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Komatsu PC200LC-8 PC220LC-8 Excavator Operator Manual (SN A88001+) PDF
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- KOMATSU PC200LC-8 PC220LC-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual
- SERIAL NUMBER:A88001 and UP
- PUBLICATION NUMBER:CEAM007102
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Description
KOMATSU PC200LC-8 PC220LC-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual (SN:A88001 and UP)
KOMATSU PC200LC-8 PC220LC-8 HYDRAULIC EXCAVATOR OPERATION AND MAINTENANCE MANUAL (SN:A88001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC200LC-8 PC220LC-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual (SN:A88001 and UP)
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
● Read this manual thoroughly and understand its contents fully.
● Read the safety messages and safety labels given in this manual carefully so that they are understood fully.
● Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically.
● In case this manual is lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
● When you sell the machine, make sure that this manual is provided to the new owner together with the machine.
● In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in the past are also displayed in ( ).
TABLE OF CONTENTS:
KOMATSU PC200LC-8 PC220LC-8 HYDRAULIC EXCAVATOR Operation and Maintenance Manual (SN:A88001 and UP)
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..................................................................................................................................................... 22 Location of Safety Labels..................................................................................................................................... 22 Safety Labels................................................................................................................................................. 24 SAFETY INFORMATION................................................................................................................................................ 30 Understanding the Machine..................................................................................................................................... 30 Precautions Regarding Safety-related Equipment................................................................................................................ 30 Safety Rules.................................................................................................................................................. 30 If Problems Are Found......................................................................................................................................... 30 Clothing and Personal Protective Items........................................................................................................................ 31 Fire Extinguisher and First Aid Kit........................................................................................................................... 31 Safety Equipment.............................................................................................................................................. 31 Keep Machine Clean............................................................................................................................................ 31 Keep Operator's Compartment Clean............................................................................................................................. 32 Leaving Operator's Seat with Lock............................................................................................................................. 32 Handrails and Steps........................................................................................................................................... 33 Mounting and Dismounting...................................................................................................................................... 33 No Persons on Attachments..................................................................................................................................... 33 Do Not Get Caught in Work Equipment........................................................................................................................... 34 Burn Prevention............................................................................................................................................... 34 Hot coolant............................................................................................................................................... 34 Hot oil................................................................................................................................................... 34 Fire Prevention and Explosion Prevention...................................................................................................................... 35 Action if Fire Occurs......................................................................................................................................... 35 Windshield Washer Fluid....................................................................................................................................... 36 Falling Objects, Flying Objects and Intruding Objects Prevention.............................................................................................. 36 Attachment Installation....................................................................................................................................... 36 Attachment Combinations....................................................................................................................................... 36 Cab Window Glasses............................................................................................................................................ 36 Unauthorized Modifications.................................................................................................................................... 37 Safety at Jobsite............................................................................................................................................. 37 Working On Loose Ground....................................................................................................................................... 37 Distance to High Voltage Cables............................................................................................................................... 37 Ensure Good Visibility........................................................................................................................................ 38 Ventilation for Enclosed Area................................................................................................................................. 38 Signalman's Signal and Signs.................................................................................................................................. 38 Emergency Exit from Operator's Cab............................................................................................................................ 39 Asbestos Dust Hazard Prevention............................................................................................................................... 39 SAFETY MACHINE OPERATION.......................................................................................................................................... 40 Starting Engine............................................................................................................................................... 40 Checks Before Starting Engine............................................................................................................................. 40 Safety Rules for Starting Engine.......................................................................................................................... 41 Starting Engine in Cold Weather........................................................................................................................... 41 Operation..................................................................................................................................................... 42 Checks Before Operation................................................................................................................................... 42 Safety Rules for Changing Machine Directions.............................................................................................................. 42 Safety Rules for Traveling................................................................................................................................ 43 Traveling on Slopes....................................................................................................................................... 44 Operations on Slopes...................................................................................................................................... 45 Prohibited Operations..................................................................................................................................... 45 Operations on Snow........................................................................................................................................ 47 Parking Machine........................................................................................................................................... 47 TRANSPORTATION.................................................................................................................................................... 48 Loading and Unloading......................................................................................................................................... 48 Shipping the Machine.......................................................................................................................................... 48 BATTERY........................................................................................................................................................... 49 Battery Hazard Prevention..................................................................................................................................... 49 Starting Engine with Booster Cables........................................................................................................................... 50 TOWING............................................................................................................................................................ 51 Safety Rules for Towing....................................................................................................................................... 51 LIFTING OBJECTS WITH BUCKET....................................................................................................................................... 52 Safety Rules for Lifting Objects.............................................................................................................................. 52 SAFETY MAINTENANCE INFORMATION.................................................................................................................................... 53 Warning Tag................................................................................................................................................... 53 Keep Work Place Clean and Tidy................................................................................................................................ 53 Appoint Leader When Working With Others....................................................................................................................... 53 Precautions When Working at High Places....................................................................................................................... 53 Stop Engine Before Carrying Out Maintenance................................................................................................................... 54 Two Workers for Maintenance When Engine Is Running............................................................................................................ 