Komatsu Pc200Lc-8 Latin America Crawler Excavator Operation & Maintenance Manual SN A90301 and Up – DOWNLOAD

Description

Komatsu Pc200Lc-8 Latin America Crawler Excavator Operation & Maintenance Manual

DESCRIPTION:

Komatsu Pc200Lc-8 Latin America Crawler Excavator Operation & Maintenance Manual 

FOREWORD:

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.

KOMATSU PC200LC-8 LATIN AMERICA CRAWLER EXCAVATOR OPERATION & MAINTENANCE MANUAL SN A90301 AND UP – DOWNLOAD:

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TABLE OF CONTENTS:

Komatsu Pc200Lc-8 Latin America Crawler Excavator Operation & Maintenance Manual 

COVER.................................................................................................................................................................  0
INTRODUCTION..........................................................................................................................................................  3
	FORWARD...........................................................................................................................................................  4
	SAFETY INFORMATION................................................................................................................................................  5
	INTRODUCTION......................................................................................................................................................  7
		Directions of Machine.........................................................................................................................................  7
		Visibility from Operator's Seat...............................................................................................................................  7
		Breaking-in the New Machine...................................................................................................................................  8
		Product Information...........................................................................................................................................  9
			Product Identification Number (Pin) / Machine Serial No. Plate............................................................................................  9
			EPA* Regulations, Engine Number Plate.....................................................................................................................  9
		Service Meter Location........................................................................................................................................ 10
		Your Machine Serial Numbers and Distributor................................................................................................................... 10
		TABLE OF CONTENTS............................................................................................................................................. 11
SAFETY................................................................................................................................................................ 21
	SAFETY LABELS..................................................................................................................................................... 23
		Location of Safety Labels..................................................................................................................................... 23
		Safety Labels................................................................................................................................................. 25
	SAFETY INFORMATION................................................................................................................................................ 31
		Understanding the Machine..................................................................................................................................... 31
		Precautions Regarding Safety-related Equipment................................................................................................................ 31
		Safety Rules.................................................................................................................................................. 31
		If Problems Are Found......................................................................................................................................... 31
		Clothing and Personal Protective Items........................................................................................................................ 32
		Fire Extinguisher and First Aid Kit........................................................................................................................... 32
		Safety Equipment.............................................................................................................................................. 32
		Keep Machine Clean............................................................................................................................................ 32
		Keep Operator's Compartment Clean............................................................................................................................. 33
		Leaving Operator's Seat with Lock............................................................................................................................. 33
		Handrails and Steps........................................................................................................................................... 34
		Mounting and Dismounting...................................................................................................................................... 34
		No Persons on Attachments..................................................................................................................................... 34
		Do Not Get Caught in Work Equipment........................................................................................................................... 35
		Burn Prevention............................................................................................................................................... 35
			Hot coolant............................................................................................................................................... 35
			Hot oil................................................................................................................................................... 35
		Fire Prevention and Explosion Prevention...................................................................................................................... 36
		Action if Fire Occurs......................................................................................................................................... 36
		Windshield Washer Fluid....................................................................................................................................... 37
		Falling Objects, Flying Objects and Intruding Objects Prevention.............................................................................................. 37
		Attachment Installation....................................................................................................................................... 37
		Attachment Combinations....................................................................................................................................... 37
		Cab Window Glasses............................................................................................................................................ 37
		Unauthorized Modifications.................................................................................................................................... 38
		Safety at Jobsite............................................................................................................................................. 38
		Working On Loose Ground....................................................................................................................................... 38
		Distance to High Voltage Cables............................................................................................................................... 38
		Ensure Good Visibility........................................................................................................................................ 39
		Ventilation for Enclosed Area................................................................................................................................. 39
		Signalman's Signal and Signs.................................................................................................................................. 39
		Emergency Exit from Operator's Cab............................................................................................................................ 40
		Asbestos Dust Hazard Prevention............................................................................................................................... 40
	SAFETY MACHINE OPERATION.......................................................................................................................................... 41
		Starting Engine............................................................................................................................................... 41
			Checks Before Starting Engine............................................................................................................................. 41
			Safety Rules for Starting Engine.......................................................................................................................... 42
			Starting Engine in Cold Weather........................................................................................................................... 42
		Operation..................................................................................................................................................... 43
			Checks Before Operation................................................................................................................................... 43
			Safety Rules for Changing Machine Directions.............................................................................................................. 43
			Safety Rules for Traveling................................................................................................................................ 44
