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Komatsu Pc200LL-7L, Pc220LL-7L Logging Excavator Operation & Maintenance Manual SN A86001 and up – PDF DOWNLOAD
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Komatsu Pc200LL-7L, Pc220LL-7L Logging Excavator Operation & Maintenance Manual
Book Code : CEAM014400
MACHINE MODEL SERIAL NUMBERS
PC200LL-7L A86001 and UP
PC220LL-7L A86001 and UP
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Description
Komatsu Pc200LL-7L, Pc220LL-7L Logging Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pc200LL-7L, Pc220LL-7L Logging Excavator Operation & Maintenance Manual
Model Specification: KOMATSU PC200LL-7L, PC220LL-7L LOGGING EXCAVATOR
Language: English
File Format: PDF
Total Pages: 294
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PC200LL-7L, PC220LL-7L LOGGING EXCAVATOR OPERATION & MAINTENANCE MANUAL SN A86001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pc200LL-7L, Pc220LL-7L Logging 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.
TABLE OF CONTENTS:
Komatsu Pc200LL-7L, Pc220LL-7L Logging Excavator Operation & Maintenance Manual
MAIN MENU.......................................................................... 0 COVER.............................................................................. 1 INTRODUCTION....................................................................... 7 FOREWORD....................................................................... 8 SAFETY INFORMATION............................................................. 9 SIGNAL WORDS............................................................... 9 OTHER SIGNAL WORDS......................................................... 9 INTRODUCTION................................................................... 10 INTENDED USE............................................................... 10 DIRECTIONS OF MACHINE.......................................................... 10 BREAKING IN THE MACHINE........................................................ 10 PRODUCT INFORMATION............................................................ 11 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION............................... 11 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................ 11 SERVICE METER LOCATION..................................................... 12 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................ 12 TABLE OF CONTENTS.................................................................. 13 SAFETY............................................................................. 23 SAFETY LABELS.................................................................. 24 POSITION FOR ATTACHING SAFETY LABELS....................................... 24 UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS............ 30 SAFETY INFORMATION............................................................. 36 SAFETY RULES............................................................... 36 IF ABNORMALITIES ARE FOUND................................................. 36 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................. 36 FIRE EXTINGUISHER AND FIRST AID KIT........................................ 36 SAFETY EQUIPMENT........................................................... 36 KEEP MACHINE CLEAN......................................................... 37 KEEP OPERATOR'S COMPARTMENT CLEAN.......................................... 37 LEAVING OPERATOR'S SEAT WITH LOCK.......................................... 37 HANDRAILS AND STEPS........................................................ 38 MOUNTING AND DISMOUNTING................................................... 38 NO PERSONS ON ATTACHMENTS.................................................. 38 BURN PREVENTION............................................................ 39 HOT COOLANT............................................................ 39 HOT OIL................................................................ 39 FIRE PREVENTION AND EXPLOSION PREVENTION................................... 39 FIRE CAUSED BY FUEL OR OIL............................................. 39 FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...................... 40 FIRE COMING FROM ELECTRIC WIRING....................................... 40 FIRE COMING FROM HYDRAULIC LINE........................................ 40 EXPLOSION CAUSED BY LIGHTING EQUIPMENT................................. 40 ACTION IF FIRE OCCURS...................................................... 40 WINDSHIELD WASHER FLUID.................................................... 40 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION........... 40 PROTECTION AGAINST FALLING OR FLYING OBJECTS............................... 41 ATTACHMENT INSTALLATION.................................................... 42 ATTACHMENT COMBINATIONS.................................................... 42 CAB WIDOW GLASS............................................................ 42 UNAUTHORIZED MODIFICATIONS................................................. 42 SAFETY AT JOBSITE.......................................................... 42 WORKING ON LOOSE GROUND.................................................... 43 DISTANCE TO HIGH VOLTAGE CABLES............................................ 43 ENSURE GOOD VISIBILITY..................................................... 44 VENTILATION FOR ENCLOSED AREA.............................................. 44 SIGNALMAN'S SIGNAL AND SIGNS............................................... 44 EMERGENCY EXIT FROM OPERATOR'S CAB......................................... 44 ASBESTOS DUST HAZARD PREVENTION............................................ 45 SAFE MACHINE OPERATION......................................................... 46 STARTING ENGINE............................................................ 46 CHECKS BEFORE STARTING ENGINE.............................................. 46 SAFETY RULES FOR STARTING ENGINE........................................... 46 STARTING ENGINE IN COLD WEATHER............................................ 46 OPERATION...................................................................... 47 CHECKS AFTER STARTING ENGINE, BEFORE OPERATION............................. 47 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS............................... 47 SAFETY RULES FOR TRAVELING................................................. 48 TRAVELING ON SLOPES........................................................ 48 OPERATIONS ON SLOPES....................................................... 49 PROHIBITED OPERATIONS...................................................... 49 OPERATIONS ON SNOW......................................................... 50 PARKING MACHINE............................................................ 51 TRANSPORTATION............................................................. 52 SHIPPING THE MACHINE....................................................... 52 BATTERY.................................................................... 53 BATTERY HAZARD PREVENTION.............................................. 53 STARTING ENGINE WITH BOOSTER CABLES.................................... 54 TOWING..................................................................... 55 SAFETY RULES FOR TOWING................................................ 55 LIFTING OBJECTS WITH BUCKET................................................ 56 SAFETY RULES FOR LIFTING OBJECTS....................................... 56 SAFETY MAINTENANCE INFORMATION................................................. 57 WARNING TAG................................................................ 57 KEEP WORK PLACE CLEAN AND TIDY............................................. 57 APPOINT LEADER WHEN WORKING WITH OTHERS.................................... 57 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................ 58 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................... 59 PROPER TOOLS............................................................... 59 ACCUMULATOR................................................................ 59 PERSONNEL.................................................................. 60 ATTACHMENTS................................................................ 60 NOISE...................................................................... 60 WELDING.................................................................... 61 REMOVING BATTERY TERMINALS................................................. 61 DO NOT DISASSEMBLE RECOIL SPRINGS.......................................... 62 SAFETY RULES FOR HIGH-PRESSURE OIL......................................... 62 SAFETY HANDLING HIGH-PRESSURE HOSES........................................ 62 WASTE MATERIALS............................................................ 63 AIR CONDITIONER MAINTENANCE................................................ 63 COMPRESSED AIR............................................................. 63 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................. 63 OPERATION.......................................................................... 65 GENERAL VIEW................................................................... 66 GENERAL VIEW OF LOG LOADER MACHINE......................................... 66 GENERAL VIEW OF ROAD BUILDER MACHINE....................................... 67 GENERAL VIEW CONTROLS AND GAUGES........................................... 68 EXPLANATION OF COMPONENTS...................................................... 69 MACHINE MONITOR............................................................ 69 BASIC OPERATION OF MACHINE MONITOR......................................... 70 IF THERE IS ABNORMALITY WHEN STARTING ENGINE........................... 70 IF ANY ABNORMALITY OCCURS DURING OPERATION............................. 71 BASIC CHECK ITEMS.......................................................... 72 RADIATOR WATER LEVEL MONITOR........................................... 72 ENGINE OIL LEVEL MONITOR............................................... 73 MAINTENANCE INTERVAL MONITOR........................................... 73 CAUTION ITEMS.............................................................. 74 CHARGE MONITOR......................................................... 74 FUEL LEVEL MONITOR..................................................... 75 AIR CLEANER CLOGGING MONITOR........................................... 75 ENGINE WATER TEMPERATURE MONITOR....................................... 75 EMERGENCY STOP ITEMS....................................................... 76 ENGINE WATER TEMPERATURE MONITOR....................................... 76 HYDRAULIC OIL TEMPERATURE MONITOR...................................... 77 ENGINE OIL PRESSURE MONITOR............................................ 77 METER DISPLAY PORTION...................................................... 78 PILOT DISPLAY.......................................................... 78 METERS................................................................. 80 MONITOR SWITCHES........................................................... 82 WORKING MODE SELECTOR SWITCH (BASIC SWITCH)............................ 83 AUTO-DECELERATION SWITCH............................................... 84 TRAVEL SPEED SELECTOR SWITCH........................................... 85 WIPER SWITCH........................................................... 86 WINDOW WASHER SWITCH................................................... 86 MAINTENANCE SWITCH..................................................... 87 SELECT SWITCH.......................................................... 89 BACK SWITCH............................................................ 90 UP SWITCH, DOWN SWITCH................................................. 90 INPUT CONFIRMATION SWITCH.............................................. 90 LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH............................... 91 SWITCHES................................................................... 94 STARTING SWITCH........................................................ 95 FUEL CONTROL DIAL...................................................... 96 CIGARETTE LIGHTER...................................................... 96 SWING LOCK SWITCH...................................................... 96 LAMP SWITCH............................................................ 97 ALARM BUZZER STOP SWITCH............................................... 97 HORN SWITCH............................................................ 97 LOG LOADER GRAPPLE ROTATION CW SWITCH.................................. 97 LOG LOADER GRAPPLE CLOSE SWITCH........................................ 97 POWER MAX SWITCH....................................................... 98 LOG LOADER GRAPPLE ROTATION CCW SWITCH................................. 98 LOG LOADER GRAPPLE OPEN SWITCH......................................... 98 ROOM LAMP SWITCH....................................................... 98 EMERGENCY PUMP DRIVE SWITCH............................................ 99 SWING BRAKE CANCEL SWITCH.............................................. 99 CONTROL LEVERS, PEDALS.....................................................100 SAFETY LOCK LEVER......................................................100 TRAVEL LEVERS..........................................................101 WORK EQUIPMENT CONTROL LEVER...........................................102 CEILING WINDOW.............................................................103 FRONT WINDOW...............................................................103 EMERGENCY EXIT FROM OPERATOR'S CAB - FROM INSIDE...........................108 EMERGENCY EXIT FROM OPERATOR'S CAB - FROM OUTSIDE..........................108 DOOR LOCK..................................................................110 CAP, COVER WITH LOCK.......................................................110 METHOD OF OPENING AND CLOSING CAP WITH LOCK............................110 METHOD OF OPENING AND CLOSING COVER WITH LOCK..........................111 HOT AND COOL BOX...........................................................111 MAGAZINE BOX WITH CUP HOLDER...............................................111 ASHTRAY....................................................................111 AIR CONDITIONER............................................................112 GENERAL LOCATION OF CONTROL PANEL......................................112 METHOD OF OPERATION....................................................116 PRECAUTIONS WHEN USING AIR CONDITIONER.................................123 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER..................123 OTHER FUNCTIONS........................................................124 CAR RADIO..................................................................125 EXPLANATION OF COMPONENTS..............................................125 METHOD OF OPERATION....................................................128 POWER PICK-UP PORT.....................................................130 FUSE.......................................................................130 FUSE CAPACITIES AND CIRCUIT NAMES......................................131 FUSIBLE LINK...............................................................131 CONTROLLER.................................................................132 TOOLBOX....................................................................132 GREASE GUN HOLDER..........................................................132 HANDLING THE ACCUMULATOR...................................................133 RELEASING PRESSURE IN CONTROL CIRCUIT..................................133 MACHINE OPERATIONS AND CONTROLS................................................134 BEFORE STARTING ENGINE.....................................................134 WALK-AROUND CHECKS.....................................................134 CHECKS BEFORE STARTING.................................................135 ADJUSTMENTS BEFORE OPERATION...........................................142 ADJUSTMENT OF MIRRORS..................................................143 SEAT BELT..............................................................144 BEFORE STARTING ENGINE.................................................145 STARTING ENGINE............................................................148 NORMAL STARTING........................................................148 STARTING ENGINE IN COLD WEATHER........................................149 AFTER STARTING ENGINE......................................................152 BREAKING-IN THE NEW MACHINE............................................152 WARM-UP OPERATION......................................................153 AUTOMATIC WARM-UP OPERATION................................................157 STOPPING THE ENGINE........................................................161 CHECK AFTER SHUTING OFF ENGINE.............................................161 MACHINE OPERATION..........................................................162 PREPARATIONS FOR MOVING THE MACHINE....................................162 MOVING MACHINE FORWARD.................................................163 MOVING MACHINE BACKWARD................................................164 STOPPING MACHINE.......................................................165 STEERING THE MACHINE.......................................................166 STEERING THE MACHINE WHEN STOPPED......................................166 CHANGING DIRECTION OF THE MACHINE......................................167 COUNTER-ROTATION TURN (SPIN TURN)......................................167 SWINGING...................................................................168 WORK EQUIPMENT CONTROLS AND OPERATIONS.....................................169 OPERATING WORKING MODE.....................................................170 WORKING MODE...........................................................170 ONE-TOUCH POWER MAX. SWITCH............................................170 PROHIBITED OPERATIONS......................................................171 OPERATIONS USING SWING FORCE...........................................171 OPERATIONS USING TRAVEL FORCE..........................................171 OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS........................171 OPERATIONS USING BUCKET DROPPING FORCE.................................172 OPERATIONS USING MACHINE DROPPING FORCE................................172 DIGGING HARD ROCKY GROUND..............................................172 SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL................................172 GENERAL OPERATION INFORMATION..............................................173 TRAVELING..............................................................173 HIGH SPEED TRAVEL......................................................173 PERMISSIBLE WATER DEPTH................................................173 TRAVELING ON SLOPES........................................................174 TRAVELING DOWNHILL.....................................................175 