55 Proper Tools.................................................................................................................................................. 55 Accumulator................................................................................................................................................... 55 Handling Gas Spring........................................................................................................................................... 56 Precautions when using.................................................................................................................................... 56 Precautions when discarding............................................................................................................................... 56 Personnel..................................................................................................................................................... 56 Attachments................................................................................................................................................... 57 Work Under the Machine........................................................................................................................................ 57 Noise......................................................................................................................................................... 57 When using Hammer............................................................................................................................................. 57 Welding....................................................................................................................................................... 58 Removing Battery Terminals.................................................................................................................................... 58 Safety First when using High-pressure Grease to Adjust Track Tension.......................................................................................... 58 Do Not Disassemble Recoil Springs............................................................................................................................. 58 Safety Rules for High-pressure Oil............................................................................................................................ 59 Precaution for High Fuel Pressure......................................................................................................................... 59 Safety Handling High-Pressure Hoses....................................................................................................................... 59 Precaution for High Voltage................................................................................................................................... 60 Waste Materials............................................................................................................................................... 60 Mercury Containing Component(s)............................................................................................................................... 60 Air Conditioner Maintenance................................................................................................................................... 60 Compressed Air................................................................................................................................................ 60 Periodic Replacement of Safety Critical Parts................................................................................................................. 60 OPERATION............................................................................................................................................................. 61 MACHINE VIEW ILLUSTRATIONS........................................................................................................................................ 62 Overall Machine View.......................................................................................................................................... 62 CONTROLS AND GAUGES............................................................................................................................................... 63 Machine Monitors.............................................................................................................................................. 64 DETAILED CONTROLS AND GAUGES...................................................................................................................................... 65 Monitoring System............................................................................................................................................. 65 Basic Operation of Machine Monitor........................................................................................................................ 66 Emergency Monitors........................................................................................................................................ 71 Caution Monitors.......................................................................................................................................... 73 Basic Check Monitors...................................................................................................................................... 76 Meter Display Portion..................................................................................................................................... 78 Pilot Display............................................................................................................................................. 78 Gauges and Meter.......................................................................................................................................... 81 Function Switches......................................................................................................................................... 93 Handling Function Switches................................................................................................................................ 94 Service Meter/Clock Display Selector Switch...............................................................................................................101 Maintenance Selector Switch...............................................................................................................................102 User Mode Selector Switch.................................................................................................................................105 SWITCHES..........................................................................................................................................................135 CONTROL LEVERS AND PEDALS.........................................................................................................................................140 SUN ROOF..........................................................................................................................................................143 WINDSHIELD........................................................................................................................................................143 EMERGENCY ESCAPE HAMMER...........................................................................................................................................149 DOOR LOCK.........................................................................................................................................................150 COVER WITH LOCK...................................................................................................................................................150 CAP WITH LOCK.....................................................................................................................................................151 DRINK BOX.........................................................................................................................................................152 MAGAZINE BOX......................................................................................................................................................152 ASHTRAY...........................................................................................................................................................152 AIR CONDITIONER CONTROLS..........................................................................................................................................153 Air Conditioner Control Panel.................................................................................................................................153 Method of Operation...........................................................................................................................................158 Automatic Operation.......................................................................................................................................158 Stopping Automatic Operation..............................................................................................................................159 Manual Operation..........................................................................................................................................159 Stopping Manual Operation.................................................................................................................................161 Operation with Cold Air to Face and Warm Air to Feet......................................................................................................161 Defroster Operation.......................................................................................................................................163 Use Air Conditioner with Care.................................................................................................................................165 Air Conditioner Maintenance...................................................................................................................................165 RADIO.............................................................................................................................................................166 Control Panel.................................................................................................................................................166 Controls of Radio.............................................................................................................................................168 Preset Station Buttons....................................................................................................................................168 Method of Operating Mode..................................................................................................................................169 Setting Correct Time......................................................................................................................................169 Use Radio with Care...........................................................................................................................................170 AUXILIARY ELECTRIC POWER..........................................................................................................................................171 24 V power source.............................................................................................................................................171 12 V power source.............................................................................................................................................171 FUSE..............................................................................................................................................................172 FUSIBLE LINK......................................................................................................................................................173 CONTROLLER........................................................................................................................................................173 TOOL BOX..........................................................................................................................................................173 