			Traveling on Slopes....................................................................................................................................... 45
			Operations on Slopes...................................................................................................................................... 46
			Prohibited Operations..................................................................................................................................... 46
			Operations on Snow........................................................................................................................................ 48
			Parking Machine........................................................................................................................................... 48
	TRANSPORTATION.................................................................................................................................................... 49
		Loading and Unloading......................................................................................................................................... 49
		Shipping the Machine.......................................................................................................................................... 49
	BATTERY........................................................................................................................................................... 50
		Battery Hazard Prevention..................................................................................................................................... 50
		Starting Engine with Booster Cables........................................................................................................................... 51
	TOWING............................................................................................................................................................ 52
		Safety Rules for Towing....................................................................................................................................... 52
	LIFTING OBJECTS WITH BUCKET....................................................................................................................................... 53
		Safety Rules for Lifting Objects.............................................................................................................................. 53
	SAFETY MAINTENANCE INFORMATION.................................................................................................................................... 54
		Warning Tag................................................................................................................................................... 54
		Keep Work Place Clean and Tidy................................................................................................................................ 54
		Appoint Leader When Working With Others....................................................................................................................... 54
		Precautions When Working at High Places....................................................................................................................... 54
		Stop Engine Before Carrying Out Maintenance................................................................................................................... 55
		Two Workers for Maintenance When Engine Is Running............................................................................................................ 56
		Proper Tools.................................................................................................................................................. 56
		Accumulator................................................................................................................................................... 56
		Handling Gas Spring........................................................................................................................................... 57
			Precautions when using.................................................................................................................................... 57
			Precautions when discarding............................................................................................................................... 57
		Personnel..................................................................................................................................................... 57
		Attachments................................................................................................................................................... 58
		Work Under the Machine........................................................................................................................................ 58
		Noise......................................................................................................................................................... 58
		When using Hammer............................................................................................................................................. 58
		Welding....................................................................................................................................................... 59
		Removing Battery Terminals.................................................................................................................................... 59
		Safety First when using High-pressure Grease to Adjust Track Tension.......................................................................................... 59
		Do Not Disassemble Recoil Springs............................................................................................................................. 59
		Safety Rules for High-pressure Oil............................................................................................................................ 60
			Precaution for High Fuel Pressure......................................................................................................................... 60
			Safety Handling High-Pressure Hoses....................................................................................................................... 60
		Precaution for High Voltage................................................................................................................................... 61
		Waste Materials............................................................................................................................................... 61
		Mercury Containing Component(s)............................................................................................................................... 61
		Air Conditioner Maintenance................................................................................................................................... 61
		Compressed Air................................................................................................................................................ 61
		Periodic Replacement of Safety Critical Parts................................................................................................................. 61
OPERATION............................................................................................................................................................. 63
	MACHINE VIEW ILLUSTRATIONS........................................................................................................................................ 64
		Overall Machine View.......................................................................................................................................... 64
	CONTROLS AND GAUGES............................................................................................................................................... 65
		Machine Monitors.............................................................................................................................................. 66
	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
			Pilot Display............................................................................................................................................. 80
			Gauges and Meter.......................................................................................................................................... 83
			Function Switches......................................................................................................................................... 95
			Handling Function Switches................................................................................................................................ 96
			Service Meter/Clock Display Selector Switch...............................................................................................................103
			Maintenance Selector Switch...............................................................................................................................104
			User Mode Selector Switch.................................................................................................................................107
	SWITCHES..........................................................................................................................................................137
	CONTROL LEVERS AND PEDALS.........................................................................................................................................142
	SUN ROOF..........................................................................................................................................................145
	WINDSHIELD........................................................................................................................................................145
	EMERGENCY ESCAPE HAMMER...........................................................................................................................................151
	DOOR LOCK.........................................................................................................................................................152
	COVER WITH LOCK...................................................................................................................................................152
	CAP WITH LOCK.....................................................................................................................................................153
