KOMATSU PC200,200LC PC210LC-6 Pc220LC-6 PC25OLC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A82001 & UP) – PDF DOWNLOAD

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KOMATSU PC200,200LC PC210LC-6 Pc220LC-6 PC25OLC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A82001 & UP)

KOMATSU PC200,200LC PC210LC-6 PC220LC-6 PC25OLC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A82001 & UP) – PDF DOWNLOAD:

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KOMATSU PC200,200LC PC210LC-6 Pc220LC-6 PC25OLC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A82001 & UP)

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from 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 PC200,200LC PC210LC-6 Pc220LC-6 PC25OLC-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A82001 & UP)

MAIN MENU.......................................................................................................................................  0
INTRODUCTION....................................................................................................................................  3
	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
SAFETY.......................................................................................................................................... 12
	6. GENERAL PRECAUTIONS...................................................................................................................... 13
	7. PRECAUTIONS DURING OPERATION............................................................................................................. 20
		7.1 BEFORE STARTING ENGINE.............................................................................................................. 20
		7.2 OPERATING MACHINE................................................................................................................... 22
		7.3 TRANSPORTATION...................................................................................................................... 28
		7.4 BATTERY............................................................................................................................. 29
		7.5 TOWING.............................................................................................................................. 30
		7.6 BUCKET WITH HOOK.................................................................................................................... 31
			7.6.1 GENERAL PRECAUTIONS........................................................................................................... 31
			7.6.2 PRECAUTIONS FOR LIFTING OPERATION............................................................................................. 32
	8. PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 33
		8.1 BEFORE CARRYING OUT MAINTENANCE..................................................................................................... 33
		8.2 DURING MAINTENANCE.................................................................................................................. 36
	9. POSITION FOR ATTACHING SAFETY LABELS..................................................................................................... 40
OPERATION....................................................................................................................................... 44
	10. GENERAL VIEW............................................................................................................................ 45
		10.1 GENERAL VIEW OF MACHINE............................................................................................................ 45
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................................................................ 46
	11. EXPLANATION OF COMPONENTS............................................................................................................... 47
		11.1 MACHINE MONITOR.................................................................................................................... 47
			11.1.1 BASIC CHECK ITEMS............................................................................................................ 47
			11.1.2 CAUTION ITEMS................................................................................................................ 48
			11.1.3 EMERGENCY STOP ITEMS......................................................................................................... 48
			11.1.4 METER DISPLAY PORTION........................................................................................................ 48
			11.1.15 SWITCHES.................................................................................................................... 48
		11.2 METER.............................................................................................................................. 58
		11.3 SWITCHES........................................................................................................................... 59
		11.4 CONTROL LEVERS, PEDALS............................................................................................................. 63
		11.5 CEILING WINDOW..................................................................................................................... 68
		11.6 FRONT WINDOW....................................................................................................................... 69
		11.7 DOOR LOCK.......................................................................................................................... 71
		11.8 CAP, COVER WITH LOCK............................................................................................................... 72
			11.8.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................. 72
			11.8.2 METHOD OF OPENING AND CLOSING COVER WITH LOCK................................................................................ 72
		11.9 HOT/COOL BOX....................................................................................................................... 73
		11.10 LUGGAGE BOX....................................................................................................................... 73
		11.11 ASHTRAY........................................................................................................................... 73
		11.12 CAB HEATER........................................................................................................................ 74
		11.13 CAR RADIO......................................................................................................................... 76
			11.13.1 EXPLANATION OF COMPONENTS................................................................................................... 76
			11.13.2 LOCATION AND FUNCTION OF CONTROLS........................................................................................... 76
			11.13.3 METHOD OF OPERATION......................................................................................................... 79
			11.13.4 PRECAUTIONS WHEN USING...................................................................................................... 80
			11.13.5 SPECIFICATIONS.............................................................................................................. 80
		11.14 FUSE.............................................................................................................................. 81
		11.15 FUSIBLE LINK...................................................................................................................... 82
		11.16 CONTROLLERS....................................................................................................................... 82
		11.17 TOOL BOX.......................................................................................................................... 82
		11.18 GREASE PUMP HOLDER................................................................................................................ 82
		11.19 HANDLING ACCUMULATOR.............................................................................................................. 83
			11.19.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR........................................ 83
	12. OPERATION............................................................................................................................... 84