GREASE GUN HOLDER.................................................................................................................................................173 FIRE EXTINGUISHER.................................................................................................................................................174 MACHINE OPERATIONS AND CONTROLS...................................................................................................................................175 Before Starting Engine........................................................................................................................................175 Walk-Around Checks........................................................................................................................................175 Checks Before Starting....................................................................................................................................176 Adjustment................................................................................................................................................184 Seat Belt Inspection..........................................................................................................................................190 Operations Before Starting Engine.............................................................................................................................192 STARTING ENGINE...................................................................................................................................................194 Turbo Protect Function........................................................................................................................................197 AFTER STARTING ENGINE.............................................................................................................................................198 Breaking-in the New Machine...................................................................................................................................199 Engine Warm Up................................................................................................................................................199 Hydraulic System Warm-Up......................................................................................................................................202 Operation after Completion of Warming-Up Operation............................................................................................................208 STOPPING THE ENGINE...............................................................................................................................................210 MACHINE OPERATION.................................................................................................................................................211 Preparations for Moving the Machine...........................................................................................................................211 Moving Machine Forward........................................................................................................................................212 Moving Machine Backward.......................................................................................................................................213 Stopping Machine..............................................................................................................................................214 STEERING THE MACHINE..............................................................................................................................................215 Steering......................................................................................................................................................215 Steering the Machine when Stopped.........................................................................................................................215 Changing Direction of the Machine.........................................................................................................................216 Counter-Rotation Turn (Spin Turn).........................................................................................................................216 SWINGING..........................................................................................................................................................217 WORK EQUIPMENT CONTROLS AND OPERATIONS............................................................................................................................218 WORKING MODE......................................................................................................................................................220 Working Mode Switch...........................................................................................................................................220 One-Touch Power Max. Switch...................................................................................................................................221 PROHIBITED OPERATIONS.............................................................................................................................................222 GENERAL OPERATION INFORMATION.....................................................................................................................................224 Traveling.....................................................................................................................................................224 High Speed Travel.............................................................................................................................................224 Permissible Water Depth.......................................................................................................................................225 TRAVELING ON SLOPES...............................................................................................................................................226 ESCAPE FROM MUD...................................................................................................................................................228 Track on One Side Stuck.......................................................................................................................................228 Tracks on Both Sides Stuck....................................................................................................................................228 RECOMMENDED APPLICATIONS..........................................................................................................................................229 Backhoe Work..................................................................................................................................................229 Shovel Work...................................................................................................................................................229 Ditching Work.................................................................................................................................................229 Loading Work..................................................................................................................................................230 BUCKET REPLACEMENT AND INVERSION..................................................................................................................................231 Replacement...................................................................................................................................................231 Inversion.....................................................................................................................................................233 PARKING MACHINE...................................................................................................................................................235 MACHINE INSPECTION AFTER DAILY WORK...............................................................................................................................237 LOCKING...........................................................................................................................................................237 TRANSPORTATION....................................................................................................................................................237 Transportation Procedure......................................................................................................................................237 Loading and Unloading with Trailer............................................................................................................................238 Loading...................................................................................................................................................239 Securing Machine..........................................................................................................................................242 Stowing Radio Antenna.....................................................................................................................................243 Rearview Mirrors..........................................................................................................................................243 Unloading.................................................................................................................................................245 LONG DISTANCE TRANSPORT MODE......................................................................................................................................247 Normal Mode Display...........................................................................................................................................247 Long Distance Transport Mode Display..........................................................................................................................247 LIFTING MACHINE...................................................................................................................................................249 Standard Specification Machine................................................................................................................................249 COLD WEATHER OPERATION............................................................................................................................................251 Cold Weather Operation Information............................................................................................................................251 Fuel and Lubricants.......................................................................................................................................251 Cooling System Coolant....................................................................................................................................251 Battery...................................................................................................................................................252 AFTER DAILY WORK COMPLETION.......................................................................................................................................253 AFTER COLD WEATHER SEASON.........................................................................................................................................253 LONG TERM STORAGE.................................................................................................................................................254 Before Storage................................................................................................................................................254 During Storage................................................................................................................................................254 After Storage.................................................................................................................................................255 Starting Machine after Long-Term