	DRINK BOX.........................................................................................................................................................154
	MAGAZINE BOX......................................................................................................................................................154
	ASHTRAY...........................................................................................................................................................154
	AIR CONDITIONER CONTROLS..........................................................................................................................................155
		Air Conditioner Control Panel.................................................................................................................................155
		Method of Operation...........................................................................................................................................160
			Automatic Operation.......................................................................................................................................160
			Stopping Automatic Operation..............................................................................................................................161
			Manual Operation..........................................................................................................................................161
			Stopping Manual Operation.................................................................................................................................163
			Operation with Cold Air to Face and Warm Air to Feet......................................................................................................163
			Defroster Operation.......................................................................................................................................165
		Use Air Conditioner with Care.................................................................................................................................167
		Air Conditioner Maintenance...................................................................................................................................167
	RADIO.............................................................................................................................................................168
		Control Panel.................................................................................................................................................168
		Controls of Radio.............................................................................................................................................170
			Preset Station Buttons....................................................................................................................................170
			Method of Operating Mode..................................................................................................................................171
			Setting Correct Time......................................................................................................................................171
		Use Radio with Care...........................................................................................................................................172
	AUXILIARY ELECTRIC POWER..........................................................................................................................................173
		24 V power source.............................................................................................................................................173
		12 V power source.............................................................................................................................................173
	FUSE..............................................................................................................................................................174
	FUSIBLE LINK......................................................................................................................................................175
	CONTROLLER........................................................................................................................................................175
	TOOL BOX..........................................................................................................................................................175
	GREASE GUN HOLDER.................................................................................................................................................175
	FIRE EXTINGUISHER.................................................................................................................................................176
	MACHINE OPERATIONS AND CONTROLS...................................................................................................................................177
		Before Starting Engine........................................................................................................................................177
			Walk-Around Checks........................................................................................................................................177
			Checks Before Starting....................................................................................................................................178
			Adjustment................................................................................................................................................186
		Seat Belt Inspection..........................................................................................................................................192
		Operations Before Starting Engine.............................................................................................................................194
	STARTING ENGINE...................................................................................................................................................196
		Turbo Protect Function........................................................................................................................................199
	AFTER STARTING ENGINE.............................................................................................................................................200
		Breaking-in the New Machine...................................................................................................................................201
		Engine Warm Up................................................................................................................................................201
		Hydraulic System Warm-Up......................................................................................................................................204
		Operation after Completion of Warming-Up Operation............................................................................................................210
	STOPPING THE ENGINE...............................................................................................................................................212
	MACHINE OPERATION.................................................................................................................................................213
		Preparations for Moving the Machine...........................................................................................................................213
		Moving Machine Forward........................................................................................................................................214
		Moving Machine Backward.......................................................................................................................................215
		Stopping Machine..............................................................................................................................................216
	STEERING THE MACHINE..............................................................................................................................................217
		Steering......................................................................................................................................................217
			Steering the Machine when Stopped.........................................................................................................................217
			Changing Direction of the Machine.........................................................................................................................218
			Counter-Rotation Turn (Spin Turn).........................................................................................................................218
	SWINGING..........................................................................................................................................................219
	WORK EQUIPMENT CONTROLS AND OPERATIONS............................................................................................................................220
	WORKING MODE......................................................................................................................................................222
		Working Mode Switch...........................................................................................................................................222
		One-Touch Power Max. Switch...................................................................................................................................223
	PROHIBITED OPERATIONS.............................................................................................................................................224
	GENERAL OPERATION INFORMATION.....................................................................................................................................226
		Traveling.....................................................................................................................................................226
		High Speed Travel.............................................................................................................................................226