ENGINE STOPPED ON SLOPE................................................175 PRECAUTIONS ON SLOPES..................................................175 ESCAPE FROM MUD............................................................176 STUCK ONE SIDE OF TRACK................................................176 STUCK BOTH SIDES OF TRACKS.............................................176 ROAD BUILDER RECOMMENDED APPLICATIONS......................................177 BACKHOE WORK...........................................................177 SHOVEL WORK............................................................177 DITCHING WORK..........................................................177 LOADING WORK...........................................................178 REPLACEMENT AND INVERSION OF BUCKET........................................179 REPLACEMENT............................................................179 INVERSION..............................................................181 PARKING MACHINE............................................................182 CHECK AFTER FINISHING WORK.................................................184 LOCKING....................................................................185 TRANSPORTATION.................................................................186 TRANSPORTATION PROCEDURE...................................................186 LOADING AND UNLOADING WITH TRAILER.........................................187 LOADING................................................................187 SECURING THE MACHINE...................................................190 MACHINES WITH CAB RISER................................................192 UNLOADING..............................................................194 LIFTING THE MACHINE........................................................197 COLD WEATHER OPERATION.........................................................198 FUEL AND LUBRICANTS........................................................198 COOLING SYSTEM COOLANT.....................................................198 BATTERY....................................................................199 AFTER OPERATIONS...........................................................200 AFTER COLD WEATHER SEASON..................................................200 LONG TERM STORAGE..............................................................201 BEFORE STORAGE.............................................................201 DURING STORAGE.............................................................201 AFTER STORAGE..............................................................201 STARTING MACHINE.......................................................202 TROUBLESHOOTING................................................................202 AFTER RUNNING OUT OF FUEL..................................................202 PHENOMENA THAT ARE NOT FAILURES............................................202 TOWING THE MACHINE.........................................................203 LIGHTWEIGHT TOWING HOOK....................................................203 PRECAUTIONS ON PARTICULAR JOBSITES.........................................204 DISCHARGED BATTERY.........................................................204 REMOVAL AND INSTALLATION OF BATTERY....................................205 BATTERY CHARGES........................................................205 STARTING ENGINE WITH BOOSTER CABLES....................................206 OTHER TROUBLE..............................................................208 ELECTRICAL SYSTEM......................................................208 CHASSIS................................................................209 ENGINE.................................................................209 ELECTRONIC CONTROL SYSTEM..............................................211 MAINTENANCE........................................................................213 MAINTENANCE INFORMATION........................................................214 SERVICE METER READING......................................................214 KOMATSU GENUINE REPLACEMENT PARTS..........................................214 KOMATSU GENUINE LUBRICANTS.................................................214 WINDSHIELD WASHER FLUID....................................................214 FRESH AND CLEAN LUBRICANTS.................................................214 CHECK DRAINED OIL AND USED FILTER..........................................214 FUEL STRAINER..............................................................214 WELDING INSTRUCTIONS.......................................................214 DO NOT DROP THINGS INSIDE MACHINE..........................................214 DUSTY JOBSITE..............................................................215 AVOID MIXING LUBRICANTS....................................................215 LOCKING THE INSPECTION COVERS..............................................215 HYDRAULIC SYSTEM - AIR BLEEDING............................................215 HYDRAULIC HOSE INSTALLATION................................................215 CHECKS AFTER INSPECTION AND MAINTENANCE WORKS..............................215 SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE.................216 LUBRICANTS, COOLANT AND FILTERS................................................216 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................216 OIL....................................................................216 FUEL...................................................................216 COOLING SYSTEM COOLANT.................................................217 GREASE.................................................................217 CARRYING OUT KOWA......................................................217 OIL AND FUEL STORAGE...................................................218 FILTERS................................................................218 ELECTRIC SYSTEM MAINTENANCE................................................219 HANDLING HYDRAULIC SYSTEM..................................................219 WEAR PARTS LIST................................................................220 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...........221 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...........................221 TIGHTENING TORQUE