KOMATSU PC200Z-6LE HYDRAULIC EXCAVATOR OPERATION & MAINTENACE MANUAL (SN:A83001 & UP) – PDF DOWNLOAD

Description

KOMATSU PC200Z-6LE HYDRAULIC EXCAVATOR OPERATION & MAINTENACE MANUAL (SN:A83001 & UP)

KOMATSU PC200Z-6LE HYDRAULIC EXCAVATOR OPERATION & MAINTENACE MANUAL (SN:A83001 & UP) – PDF DOWNLOAD:

Image Preview:

Description:

KOMATSU PC200Z-6LE HYDRAULIC EXCAVATOR OPERATION & MAINTENACE MANUAL (SN:A83001 & UP)

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor.
• If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual

Table of Contents:

KOMATSU PC200Z-6LE HYDRAULIC EXCAVATOR OPERATION & MAINTENACE MANUAL (SN:A83001 & UP)

MAIN MENU.......................................................................................................................................  0
COVER...........................................................................................................................................  1
INTRODUCTION....................................................................................................................................  4
	1. FORWARD..................................................................................................................................  5
	2. SAFETY INFORMATION.......................................................................................................................  6
	3. INTRODUCTION.............................................................................................................................  7
		3.1 INTENDED USE........................................................................................................................  7
		3.2 FEATURES............................................................................................................................  7
		3.3 BREAKING IN A NEW MACHINE...........................................................................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION...................................................................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION....................................................................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...........................................................................................  8
	5. TABLE OF CONTENTS........................................................................................................................  9
SAFETY.......................................................................................................................................... 14
	6. GENERAL PRECAUTIONS...................................................................................................................... 15
	7. PRECAUTIONS DURING OPERATION............................................................................................................. 22
		7.1 BEFORE STARTING ENGINE.............................................................................................................. 22
		7.2 OPERATING MACHINE................................................................................................................... 24
		7.3 TRANSPORTATION...................................................................................................................... 30
		7.4 BATTERY............................................................................................................................. 32
		7.5 TOWING.............................................................................................................................. 34
		7.6 BUCKET WITH HOOK.................................................................................................................... 35
			7.6.1 GENERAL PRECAUTIONS........................................................................................................... 35
			7.6.2 PRECAUTIONS FOR LIFTING OPERATION............................................................................................. 36
	8. PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 37
		8.1 BEFORE CARRYING OUT MAINTENANCE..................................................................................................... 37
		8.2 DURING MAINTENANCE.................................................................................................................. 40
	9. POSITION FOR ATTACHING SAFETY LABELS..................................................................................................... 45
OPERATION....................................................................................................................................... 49
	10. GENERAL VIEW............................................................................................................................ 50
		10.1 GENERAL VIEW OF MACHINE............................................................................................................ 50
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................................................................ 51
	11. EXPLANATION OF COMPONENTS............................................................................................................... 52
		11.1 MACHINE MONITOR.................................................................................................................... 52
			11.1.1 A. CAUTION ITEMS............................................................................................................. 53
			11.1.2 B. EMERGENCY STOP ITEMS...................................................................................................... 53
			11.1.3 C. METER DISPLAY PORTION..................................................................................................... 54
		11.2 SWITCHES........................................................................................................................... 55
		11.3 CONTROL LEVERS, PEDALS............................................................................................................. 58
		11.4 CEILING WINDOW..................................................................................................................... 62
		11.5 FRONT WINDOW....................................................................................................................... 62
		11.6 DOOR LOCK.......................................................................................................................... 65
		11.7 ASHTRAY............................................................................................................................ 65
		11.8 CAP, COVER WITH LOCK............................................................................................................... 65
			11.8.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port).................................................. 65
			11.8.2 METHOD OF OPENING AND CLOSING COVER WITH LOCK................................................................................ 66
		11.9 CAB HEATER......................................................................................................................... 66
			11.9.1 PREPARING CAB HEATER......................................................................................................... 67
		11.10 FUSE.............................................................................................................................. 67
		11.11 FUSIBLE LINK...................................................................................................................... 67
		11.12 TOOL BOX.......................................................................................................................... 68
		11.13 GREASE PUMP HOLDER................................................................................................................ 68
		11.14 HANDLING ACCUMULATOR.............................................................................................................. 68
			11.14.1 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR........................................ 69
	12. OPERATION............................................................................................................................... 70
		12.1 CHECK BEFORE STARTING ENGINE....................................................................................................... 70
			12.1.1 WALK-AROUND CHECK............................................................................................................ 70