		Permissible Water Depth.......................................................................................................................................227
	TRAVELING ON SLOPES...............................................................................................................................................228
	ESCAPE FROM MUD...................................................................................................................................................230
		Track on One Side Stuck.......................................................................................................................................230
		Tracks on Both Sides Stuck....................................................................................................................................230
	RECOMMENDED APPLICATIONS..........................................................................................................................................231
		Backhoe Work..................................................................................................................................................231
		Shovel Work...................................................................................................................................................231
		Ditching Work.................................................................................................................................................231
		Loading Work..................................................................................................................................................232
	BUCKET REPLACEMENT AND INVERSION..................................................................................................................................233
		Replacement...................................................................................................................................................233
		Inversion.....................................................................................................................................................235
	PARKING MACHINE...................................................................................................................................................237
	MACHINE INSPECTION AFTER DAILY WORK...............................................................................................................................239
	LOCKING...........................................................................................................................................................239
	TRANSPORTATION....................................................................................................................................................239
		Transportation Procedure......................................................................................................................................239
		Loading and Unloading with Trailer............................................................................................................................240
			Loading...................................................................................................................................................241
			Securing Machine..........................................................................................................................................244
			Stowing Radio Antenna.....................................................................................................................................245
			Rearview Mirrors..........................................................................................................................................245
			Unloading.................................................................................................................................................247
	LONG DISTANCE TRANSPORT MODE......................................................................................................................................249
		Normal Mode Display...........................................................................................................................................249
		Long Distance Transport Mode Display..........................................................................................................................249
	LIFTING MACHINE...................................................................................................................................................251
		Standard Specification Machine................................................................................................................................251
	COLD WEATHER OPERATION............................................................................................................................................253
		Cold Weather Operation Information............................................................................................................................253
			Fuel and Lubricants.......................................................................................................................................253
			Cooling System Coolant....................................................................................................................................253
			Battery...................................................................................................................................................254
	AFTER DAILY WORK COMPLETION.......................................................................................................................................255
	AFTER COLD WEATHER SEASON.........................................................................................................................................255
	LONG TERM STORAGE.................................................................................................................................................256
		Before Storage................................................................................................................................................256
		During Storage................................................................................................................................................256
		After Storage.................................................................................................................................................257
		Starting Machine after Long-Term Storage......................................................................................................................257
	TROUBLES AND ACTIONS..............................................................................................................................................258
		Running out of Fuel...........................................................................................................................................258
		Phenomena that are Not Failures...............................................................................................................................258
		Towing the Machine............................................................................................................................................259
		Lightweight Towing Hole.......................................................................................................................................260
		Severe Job Condition..........................................................................................................................................260
		Discharged Battery............................................................................................................................................261
			Battery Removal and Installation..........................................................................................................................261
			Battery Charges...........................................................................................................................................262
			Starting Engine with Booster Cables.......................................................................................................................263
	OTHER TROUBLE.....................................................................................................................................................265
		Electrical System.............................................................................................................................................265
		Chassis.......................................................................................................................................................266
		Engine........................................................................................................................................................267
		Electronic Control System.....................................................................................................................................268
			Point of Contact to Telephone when Error Occurs...........................................................................................................269
MAINTENANCE...........................................................................................................................................................271
	MAINTENANCE INFORMATION...........................................................................................................................................272
	OUTLINE OF SERVICE................................................................................................................................................274
		Handling Oil, Fuel, Coolant, and Performing Oil Clinic........................................................................................................274
			Oil.......................................................................................................................................................274
			Fuel......................................................................................................................................................275
			Coolant and Water for Dilution............................................................................................................................275
			Grease....................................................................................................................................................276