		12.1 CHECK BEFORE STARTING ENGINE....................................................................................................... 84
			12.1.1 WALK-AROUND CHECK............................................................................................................ 84
			12.1.2 CHECK BEFORE STARTING........................................................................................................ 86
			12.1.3 ADJUSTMENT BEFORE OPERATION.................................................................................................. 90
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................................................. 92
		12.2 STARTING ENGINE.................................................................................................................... 93
			12.2.1 NORMAL STARTING.............................................................................................................. 93
			12.2.2 STARTING IN COLD WEATHER..................................................................................................... 94
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................................................ 96
			12.3.1 WHEN NORMAL.................................................................................................................. 96
			12.3.2 IN COLD AREAS................................................................................................................ 98
		12.4 MOVING MACHINE.....................................................................................................................101
			12.4.1 MOVING MACHINE FORWARD.......................................................................................................101
			12.4.2 MOVING MACHINE BACKWARD......................................................................................................102
		12.5 STEERING MACHINE...................................................................................................................104
			12.5.1 STEERING (CHANGING DIRECTION)................................................................................................104
		12.6 STOPPING MACHINE...................................................................................................................106
		12.7 SWINGING...........................................................................................................................107
		12.8 OPERATION OF WORK EQUIPMENT........................................................................................................108
		12.9 WORKING MODE SELECTION.............................................................................................................109
		12.10 PROHIBITIONS FOR OPERATION........................................................................................................111
		12.11 PRECAUTIONS FOR OPERATION.........................................................................................................113
		12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................................................114
		12.13 HOW TO ESCAPE FROM MUD............................................................................................................116
			12.13.1 WHEN ONE SIDE IS STUCK......................................................................................................116
			12.13.2 WHEN BOTH SIDES ARE STUCK...................................................................................................116
		12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................................................................................117
			12.14.1 BACKHOE WORK................................................................................................................117
			12.14.2 SHOVEL WORK.................................................................................................................117
			12.14.3 DITCHING WORK...............................................................................................................117
			12.14.4 LOADING WORK................................................................................................................117
		12.15 REPLACEMENT AND INVERSION OF BUCKET...............................................................................................118
			12.15.1 REPLACEMENT.................................................................................................................118
			12.15.2 INVERSION...................................................................................................................119
		12.16 PARKING MACHINE...................................................................................................................120
		12.17 CHECK AFTER FINISHING WORK........................................................................................................121
		12.18 STOPPING ENGINE...................................................................................................................122
		12.19 CHECK AFTER STOPPING ENGINE.......................................................................................................123
		12.20 LOCKING AND SECURING MACHINE......................................................................................................123
	13. TRANSPORTATION..........................................................................................................................124
		13.1 LOADING, UNLOADING WORK............................................................................................................124
		13.2 PRECAUTIONS FOR LOADING............................................................................................................126
		13.3 PRECAUTIONS FOR TRANSPORTATION.....................................................................................................127
	14. COLD WEATHER OPERATION..................................................................................................................128
		14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................................................................................128
			14.1.1 FUEL AND LUBRICANTS..........................................................................................................128
			14.1.2 COOLANT......................................................................................................................128
			14.1.3 BATTERY......................................................................................................................129
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK...............................................................................................130
		14.3 AFTER COLD WEATHER.................................................................................................................130
	15. LONG-TERM STORAGE.......................................................................................................................131
		15.1 BEFORE STORAGE.....................................................................................................................131
		15.2 DURING STORAGE.....................................................................................................................132
		15.3 AFTER STORAGE......................................................................................................................132
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...........................................................................................132
	16. TROUBLESHOOTING.........................................................................................................................133
		16.1 PHENOMENA THAT ARE NOT FAILURES....................................................................................................133
		16.2 METHOD OF TOWING MACHINE...........................................................................................................133
		16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE..........................................................................................133
		16.4 PRECAUTIONS ON PARTICULAR JOBSITES.................................................................................................134
		16.5 IF BATTERY IS DISCHARGED...........................................................................................................134
			16.5.1 STARTING ENGINE WITH BOOSTER CABLE...........................................................................................135