Storage......................................................................................................................255 TROUBLES AND ACTIONS..............................................................................................................................................256 Running out of Fuel...........................................................................................................................................256 Phenomena that are Not Failures...............................................................................................................................256 Towing the Machine............................................................................................................................................257 Lightweight Towing Hole.......................................................................................................................................258 Severe Job Condition..........................................................................................................................................258 Discharged Battery............................................................................................................................................259 Battery Removal and Installation..........................................................................................................................259 Battery Charges...........................................................................................................................................260 Starting Engine with Booster Cables.......................................................................................................................261 OTHER TROUBLE.....................................................................................................................................................263 Electrical System.............................................................................................................................................263 Chassis.......................................................................................................................................................264 Engine........................................................................................................................................................265 Electronic Control System.....................................................................................................................................266 Point of Contact to Telephone when Error Occurs...........................................................................................................267 MAINTENANCE...........................................................................................................................................................269 MAINTENANCE INFORMATION...........................................................................................................................................270 OUTLINE OF SERVICE................................................................................................................................................272 Handling Oil, Fuel, Coolant, and Performing Oil Clinic........................................................................................................272 Oil.......................................................................................................................................................272 Fuel......................................................................................................................................................273 Coolant and Water for Dilution............................................................................................................................273 Grease....................................................................................................................................................274 Carrying Out KOWA (Komatsu Oil Wear Analysis).............................................................................................................274 Storing Oil and Fuel......................................................................................................................................275 Filters...................................................................................................................................................275 Electric System Maintenance...................................................................................................................................275 WEAR PARTS........................................................................................................................................................276 Wear Parts List...............................................................................................................................................276 RECOMMENDED FUEL, COOLANT, AND LUBRICANT..........................................................................................................................277 Recommended Brands, Recommended Quality for products other than Komatsu Genuine Oil...........................................................................279 TORQUE SPECIFICATIONS.............................................................................................................................................280 Torque List...................................................................................................................................................280 Torque of Bolts...........................................................................................................................................280 Torque of Hose Nuts.......................................................................................................................................281 Torque of Split Flange Bolts..............................................................................................................................281 Torque for Flared Nuts....................................................................................................................................282 Torque for O-ring Boss Piping Joints......................................................................................................................282 Torque for O-ring Boss Plugs..............................................................................................................................283 Torque for Hoses (Taper Seal Type and Face Seal Type).....................................................................................................283 SAFETY CRITICAL PARTS.............................................................................................................................................284 Safety Critical Parts List....................................................................................................................................285 MAINTENANCE SCHEDULE..............................................................................................................................................286 Maintenance Schedule Chart....................................................................................................................................286 Maintenance Interval for Hydraulic Breaker....................................................................................................................288 MAINTENANCE PROCEDURE.............................................................................................................................................289 Initial Ten Hours Maintenance.................................................................................................................................289 Initial 250 Hours Maintenance (Only After the First 250 Hours)................................................................................................289 Initial 500 Hours Maintenance (Only After the First 500 Hours)................................................................................................289 When Required.................................................................................................................................................290 Check, Clean and Replace Air Cleaner Element..............................................................................................................290 Clean Inside of Cooling System............................................................................................................................297 Check and Tighten Track Shoe Bolts........................................................................................................................301 Check and Adjust Track Tension............................................................................................................................302 Replace Bucket Teeth (Vertical Pin Type)..................................................................................................................304 Replace Bucket Teeth (Horizontal Pin Type)................................................................................................................307 Adjust Bucket Clearance...................................................................................................................................309 Check Window Washer Fluid Level, Add Fluid................................................................................................................310 Check and Maintenance Air Conditioner.....................................................................................................................311 Wash Washable Floor.......................................................................................................................................312 Check Gas Spring..........................................................................................................................................316 Bleeding Air from Hydraulic System........................................................................................................................317 Check Before Starting.........................................................................................................................................319 Every 100 Hours Maintenance...................................................................................................................................320 Lubricating...............................................................................................................................................320 Every 250 Hours Maintenance...................................................................................................................................322 Check Level of Battery Electrolyte........................................................................................................................322 Check Air Conditioner Compressor Belt Tension, Adjust.....................................................................................................324 Every 500 Hours Maintenance...................................................................................................................................326 Lubricating...............................................................................................................................................326 Change Oil in Engine Oil Pan..............................................................................................................................328 Replace Engine Oil Filter Cartridge.......................................................................................................................328 Replace Fuel Pre-Filter Cartridge.........................................................................................................................330 Check Swing Pinion Grease Level, Add Grease...............................................................................................................332 Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins (Only Machines Equipped With Air Conditioner)....333 Clean Air Conditioner Fresh/Recirc Filters................................................................................................................336 Replace Breather Element in Hydraulic Tank................................................................................................................337 