			12.1.2 CHECK BEFORE STARTING........................................................................................................ 71
			12.1.3 ADJUSTMENT BEFORE OPERATION.................................................................................................. 71
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE................................................................................. 73
		12.2 STARTING ENGINE.................................................................................................................... 74
			12.2.1 NORMAL STARTING.............................................................................................................. 74
			12.2.2 STARTING IN COLD WEATHER..................................................................................................... 75
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................................................ 76
		12.4 MOVING MACHINE..................................................................................................................... 78
			12.4.1 MOVING MACHINE FORWARD....................................................................................................... 78
			12.4.2 MOVING MACHINE BACKWARD...................................................................................................... 79
		12.5 STEERING MACHINE................................................................................................................... 81
		12.6 STOPPING MACHINE................................................................................................................... 83
		12.7 SWINGING........................................................................................................................... 84
		12.8 OPERATION OF WORK EQUIPMENT........................................................................................................ 85
		12.9 PROHIBITIONS FOR OPERATION......................................................................................................... 86
		12.10 PRECAUTIONS FOR OPERATION......................................................................................................... 88
		12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....................................................................................... 89
		12.12 HOW TO ESCAPE FROM MUD............................................................................................................ 91
			12.12.1 WHEN ONE SIDE IS STUCK...................................................................................................... 91
			12.12.2 WHEN BOTH SIDES ARE STUCK................................................................................................... 91
		12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR........................................................................................... 92
			12.13.1 BACKHOE WORK................................................................................................................ 92
			12.13.2 SHOVEL WORK................................................................................................................. 92
			12.13.3 DITCHING WORK............................................................................................................... 92
			12.13.4 LOADING WORK................................................................................................................ 92
		12.14 REPLACEMENT AND INVERSION OF BUCKET............................................................................................... 93
			12.14.1 REPLACEMENT................................................................................................................. 93
			12.14.2 INVERSION................................................................................................................... 94
		12.15 PARKING MACHINE................................................................................................................... 95
		12.16 CHECK AFTER FINISHING WORK........................................................................................................ 96
		12.17 STOPPING ENGINE................................................................................................................... 97
		12.18 CHECK AFTER STOPPING ENGINE....................................................................................................... 97
		12.19 LOCKING AND SECURING MACHINE...................................................................................................... 98
	13. TRANSPORTATION.......................................................................................................................... 99
		13.1 LOADING, UNLOADING WORK............................................................................................................ 99
		13.2 PRECAUTIONS FOR LOADING............................................................................................................101
		13.3 PRECAUTIONS FOR TRANSPORTATION.....................................................................................................101
	14. COLD WEATHER OPERATION..................................................................................................................102
		14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................................................................................102
			14.1.1 FUEL AND LUBRICANTS..........................................................................................................102
			14.1.2 COOLANT......................................................................................................................102
			14.1.3 BATTERY......................................................................................................................103
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK...............................................................................................104
		14.3 AFTER COLD WEATHER.................................................................................................................104
	15. LONG-TERM STORAGE.......................................................................................................................105
		15.1 BEFORE STORAGE.....................................................................................................................105
		15.2 DURING STORAGE.....................................................................................................................106
		15.3 AFTER STORAGE......................................................................................................................106
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...........................................................................................106
	16. TROUBLESHOOTING.........................................................................................................................107
		16.1 PHENOMENA THAT ARE NOT FAILURES....................................................................................................107
		16.2 METHOD OF TOWING MACHINE...........................................................................................................107
		16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE..........................................................................................107
		16.4 PRECAUTIONS ON PARTICULAR JOBSITES.................................................................................................108
		16.5 IF BATTERY IS DISCHARGED...........................................................................................................108
			16.5.1 STARTING ENGINE WITH BOOSTER CABLE...........................................................................................109
			16.5.2 REMOVAL AND INSTALLATION OF BATTERY..........................................................................................111
		16.6 OTHER TROUBLE......................................................................................................................112
			16.6.1 ELECTRICAL SYSTEM............................................................................................................112
			16.6.2 CHASSIS......................................................................................................................113