		16.6 OTHER TROUBLE......................................................................................................................137
			16.6.1 ELECTRICAL SYSTEM............................................................................................................137
			16.6.2 CHASSIS......................................................................................................................138
			16.6.3 ENGINE.......................................................................................................................139
			16.6.4 ELECTRONIC CONTROL SYSTEM....................................................................................................141
MAINTENANCE.....................................................................................................................................142
	17. GUIDES TO MAINTENANCE...................................................................................................................143
	18. OUTLINES OF SERVICE.....................................................................................................................146
		18.1 OUTLINE OF OIL, FUEL, COOLANT......................................................................................................146
			18.1.1 OIL..........................................................................................................................146
			18.1.2 FUEL.........................................................................................................................147
			18.1.3 COOLANT......................................................................................................................147
			18.1.4 GREASE.......................................................................................................................148
			18.1.5 STORING OIL AND FUEL.........................................................................................................148
			18.1.6 FILTERS......................................................................................................................148
		18.2 OUTLINE OF ELECTRICAL SYSTEM.......................................................................................................149
		18.3 OUTLINE OF HYDRAULIC SYSTEM........................................................................................................150
	19. WEAR PARTS LIST.........................................................................................................................151
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................................................................153
		20.1 ENGINE OIL SPECIFICATION...........................................................................................................154
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................................................................................156
		21.1 INTRODUCTION OF NECESSARY TOOLS....................................................................................................156
		21.2 TORQUE LIST........................................................................................................................157
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................................................................................158
	23. MAINTENANCE SCHEDULE CHART..............................................................................................................160
		23.1 MAINTENANCE SCHEDULE CHART.........................................................................................................160
		23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER..................................................................................162
	24. SERVICE PROCEDURE.......................................................................................................................163
		24.1 INITIAL 250 HOURS SERVICE..........................................................................................................163
		24.2 WHEN REQUIRED......................................................................................................................164
			24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.................................................................................164
			24.2.2 CLEAN INSIDE OF COOLING SYSTEM (2 years or 2000 hours whichever occurs first)................................................166
			24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS...........................................................................................170
			24.2.4 CHECK AND ADJUST TRACK TENSION...............................................................................................171
			24.2.5 CHECK ENGINE INTAKE AIR HEATER (ELECTRICAL)..................................................................................173
			24.2.6 INSTALLATION OF BUCKET TEETH (ESCO VERTALOK® TYPE)...........................................................................174
			24.2.7 INSTALLATION OF BUCKET TEETH (ESCO SUPERV ® TYPE)............................................................................177
			24.2.8 REMOVAL OF BUCKET TEETH (ESCO VERTALOK® TYPE)................................................................................179
			24.2.9 REMOVAL OF BUCKET TEETH (ESCO SUPERV ® TYPE).................................................................................181
			24.2.10 ADJUST BUCKET CLEARANCE.....................................................................................................183
			24.2.11 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................184
			24.2.12 CHECK AND ADJUST AIR CONDITIONER............................................................................................185
			24.2.13 REPLACE ADDITIONAL BREAKER FILTER ELEMENT...................................................................................186
			24.2.14 CLEAN INLINE FILTER (CYLINDRICAL HOUSING)...................................................................................187
			24.2.15 CLEAN INLINE FILTER (RECTANGULAR HOUSING)...................................................................................188
		24.3 CHECK BEFORE STARTING..............................................................................................................189
			24.3.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................................................................189
			24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...................................................................................189
			24.3.3 CHECK FUEL LEVEL, ADD FUEL...................................................................................................190
			24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...................................................................................191
			24.3.5 CHECK AIR CLEANER FOR CLOGGING...............................................................................................191
			24.3.6 CHECK ELECTRIC WIRING........................................................................................................192
			24.3.7 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR, DRAIN WATER AND SEDIMENT.........................................................192
		24.4 EVERY 100 HOURS SERVICE............................................................................................................193
			24.4.1 LUBRICATING..................................................................................................................193
			24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.............................................................................195
			24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK......................................................................................195
		24.5 EVERY 250 HOURS SERVICE............................................................................................................196
			24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................196
			24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE...........................................................................................197
			24.5.3 REPLACE HYDRAULIC FILTER ELEMENT.............................................................................................198