SPECIFICATIONS...............................................223 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................224 SAFETY CRITICAL PARTS......................................................224 MAINTENANCE SCHEDULE...........................................................225 MAINTENANCE SCHEDULE CHART.................................................225 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.................................228 REPLACING HYDRAULIC ELEMENT............................................228 CHANGING OIL IN HYDRAULIC TANK.........................................228 REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER........................228 MAINTENANCE PROCEDURE..........................................................229 INITIAL 10 HOURS MAINTENANCE...............................................229 LUBRICATION ROAD BUILDER MACHINE.......................................229 INITIAL 250 HOURS MAINTENANCE..............................................231 WHEN REQUIRED..............................................................232 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................232 CLEAN INSIDE OF COOLING SYSTEM.........................................235 CHECK AND TIGHTEN TRACK SHOE BOLTS.....................................237 CHECK AND ADJUST TRACK TENSION.........................................238 CHECK ELECTRICAL INTAKE AIR HEATER.....................................239 ADJUST BUCKET CLEARANCE................................................240 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................241 CHECK AND ADJUST AIR CONDITIONER.......................................242 CLEANING CAB FLOOR.....................................................244 BLEEDING AIR FROM HYDRAULIC SYSTEM.....................................246 RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT.......................248 CHECK BEFORE STARTING......................................................249 EVERY 100 HOURS MAINTENANCE................................................250 LUBRICATING............................................................250 EVERY 250 HOURS MAINTENANCE................................................251 LUBRICATION............................................................251 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL.............................251 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................252 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................253 LUBRICATE SWING CIRCLE (3 POINTS)......................................255 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...............255 EVERY 500 HOURS MAINTENANCE................................................256 LUBRICATION............................................................256 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......257 REPLACE FUEL FILTER CARTRIDGE..........................................258 CHECK SWING PINION GREASE LEVEL, ADD GREASE............................259 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....260 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM......261 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.............................262 EVERY 1000 HOURS MAINTENANCE...............................................263 REPLACE HYDRAULIC FILTER ELEMENT.......................................263 CHANGE OIL IN SWING MACHINERY CASE.....................................264 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL................................266 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.............................266 CHECK PLAY OF TURBOCHARGER ROTOR.......................................266 CHECK FAN BELT TENSION AND REPLACE FAN BELT............................266 EVERY 2000 HOURS MAINTENANCE...............................................267 CHANGE OIL IN FINAL DRIVE CASE.........................................267 CLEAN HYDRAULIC TANK STRAINER..........................................268 CLEAN, CHECK TURBOCHARGER..............................................268 CHECK ALTERNATOR, STARTING MOTOR.......................................268 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................268 CHECK VIBRATION DAMPER.................................................268 EVERY 4000 HOURS MAINTENENCE...............................................269 CHECK WATER PUMP.......................................................269 EVERY 5000 HOURS MAINTENANCE...............................................270 CHANGE OIL IN HYDRAULIC TANK...........................................270 SPECIFICATIONS.....................................................................271 SPECIFICATIONS.................................................................272 DIMENSIONS.................................................................272 WORKING RANGE..............................................................274 WORKING RANGE - ROAD BUILDER...........................................274 LIFTING CAPACITY- ROAD BUILDER.........................................276 OPTIONS, ATTACHMENTS...............................................................281 GENERAL PRECAUTIONS............................................................282 PRECAUTIONS RELATED TO SAFETY..............................................282 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....................................284 HANDLING BUCKET WITH HOOK......................................................285 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....................................285 PROHIBITED OPERATIONS......................................................285 PRECAUTIONS DURING OPERATIONS..........................................285 ATTACHMENT GUIDE...............................................................286 COMBINATIONS OF WORK EQUIPMENT.............................................286 PC200LL-7L.............................................................287 PC220LL-7L.............................................................288 SELECTION OF TRACK SHOES...................................................289 METHOD OF SELECTING SHOES..............................................289 SOFT SWING FUNCTION............................................................290
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