEATER..........................................................................................................240 29.1 EXPLANATION OF COMPONENTS...............................................................................................240 29.2 PREPARING CAR HEATER....................................................................................................241 30. MACHINE READY FOR ATTACHMENTS................................................................................................242 30.1 EXPLANATION OF COMPONENTS...............................................................................................242 30.2 HYDRAULIC CIRCUIT.......................................................................................................244 30.3 ATTACHMENT MOUNTING/D IMOUNTING.........................................................................................246 30.4 OPERATION..............................................................................................................248 30.5 LONG-TERM STORAGE.......................................................................................................249 30.6 SPECIFICATIONS..........................................................................................................249 31. INTRODUCTION OF ATTACHMENTS..................................................................................................250 31.1 SPECIFICATION, USE......................................................................................................250 31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...............................................................................251 31.3 SELECTION OF TRACK SHOES................................................................................................252 31.4 SELECTION OF BUCKET TEETH...............................................................................................253 31.5 HANDLING RUBBER PAD SHOE................................................................................................254 31.6 HANDLING TAPEZOID ......................................................................................................256 31.7 HANDING EXTENSION ARM...................................................................................................257 31.8 HANDLING CLAMSHELL BUCKET...............................................................................................258 31.9 HANDLING VARIABLE 2-PIECE BOOM, ROTATING ARM............................................................................259 32. EXTENDING MACHINE SERVICE LIFE...............................................................................................268 32.1 HYDRAULIC BREAKER.......................................................................................................268 32.2 POWER RIPPER............................................................................................................272 32.3 FORK GRAB...............................................................................................................273 32.4 GRAPPLE BUCKET..........................................................................................................274 32.5 SCRAP BUCKET............................................................................................................275 32.6 CRUSHER & CUTTER........................................................................................................276 32.7 HYDRAULIC PILE DRIVER...................................................................................................277 32.8 HYDRAULIC EXCAVTOR WITH MULTI-PURPOSE CRANE ............................................................................278
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