			Carrying Out KOWA (Komatsu Oil Wear Analysis).............................................................................................................276
			Storing Oil and Fuel......................................................................................................................................277
			Filters...................................................................................................................................................277
		Electric System Maintenance...................................................................................................................................277
	WEAR PARTS........................................................................................................................................................278
		Wear Parts List...............................................................................................................................................278
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT..........................................................................................................................279
		Recommended Brands, Recommended Quality for products other than Komatsu Genuine Oil...........................................................................281
	TORQUE SPECIFICATIONS.............................................................................................................................................282
		Torque List...................................................................................................................................................282
			Torque of Bolts...........................................................................................................................................282
			Torque of Hose Nuts.......................................................................................................................................283
			Torque of Split Flange Bolts..............................................................................................................................283
			Torque for Flared Nuts....................................................................................................................................284
			Torque for O-ring Boss Piping Joints......................................................................................................................284
			Torque for O-ring Boss Plugs..............................................................................................................................285
			Torque for Hoses (Taper Seal Type and Face Seal Type).....................................................................................................285
	SAFETY CRITICAL PARTS.............................................................................................................................................286
		Safety Critical Parts List....................................................................................................................................287
	MAINTENANCE SCHEDULE..............................................................................................................................................288
		Maintenance Schedule Chart....................................................................................................................................288
		Maintenance Interval for Hydraulic Breaker....................................................................................................................290
	MAINTENANCE PROCEDURE.............................................................................................................................................291
		Initial Ten Hours Maintenance.................................................................................................................................291
		Initial 250 Hours Maintenance (Only After the First 250 Hours)................................................................................................291
		Initial 500 Hours Maintenance (Only After the First 500 Hours)................................................................................................291
		When Required.................................................................................................................................................292
			Check, Clean and Replace Air Cleaner Element..............................................................................................................292
			Clean Inside of Cooling System............................................................................................................................299
			Check and Tighten Track Shoe Bolts........................................................................................................................303
			Check and Adjust Track Tension............................................................................................................................304
			Replace Bucket Teeth (Vertical Pin Type)..................................................................................................................306
			Replace Bucket Teeth (Horizontal Pin Type)................................................................................................................309
			Adjust Bucket Clearance...................................................................................................................................311
			Check Window Washer Fluid Level, Add Fluid................................................................................................................312
			Check and Maintenance Air Conditioner.....................................................................................................................313
			Wash Washable Floor.......................................................................................................................................314
			Check Gas Spring..........................................................................................................................................318
			Bleeding Air from Hydraulic System........................................................................................................................319
		Check Before Starting.........................................................................................................................................321
		Every 100 Hours Maintenance...................................................................................................................................322
			Lubricating...............................................................................................................................................322
		Every 250 Hours Maintenance...................................................................................................................................324
			Check Level of Battery Electrolyte........................................................................................................................324
			Check Air Conditioner Compressor Belt Tension, Adjust.....................................................................................................326
		Every 500 Hours Maintenance...................................................................................................................................328
			Lubricating...............................................................................................................................................328
			Change Oil in Engine Oil Pan..............................................................................................................................330
			Replace Engine Oil Filter Cartridge.......................................................................................................................330
			Replace Fuel Pre-Filter Cartridge.........................................................................................................................332
			Check Swing Pinion Grease Level, Add Grease...............................................................................................................334
			Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins (Only Machines Equipped With Air Conditioner)....335
			Clean Air Conditioner Fresh/Recirc Filters................................................................................................................338
			Replace Breather Element in Hydraulic Tank................................................................................................................339
			Check Oil Level in Swing Machinery Case, Add Oil..........................................................................................................340
			Check Oil Level in Final Drive Case, Add Oil..............................................................................................................341
		Every 1000 Hours Maintenance..................................................................................................................................342
			Replace Hydraulic Oil Filter Element......................................................................................................................342
			Change Oil in Swing Machinery Case........................................................................................................................343
			Check Oil Level in Damper Case, Add Oil...................................................................................................................344
			Replace Fuel Main Filter Cartridge........................................................................................................................345
			Check All Tightening Points of Engine Exhaust Pipe Clamps.................................................................................................347
			Check Fan Belt Tension and Replace Fan Belt...............................................................................................................347
			Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)...........................................................................................347
		Every 2000 Hours Maintenance..................................................................................................................................348
			Change Oil in Final Drive Case............................................................................................................................348
			Clean Hydraulic Tank Strainer.............................................................................................................................349
			Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit).............................................................................350
			Check Alternator..........................................................................................................................................353
			Check Engine Valve Clearance, Adjust......................................................................................................................353
		Every 4000 Hours Maintenance..................................................................................................................................354
			Check Water Pump..........................................................................................................................................354
			Check Vibration Damper....................................................................................................................................354
			Check Starting Motor......................................................................................................................................354
			Replace Accumulator (for Control Circuit).................................................................................................................355
			Check for Looseness of High-pressure Piping Clamp, Hardening Of Rubber....................................................................................356
			Check for Missing Fuel Spray Prevention Cap, Hardening Of Rubber..........................................................................................356
			Check Operating Condition of Compressor...................................................................................................................357
		Every 5000 Hours Maintenance..................................................................................................................................358
			Change Oil in Hydraulic Tank..............................................................................................................................358
		Every 8000 Hours Maintenance..................................................................................................................................359
			Replace Fuel Spray Prevention Cap.........................................................................................................................359
			Replace High-pressure Piping Clamp........................................................................................................................359
SPECIFICATIONS........................................................................................................................................................361
	SPECIFICATIONS....................................................................................................................................................362
OPTIONS, ATTACHMENTS..................................................................................................................................................365
	GENERAL PRECAUTIONS FOR SAFETY....................................................................................................................................366
		Precautions when selecting....................................................................................................................................366
		Read the Instruction Manual Thoroughly........................................................................................................................366
		Precautions when Removing or Installing.......................................................................................................................366
		Precautions When Using........................................................................................................................................366
	BUCKET WITH HOOK..................................................................................................................................................367
		Hook Condition................................................................................................................................................367
		Prohibited Operations.........................................................................................................................................367
	MACHINE READY FOR ATTACHMENT......................................................................................................................................368
		Locations.....................................................................................................................................................368
			Stop Valve................................................................................................................................................368
			Selector Valve............................................................................................................................................369
			Attachment Control Pedal..................................................................................................................................369
			Lock Pin..................................................................................................................................................370
			Breaker Circuit Additional Oil Filter.....................................................................................................................370
			Accumulator...............................................................................................................................................371
	HYDRAULIC CIRCUIT.................................................................................................................................................372
		Switching Hydraulic Circuit...................................................................................................................................372
		Adjusting Oil Flow............................................................................................................................................372
			Switching Between Breaker and General Attachment..........................................................................................................372
		Hydraulic Circuit Connection..................................................................................................................................373
		Oil Flow Path.................................................................................................................................................374
		Replace Additional Breaker Filter Element.....................................................................................................................375
		Replace Additional Breaker Pilot Filter Element...............................................................................................................378
	ATTACHMENT REMOVAL AND INSTALLATION...............................................................................................................................381
		Attachment Removal............................................................................................................................................381
		Attachment Installation.......................................................................................................................................383
	ATTACHMENT OPERATIONS.............................................................................................................................................385
		When Using Breaker............................................................................................................................................385
		When Using General Attachment such as Crusher.................................................................................................................387
	LONG TERM STORAGE.................................................................................................................................................389
		Specifications................................................................................................................................................389
		Attachment Guide..............................................................................................................................................390
		Attachment Combinations.......................................................................................................................................390
	TRACK SHOES SELECTION.............................................................................................................................................392
	BUCKET TEETH SELECTION............................................................................................................................................393
		Selection Guide for Horizontal or Vertical Pin Type Tooth.....................................................................................................393
	TRAPEZOIDAL BUCKET................................................................................................................................................394
	HANDLING EXTENSION ARM............................................................................................................................................396
	HANDLING CLAMSHELL BUCKET.........................................................................................................................................397
	RECOMMENDED ATTACHMENT OPERATIONS.................................................................................................................................398
		Hydraulic Breaker.............................................................................................................................................398
		Prohibited Works..............................................................................................................................................400
	HANDLING MACHINES EQUIPPED WITH KOMTRAX...........................................................................................................................403
		Basic Precautions.............................................................................................................................................403

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