			24.5.4 LUBRICATE SWING CIRCLE PC200, 200LC, 210LC, 220LC: 2 POINTS PC250: 3 POINTS..................................................199
			24.5.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST........................................................................200
			24.5.6 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE............................................................201
		24.6 EVERY 500 HOURS SERVICE............................................................................................................202
			24.6.1 REPLACE FUEL FILTER CARTRIDGE................................................................................................202
			24.6.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE..................................................................................204
			24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AC....205
			24.6.4 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)..........206
			24.6.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT......................................................................................206
		24.7 EVERY 1000 HOURS SERVICE...........................................................................................................207
			24.7.1 CHANGE OIL IN SWING MACHINERY CASE...........................................................................................207
			24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................................208
			24.7.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...................................................................................208
			24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR.............................................................................................208
			24.7.5 CHECK AND ADJUST VALVE CLEARANCE.............................................................................................209
			24.7.6 CHECK FAN BELT TENSIONER BEARING, BELT AND FAN HUB...........................................................................210
			24.7.7 CHECK FAN BELT TENSION.......................................................................................................210
		24.8 EVERY 2000 HOURS SERVICE...........................................................................................................211
			24.8.1 CHANGE OIL IN FINAL DRIVE CASE...............................................................................................211
			24.8.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.................................................................................212
			24.8.3 CLEAN, CHECK TURBOCHARGER....................................................................................................215
			24.8.4 CHECK ALTERNATOR, STARTING MOTOR.............................................................................................215
			24.8.5 CHECK VIBRATION DAMPER.......................................................................................................215
			24.8.6 CHANGE ANTIFREEZE............................................................................................................215
			24.8.7 CHECK AND ADJUST VALVE CLEARANCE.............................................................................................215
		24.9 EVERY 4000 HOURS SERVICE...........................................................................................................216
			24.9.1 CHECK WATER PUMP.............................................................................................................216
SPECIFICATIONS..................................................................................................................................217
	25. SPECIFICATIONS..........................................................................................................................218
OPTIONS, ATTACHMENTS............................................................................................................................225
	26. GENERAL PRECAUTIONS.....................................................................................................................226
		26.1 PRECAUTIONS RELATED TO SAFETY......................................................................................................226
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS............................................................................................227
	27. HANDLING BUCKET WITH HOOK...............................................................................................................228
		27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK...............................................................................................228
		27.2 PROHIBITED OPERATIONS..............................................................................................................228
		27.3 PRECAUTIONS DURING OPERATIONS......................................................................................................228
	28. HANDLING AIR CONDITIONER................................................................................................................229
		28.1 GENERAL LOCATIONS ON CONTROL PANEL.................................................................................................229
		28.2 PRECAUTIONS WHEN USING AIR CONDITIONER.............................................................................................231
	29. MACHINES READY FOR ATTACHMENTS..........................................................................................................232
		29.1 EXPLANATION OF COMPONENTS..........................................................................................................232
		29.2 HYDRAULIC CIRCUIT..................................................................................................................234
			29.2.1 CONNECTING HYDRAULIC CIRCUIT.................................................................................................235
		29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE..........................................................................................236
		29.4 OPERATION..........................................................................................................................238
		29.5 LONG-TERM STORAGE..................................................................................................................239
		29.6 SPECIFICATIONS.....................................................................................................................239
	30. INTRODUCTION OF ATTACHMENTS.............................................................................................................240
		30.1 BUCKET SELECTION...................................................................................................................240
		30.2 BUCKET INSTALLATION COMBINATIONS...................................................................................................240
		30.3 SELECTION OF TRACK SHOES...........................................................................................................245
		30.4 BACKHOE CONTROL PATTERN CONVERSION.................................................................................................246
	31. EXTENDING MACHINE SERVICE LIFE..........................................................................................................247
		31.1 HYDRAULIC BREAKER..................................................................................................................247
		31.2 CRUSHER............................................................................................................................250
		31.3 GRAPPLE............................................................................................................................251
		31.4 BUCKET WITH THUMB GRAPPLE..........................................................................................................252
		31.5 ROTATING GRAPPLE...................................................................................................................253
		31.6 SHEAR..............................................................................................................................254
		31.7 HYDRAULIC PILE DRIVER..............................................................................................................255

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