			16.6.3 ENGINE.......................................................................................................................114
MAINTENANCE.....................................................................................................................................116
	17. GUIDES TO MAINTENANCE...................................................................................................................117
	18. OUTLINES OF SERVICE.....................................................................................................................120
		18.1 OUTLINE OF OIL, FUEL, COOLANT......................................................................................................120
			18.1.1 OIL..........................................................................................................................120
			18.1.2 FUEL.........................................................................................................................121
			18.1.3 COOLANT......................................................................................................................121
			18.1.4 GREASE.......................................................................................................................122
			18.1.5 STORING OIL AND FUEL.........................................................................................................122
			18.1.6 FILTERS......................................................................................................................122
		18.2 OUTLINE OF ELECTRICAL SYSTEM.......................................................................................................123
		18.3 OUTLINE OF HYDRAULIC SYSTEM........................................................................................................124
	19. WEAR PARTS LIST.........................................................................................................................125
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................................................................127
		20.1 ENGINE OIL SPECIFICATION...........................................................................................................128
			20.1.1 NORMAL OPERATION.............................................................................................................128
			20.1.2 ARCTIC OPERATION.............................................................................................................128
		20.2 DIESEL FUEL SPECIFICATIONS.........................................................................................................129
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................................................................................130
		21.1 INTRODUCTION OF NECESSARY TOOLS....................................................................................................130
		21.2 TORQUE LIST........................................................................................................................131
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................................................................................132
	23. MAINTENANCE SCHEDULE....................................................................................................................135
		23.1 MAINTENANCE SCHEDULE CHART.........................................................................................................135
		23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER..................................................................................138
	24. SERVICE PROCEDURE.......................................................................................................................139
		24.1 INITIAL 250 HOURS SERVICE..........................................................................................................139
		24.2 WHEN REQUIRED......................................................................................................................140
			24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.................................................................................140
			24.2.2 CLEAN INSIDE OF COOLING SYSTEM (2 years or 2000 hours whichever occurs first)................................................142
			24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS...........................................................................................146
			24.2.4 CHECK AND ADJUST TRACK TENSION...............................................................................................147
			24.2.5 CHECK ENGINE INTAKE AIR HEATER (ELECTRICAL)..................................................................................149
			24.2.6 INSTALLATION OF BUCKET TEETH (ESCO SUPERV ® TYPE)............................................................................150
			24.2.7 REMOVAL OF BUCKET TEETH (ESCO SUPERV ® TYPE).................................................................................152
			24.2.8 ADJUST BUCKET CLEARANCE......................................................................................................154
			24.2.9 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...................................................................................155
			24.2.10 CHECK AND ADJUST AIR CONDITIONER............................................................................................156
			24.2.11 REPLACE ADDITIONAL BREAKER FILTER ELEMENT...................................................................................157
			24.2.12 CLEAN INLINE FILTER (RECTANGULAR HOUSING)...................................................................................158
		24.3 CHECK BEFORE STARTING..............................................................................................................159
			24.3.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................................................................159
			24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...................................................................................159
			24.3.3 CHECK FUEL LEVEL, ADD FUEL...................................................................................................160
			24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...................................................................................161
			24.3.5 CHECK DUST INDICATOR.........................................................................................................162
			24.3.6 CHECK ELECTRIC WIRING........................................................................................................162
			24.3.7 CHECK FOR WATER AND SEDIMENT IN FUEL-WATER SEPERATOR.........................................................................163
		24.4 EVERY 100 HOURS SERVICE............................................................................................................163
			24.4.1 LUBRICATING..................................................................................................................163
			24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.............................................................................165
			24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK......................................................................................165
		24.5 EVERY 250 HOURS SERVICE............................................................................................................166
			24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................166
			24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE...........................................................................................167
			24.5.3 LUBRICATE SWING CIRCLE (2 POINTS)............................................................................................168
			24.5.4 CHECK FAN BELT TENSION, ADJUST...............................................................................................168
			24.5.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST........................................................................169
			24.5.6 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE............................................................170
		24.6 EVERY 500 HOURS SERVICE............................................................................................................171