Check Oil Level in Swing Machinery Case, Add Oil..........................................................................................................338 Check Oil Level in Final Drive Case, Add Oil..............................................................................................................339 Every 1000 Hours Maintenance..................................................................................................................................340 Replace Hydraulic Oil Filter Element......................................................................................................................340 Change Oil in Swing Machinery Case........................................................................................................................341 Check Oil Level in Damper Case, Add Oil...................................................................................................................342 Replace Fuel Main Filter Cartridge........................................................................................................................343 Check All Tightening Points of Engine Exhaust Pipe Clamps.................................................................................................345 Check Fan Belt Tension and Replace Fan Belt...............................................................................................................345 Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)...........................................................................................345 Every 2000 Hours Maintenance..................................................................................................................................346 Change Oil in Final Drive Case............................................................................................................................346 Clean Hydraulic Tank Strainer.............................................................................................................................347 Checking Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit).............................................................................348 Check Alternator..........................................................................................................................................351 Check Engine Valve Clearance, Adjust......................................................................................................................351 Every 4000 Hours Maintenance..................................................................................................................................352 Check Water Pump..........................................................................................................................................352 Check Vibration Damper....................................................................................................................................352 Check Starting Motor......................................................................................................................................352 Replace Accumulator (for Control Circuit).................................................................................................................353 Check for Looseness of High-pressure Piping Clamp, Hardening Of Rubber....................................................................................354 Check for Missing Fuel Spray Prevention Cap, Hardening Of Rubber..........................................................................................354 Check Operating Condition of Compressor...................................................................................................................355 Every 5000 Hours Maintenance..................................................................................................................................356 Change Oil in Hydraulic Tank..............................................................................................................................356 Every 8000 Hours Maintenance..................................................................................................................................357 Replace Fuel Spray Prevention Cap.........................................................................................................................357 Replace High-pressure Piping Clamp........................................................................................................................357 SPECIFICATIONS........................................................................................................................................................359 SPECIFICATIONS....................................................................................................................................................360 OPTIONS, ATTACHMENTS..................................................................................................................................................363 GENERAL PRECAUTIONS FOR SAFETY....................................................................................................................................364 Precautions when selecting....................................................................................................................................364 Read the Instruction Manual Thoroughly........................................................................................................................364 Precautions when Removing or Installing.......................................................................................................................364 Precautions When Using........................................................................................................................................364 BUCKET WITH HOOK..................................................................................................................................................365 Hook Condition................................................................................................................................................365 Prohibited Operations.........................................................................................................................................365 MACHINE READY FOR ATTACHMENT......................................................................................................................................366 Locations.....................................................................................................................................................366 Stop Valve................................................................................................................................................366 Selector Valve............................................................................................................................................367 Attachment Control Pedal..................................................................................................................................367 Lock Pin..................................................................................................................................................368 Breaker Circuit Additional Oil Filter.....................................................................................................................368 Accumulator...............................................................................................................................................369 HYDRAULIC CIRCUIT.................................................................................................................................................370 Switching Hydraulic Circuit...................................................................................................................................370 Adjusting Oil Flow............................................................................................................................................370 Switching Between Breaker and General Attachment..........................................................................................................370 Hydraulic Circuit Connection..................................................................................................................................371 Oil Flow Path.................................................................................................................................................372 Replace Additional Breaker Filter Element.....................................................................................................................373 Replace Additional Breaker Pilot Filter Element...............................................................................................................376 ATTACHMENT REMOVAL AND INSTALLATION...............................................................................................................................379 Attachment Removal............................................................................................................................................379 Attachment Installation.......................................................................................................................................381 ATTACHMENT OPERATIONS.............................................................................................................................................383 When Using Breaker............................................................................................................................................383 When Using General Attachment such as Crusher.................................................................................................................385 LONG TERM STORAGE.................................................................................................................................................387 Specifications................................................................................................................................................387 Attachment Guide..............................................................................................................................................388 Attachment Combinations.......................................................................................................................................388 TRACK SHOES SELECTION.............................................................................................................................................391 BUCKET TEETH SELECTION............................................................................................................................................392 Selection Guide for Horizontal or Vertical Pin Type Tooth.....................................................................................................392 TRAPEZOIDAL BUCKET................................................................................................................................................393 HANDLING EXTENSION ARM............................................................................................................................................395 HANDLING CLAMSHELL BUCKET.........................................................................................................................................396 RECOMMENDED ATTACHMENT OPERATIONS.................................................................................................................................397 Hydraulic Breaker.............................................................................................................................................397 Prohibited Works..............................................................................................................................................399 HANDLING MACHINES EQUIPPED WITH KOMTRAX...........................................................................................................................402 Basic Precautions.............................................................................................................................................402
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