KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC200-B31331 and up ,PC240-B10001 and up) – PDF DOWNLOAD

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KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC200-B31331 and up ,PC240-B10001 and up)

KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC200-B31331 AND UP ,PC240-B10001 AND UP) – PDF DOWNLOAD: 

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KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC200-B31331 and up ,PC240-B10001 and up)

• This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance.
• Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
• In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time.
• Storage location for the Operation and Maintenance Manual: magazine box on the left side of the operator’s seat. If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR (1-6).
• This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication.
• Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual

TABLE OF CONTENTS:

KOMATSU PC200-8 PC200LC-8 PC240LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:PC200-B31331 and up ,PC240-B10001 and up)

FOREWORD................................................................................................................................  3
	BEFORE READING THIS MANUAL..........................................................................................................  4
	SAFETY INFORMATION..................................................................................................................  5
	INTRODUCTION........................................................................................................................  6
		USE OF MACHINE..................................................................................................................  6
		DIRECTIONS OF MACHINE...........................................................................................................  6
		VISIBILITY FROM OPERATOR'S SEAT.................................................................................................  6
		PROTECTIVE STRUCTURE............................................................................................................  6
	PRODUCT INFORMATION.................................................................................................................  7
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....................................................................  7
		EPA REGULATIONS, ENGINE NUMBER PLATE............................................................................................  7
		SERVICE METER LOCATION..........................................................................................................  8
		YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.....................................................................................  8
CONTENTS................................................................................................................................  9
	FOREWORD............................................................................................................................  9
	SAFETY..............................................................................................................................  9
	OPERATION........................................................................................................................... 10
	MAINTENANCE......................................................................................................................... 12
	SPECIFICATIONS...................................................................................................................... 14
	ATTACHMENTS AND OPTIONS............................................................................................................. 14
	INDEX............................................................................................................................... 16
	COLOPHON............................................................................................................................ 16
SAFETY.................................................................................................................................. 17
	SAFETY.............................................................................................................................. 18
	SAFETY LABELS....................................................................................................................... 20
		LOCATION OF SAFETY LABELS....................................................................................................... 21
		SAFETY LABELS................................................................................................................... 22
	GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............................................................................. 29
		PRECAUTIONS BEFORE STARTING OPERATION........................................................................................... 29
		PREPARATIONS FOR SAFE OPERATION................................................................................................. 29
		FIRE PREVENTION................................................................................................................. 31
		PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...................................................................................... 32
		DO NOT GET CAUGHT IN WORK EQUIPMENT............................................................................................. 34
		PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.................................................................................... 34
		PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS........................................................................... 35
		UNAUTHORIZED MODIFICATION....................................................................................................... 36
		PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.................................................................................. 36
		PRECAUTIONS RELATED TO CAB GLASS................................................................................................ 36
		PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING................................................................................. 36
	PRECAUTIONS FOR OPERATION........................................................................................................... 37
		PRECAUTIONS FOR JOBSITE......................................................................................................... 37
		STARTING ENGINE................................................................................................................. 39
		OPERATION....................................................................................................................... 41
		TRANSPORTATION.................................................................................................................. 49
		TOWING.......................................................................................................................... 50
		LIFTING OBJECTS WITH BUCKET..................................................................................................... 51
	PRECAUTIONS FOR MAINTENANCE......................................................................................................... 52
		PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE.......................................................................... 52
		PRECAUTIONS FOR INSPECTION AND MAINTENANCE...................................................................................... 56
OPERATION............................................................................................................................... 63
	MACHINE VIEW ILLUSTRATIONS.......................................................................................................... 64
		OVERALL MACHINE VIEW............................................................................................................ 64
		CONTROLS AND GAUGES............................................................................................................. 65
	DETAILED CONTROLS AND GAUGES........................................................................................................ 67
		MONITORING SYSTEM............................................................................................................... 67
			Basic Operation of Machine Monitor.......................................................................................... 68
			Emergency Monitors.......................................................................................................... 73
			Caution Monitors............................................................................................................ 75
			Basic Check Monitors........................................................................................................ 78
			Meter Display Portion....................................................................................................... 80
			Monitor Switches Portion.................................................................................................... 88
			Handling Function Switches.................................................................................................. 97
		SWITCHES........................................................................................................................133
		CONTROL LEVERS AND PEDALS.......................................................................................................138
		SUN ROOF........................................................................................................................141
		WINDSHIELD......................................................................................................................141
		EMERGENCY ESCAPE HAMMER.........................................................................................................147
		DOOR LOCK.......................................................................................................................147
		CAP WITH LOCK...................................................................................................................148
		DRINK BOX.......................................................................................................................150
		MAGAZINE BOX....................................................................................................................150
		ASHTRAY.........................................................................................................................150
		AIR CONDITIONER CONTROLS........................................................................................................151
			Air Conditioner Control Panel...............................................................................................151
			Method of Operation.........................................................................................................156
			Use Air Conditioner with Care...............................................................................................163
			Inspection and maintenance of Air Conditioner Equipped Machine..............................................................163
		RADIO...........................................................................................................................164
			Control Panel...............................................................................................................164
			Controls of Radio...........................................................................................................166
			Use Radio with Care.........................................................................................................168
		AUXILIARY ELECTRIC POWER........................................................................................................169
			24V Power Source............................................................................................................169
			12V Power Source............................................................................................................169
		FUSE............................................................................................................................170
		FUSIBLE LINK....................................................................................................................171
		CONTROLLER......................................................................................................................171
		TOOL BOX........................................................................................................................171
		GREASE PUMP HOLDER..............................................................................................................171
		FIRE EXTINGUISHER...............................................................................................................172
	MACHINE OPERATIONS AND CONTROLS.....................................................................................................173
		BEFORE STARTING ENGINE..........................................................................................................173
			Walk-around Checks..........................................................................................................173
			Checks Before Starting......................................................................................................175
			Adjustment..................................................................................................................185
			Seat Belt...................................................................................................................191
			Operations Before Starting Engine...........................................................................................192
		STARTING ENGINE.................................................................................................................194
		AFTER STARTING ENGINE...........................................................................................................197
			Breaking-in the New Machine.................................................................................................198
			Engine Warm Up..............................................................................................................198
			Hydraulic Equipment Warm Up.................................................................................................200
			Operation After Completion Of Warm-Up Operation.............................................................................206
		STOPPING THE ENGINE.............................................................................................................208
		MACHINE OPERATION...............................................................................................................209
			Preparations for Moving the Machine.........................................................................................209
			Moving Machine Forward......................................................................................................210
			Moving Machine Backward.....................................................................................................211
			Stopping Machine............................................................................................................212
		STEERING THE MACHINE............................................................................................................213
			Steering....................................................................................................................213
		SWINGING........................................................................................................................215
		WORK EQUIPMENT CONTROLS AND OPERATIONS..........................................................................................216
		WORKING MODE....................................................................................................................218
		PROHIBITED OPERATIONS...........................................................................................................220
		GENERAL OPERATION INFORMATION...................................................................................................223
		TRAVELING ON SLOPES.............................................................................................................225
		ESCAPE FROM MUD.................................................................................................................227
			Track on One Side Stuck.....................................................................................................227
			Tracks on Both Sides Stuck..................................................................................................227
		RECOMMENDED APPLICATIONS........................................................................................................228
			Backhoe Work................................................................................................................228
			Shovel Work.................................................................................................................228
			Ditching Work...............................................................................................................228
			Loading Work................................................................................................................229
		BUCKET REPLACEMENT AND INVERSION................................................................................................230
			Replacement.................................................................................................................230
			Inversion...................................................................................................................232
		PARKING MACHINE.................................................................................................................234
		MACHINE INSPECTION AFTER DAILY WORK.............................................................................................235
		LOCKING.........................................................................................................................236
	TRANSPORTATION......................................................................................................................237
		TRANSPORTATION PROCEDURE........................................................................................................237
		LOADING AND UNLOADING WITH TRAILER..............................................................................................238
			Loading.....................................................................................................................239
			Securing Machine............................................................................................................242
			Unloading...................................................................................................................245
		LIFTING MACHINE.................................................................................................................247
			Standard Specification Machine..............................................................................................247
			Machines With Lifting Hook..................................................................................................248
	COLD WEATHER OPERATION..............................................................................................................250
		COLD WEATHER OPERATION INFORMATION..............................................................................................250
			Fuel and Lubricants.........................................................................................................250
			Cooling System Coolant......................................................................................................250
			Battery.....................................................................................................................251
		AFTER DAILY WORK COMPLETION.....................................................................................................252
		AFTER COLD WEATHER SEASON.......................................................................................................252
	LONG TERM STORAGE...................................................................................................................253
		BEFORE STORAGE..................................................................................................................253
		DURING STORAGE..................................................................................................................253
		AFTER STORAGE...................................................................................................................254
		STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................254
	TROUBLES AND ACTIONS................................................................................................................255
		RUNNING OUT OF FUEL.............................................................................................................255
		PHENOMENA THAT ARE NOT FAILURES.................................................................................................255
		TOWING THE MACHINE..............................................................................................................256
		LIGHTWEIGHT TOWING HOLE.........................................................................................................257
		SEVERE JOB CONDITION............................................................................................................257
		DISCHARGED BATTERY..............................................................................................................258
			Battery Removal and Installation............................................................................................258
			Battery Charges.............................................................................................................259
			Starting Engine with Booster Cables.........................................................................................260
		OTHER TROUBLE...................................................................................................................262
			Electrical System...........................................................................................................262
			Chassis.....................................................................................................................263
			Engine......................................................................................................................264
			Electronic Control System...................................................................................................266
			Point of Contact to Telephone when Error Occurs.............................................................................267
MAINTENANCE.............................................................................................................................269
	MAINTENANCE INFORMATION.............................................................................................................270
	OUTLINE OF SERVICE..................................................................................................................272
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..........................................................................272
			OIL.........................................................................................................................272
			FUEL........................................................................................................................273
			COOLANT AND WATER FOR DILUTION..............................................................................................273
			GREASE......................................................................................................................274
			CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...............................................................................274
			STORING OIL AND FUEL........................................................................................................275
			FILTERS.....................................................................................................................275
		ELECTRIC SYSTEM MAINTENANCE.....................................................................................................275
	WEAR PARTS..........................................................................................................................276
		WEAR PARTS LIST.................................................................................................................277
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT............................................................................................278
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.............................................280
	TIGHTENING TORQUE SPECIFICATIONS....................................................................................................281
		TIGHTENING TORQUE LIST..........................................................................................................281
	SAFETY CRITICAL PARTS...............................................................................................................282
		SAFETY CRITICAL PARTS LIST......................................................................................................283
	MAINTENANCE SCHEDULE................................................................................................................285
		MAINTENANCE SCHEDULE CHART......................................................................................................285
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER......................................................................................287
	MAINTENANCE PROCEDURE...............................................................................................................288
		INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..................................................................288
		INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)..................................................................288
		WHEN REQUIRED...................................................................................................................289
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT................................................................................289
			CLEAN INSIDE OF COOLING SYSTEM..............................................................................................295
			CHECK AND TIGHTEN TRACK SHOE BOLTS..........................................................................................299
			CHECK AND ADJUST TRACK TENSION..............................................................................................300
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....................................................................................302
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..................................................................................305
			ADJUST BUCKET CLEARANCE.....................................................................................................307
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................308
			CHECK AND MAINTENANCE AIR CONDITIONER.......................................................................................309
			WASH WASHABLE FLOOR.........................................................................................................310
			CHECK GAS SPRING............................................................................................................313
			BLEEDING AIR FROM HYDRAULIC SYSTEM..........................................................................................314
		CHECK BEFORE STARTING...........................................................................................................316
		EVERY 100 HOURS MAINTENANCE.....................................................................................................317
			LUBRICATING.................................................................................................................317
		EVERY 250 HOURS MAINTENANCE.....................................................................................................319
			CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................319
			CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................320
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.......................................................................322
		EVERY 500 HOURS MAINTENANCE.....................................................................................................323
			LUBRICATE SWING CIRCLE......................................................................................................323
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................324
			REPLACE FUEL PRE-FILTER CARTRIDGE...........................................................................................326
			CHECK SWING PINION GREASE LEVEL, ADD GREASE.................................................................................328
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS....329
			(only machines equipped with air conditioner)...............................................................................329
			CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS..................................................................................331
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK..................................................................................333
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL............................................................................334
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL................................................................................335
		EVERY 1000 HOURS MAINTENANCE....................................................................................................336
			REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................336
			CHANGE OIL IN SWING MACHINERY CASE..........................................................................................337
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.....................................................................................338
			REPLACE FUEL MAIN FILTER CARTRIDGE..........................................................................................339
			INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR....................................................342
			CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...................................................................345
			CHECK FAN BELT TENSION AND REPLACE FAN BELT.................................................................................345
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker).............................................................345
		EVERY 2000 HOURS MAINTENANCE....................................................................................................346
			CHANGE OIL IN FINAL DRIVE CASE..............................................................................................346
			CLEAN HYDRAULIC TANK STRAINER...............................................................................................347
			CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...............................................348
			CHECK ALTERNATOR............................................................................................................352
			CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................352
		EVERY 4000 HOURS MAINTENANCE....................................................................................................353
			CHECK WATER PUMP............................................................................................................353
			CHECK VIBRATION DAMPER......................................................................................................353
			CHECK STARTING MOTOR........................................................................................................353
			REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...................................................................................354
			CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER......................................................355
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................................................355
			CHECK OPERATING CONDITION OF COMPRESSOR.....................................................................................356
		EVERY 5000 HOURS MAINTENANCE....................................................................................................357
			CHANGE OIL IN HYDRAULIC TANK................................................................................................357
		EVERY 8000 HOURS MAINTENANCE....................................................................................................358
			REPLACE HIGH-PRESSURE PIPING CLAMP..........................................................................................358
			REPLACE FUEL SPRAY PREVENTION CAP...........................................................................................358
SPECIFICATIONS..........................................................................................................................359
	SPECIFICATIONS......................................................................................................................360
ATTACHMENTS AND OPTIONS.................................................................................................................363
	GENERAL PRECAUTIONS FOR SAFETY......................................................................................................364
		PRECAUTIONS WHEN SELECTING......................................................................................................364
		READ THE INSTRUCTION MANUAL THOROUGHLY..........................................................................................364
		PRECAUTIONS WHEN REMOVING OR INSTALLING.........................................................................................364
		PRECAUTIONS WHEN USING..........................................................................................................364
	BUCKET WITH HOOK....................................................................................................................365
		HOOK CONDITION..................................................................................................................365
		PROHIBITED OPERATIONS...........................................................................................................365
	MACHINE READY FOR ATTACHMENT........................................................................................................366
		LOCATIONS.......................................................................................................................366
		HYDRAULIC CIRCUIT...............................................................................................................370
			Switching Hydraulic Circuit.................................................................................................370
			Adjusting Oil Flow..........................................................................................................370
			Switching Between Breaker and General Attachment............................................................................370
			Hydraulic Circuit Connection................................................................................................371
			Oil Flow Path...............................................................................................................372
			Replace Additional Breaker Filter Element...................................................................................373
			Replace Additional Breaker Pilot Filter Element.............................................................................375
		ATTACHMENT REMOVAL AND INSTALLATION.............................................................................................377
			Attachment Removal..........................................................................................................377
			Attachment Installation.....................................................................................................379
		ATTACHMENT OPERATIONS...........................................................................................................381
			When Using Breaker..........................................................................................................381
			When Using General Attachment Such as Crusher...............................................................................383
		LONG TERM STORAGE...............................................................................................................384
		SPECIFICATIONS..................................................................................................................384
	ATTACHMENT GUIDE....................................................................................................................385
		ATTACHMENT COMBINATIONS.........................................................................................................385
		TRACK SHOES SELECTION...........................................................................................................388
		BUCKET TEETH SELECTION..........................................................................................................389
			Teeth Selection.............................................................................................................389
			Selection Guide for Horizontal or Vertical Pin Type Tooth...................................................................389
		HANDLING OF RUBBER PAD SHOE AND ROAD LINER......................................................................................390
			Working Environment.........................................................................................................390
			Working Conditions..........................................................................................................390
			Storage and Maintenance.....................................................................................................391
			Extent of Damage to Rubber..................................................................................................391
			Check Road Liner............................................................................................................391
			Replace Road Liner..........................................................................................................391
		TRAPEZOIDAL BUCKET..............................................................................................................392
		HANDLING EXTENSION ARM..........................................................................................................394
		HANDLING CLAMSHELL BUCKET.......................................................................................................395
	RECOMMENDED ATTACHMENT OPERATIONS...................................................................................................396
		HYDRAULIC BREAKER...............................................................................................................396
	HANDLING MACHINES EQUIPPED WITH KOMTRAX.............................................................................................400
		BASIC PRECAUTIONS...............................................................................................................400
INDEX...................................................................................................................................401
	SINDEX..............................................................................................................................403
		<A>.............................................................................................................................403
		<B>.............................................................................................................................403
		<C>.............................................................................................................................403
		<D>.............................................................................................................................403
		<E>.............................................................................................................................403
		<F>.............................................................................................................................403
		<G>.............................................................................................................................403
		<H>.............................................................................................................................403
		<I>.............................................................................................................................403
		<L>.............................................................................................................................403
		<M>.............................................................................................................................404
		<O>.............................................................................................................................404
		<P>.............................................................................................................................404
		<R>.............................................................................................................................404
		<S>.............................................................................................................................404
		<T>.............................................................................................................................404
		<U>.............................................................................................................................404
		<V>.............................................................................................................................404
		<W>.............................................................................................................................404
		<Y>.............................................................................................................................405
COLOPHON................................................................................................................................407

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