			24.6.1 REPLACE HYDRAULIC FILTER ELEMENT.............................................................................................171
			24.6.2 REPLACE FUEL FILTER CARTRIDGE AND FUEL-WATER SEPERATOR.......................................................................172
			24.6.3 CHECK SWING PINION GREASE LEVEL, ADD GREASE..................................................................................174
			24.6.4 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AC....174
			24.6.5 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AC).......................175
			24.6.6 REPLACE HYDRAULIC TANK BREATHER ELEMENT......................................................................................175
			24.6.7 REPLACE IN-LINE FUEL STRAINER................................................................................................176
		24.7 EVERY 1000 HOURS SERVICE...........................................................................................................177
			24.7.1 CHANGE OIL IN SWING MACHINERY CASE...........................................................................................177
			24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................................178
			24.7.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...................................................................................178
			24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR.............................................................................................178
			24.7.5 CHECK ALTERNATOR BELT TENSIONER BEARING, BELT AND FAN HUB....................................................................179
		24.8 EVERY 2000 HOURS SERVICE...........................................................................................................180
			24.8.1 CHANGE OIL IN FINAL DRIVE CASE...............................................................................................180
			24.8.2 CLEAN HYDRAULIC TANK STRAINER................................................................................................181
			24.8.3 CLEAN, CHECK TURBOCHARGER....................................................................................................181
			24.8.4 CHECK ALTERNATOR, STARTING MOTOR.............................................................................................181
			24.8.5 CHECK VIBRATION DAMPER.......................................................................................................181
			24.8.6 CHANGE ANTIFREEZE............................................................................................................181
			24.8.7 CHECK AND ADJUST VALVE CLEARANCE.............................................................................................182
		24.9 EVERY 5000 HOURS SERVICE...........................................................................................................183
			24.9.1 CHANGE OIL IN HYDRAULIC TANK.................................................................................................183
SPECIFICATIONS..................................................................................................................................187
	25. SPECIFICATIONS..........................................................................................................................188
		25.1 Standard specifications............................................................................................................188
		25.2 Static dimensions..................................................................................................................189
		25.3 Working dimensions.................................................................................................................190
		25.4 Lifting capacity...................................................................................................................191
OPTIONS, ATTACHMENTS............................................................................................................................193
	26. GENERAL PRECAUTIONS.....................................................................................................................194
		26.1 PRECAUTIONS RELATED TO SAFETY......................................................................................................194
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS............................................................................................195
	27. HANDLING BUCKET WITH HOOK...............................................................................................................196
		27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK...............................................................................................196
		27.2 PROHIBITED OPERATIONS..............................................................................................................196
		27.3 PRECAUTIONS DURING OPERATIONS......................................................................................................196
	28. HANDLING AIR CONDITIONER................................................................................................................197
		28.1 GENERAL LOCATIONS ON CONTROL PANEL.................................................................................................197
		28.2 PRECAUTIONS WHEN USING AIR CONDITIONER.............................................................................................199
	29. MACHINES READY FOR ATTACHMENTS..........................................................................................................200
		29.1 EXPLANATION OF COMPONENTS..........................................................................................................200
		29.2 HYDRAULIC CIRCUIT..................................................................................................................202
			29.2.1 CONNECTING HYDRAULIC CIRCUIT.................................................................................................203
		29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE..........................................................................................204
		29.4 OPERATION..........................................................................................................................205
		29.5 LONG-TERM STORAGE..................................................................................................................206
		29.6 SPECIFICATIONS.....................................................................................................................206
	30. INTRODUCTION OF ATTACHMENTS.............................................................................................................207
		30.1 BUCKET SELECTION...................................................................................................................207
		30.2 BUCKET INSTALLATION COMBINATIONS...................................................................................................207
		30.3 SELECTION OF TRACK SHOES...........................................................................................................209
		30.4 BACKHOE CONTROL PATTERN CONVERSION.................................................................................................210
	31. EXTENDING MACHINE SERVICE LIFE..........................................................................................................211
		31.1 HYDRAULIC BREAKER..................................................................................................................211
		31.2 CRUSHER............................................................................................................................214
		31.3 GRAPPLE............................................................................................................................215
		31.4 BUCKET WITH THUMB GRAPPLE..........................................................................................................216
		31.5 ROTATING GRAPPLE...................................................................................................................217
		31.6 SHEAR..............................................................................................................................218
		31.7 HYDRAULIC PILE DRIVER..............................................................................................................219

Please Note:

⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted