KOMATSU PC200-250001, PC220-65001. Manual - part 1

HYDLULIC
EXCAVATOR

PEN00014-04

PC200

-7

PC200LC

-7

PC220

-7

PC220LC

-7

SERIAL NUMBERS

PC200- 250001
PC220- 65001

and up

Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.

NOTICE

Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.

WARNING

FOREWORD

FOREWORD

1-2

FOREWORD

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions 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 for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and main-
tenance.

WARNING

Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.

Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.

Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.

Storage location for the Operation and Maintenance Manual:

magazine box on the left side of the operator's seat.

FOREWORD

SAFETY INFORMATION

1-5

SAFETY INFORMATION

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.

Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.

In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.

Example of safety message using signal word

WARNING

To avoid hitting unlocked operation levers, lower equipment to ground and move LOCK LEVER (located
near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.

Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.

This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.

This gives information that is useful to know.

DANGER

WARNING

CAUTION

NOTICE

REMARK

SAFETY INFORMATION

FOREWORD

1-6

Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.

This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.

Example of safety label using words

Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.

In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:

 (1))

Part No.

Part No.

FOREWORD

INTRODUCTION

1-7

INTRODUCTION

This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following works:

Digging work

Leveling work

Ditching work

Loading work

Demolition work

See the section "RECOMMENDED APPLICATIONS (PAGE 3-97)" for further details.

DIRECTIONS OF MACHINE

In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.

BREAKING-IN THE NEW MACHINE

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory.  How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).

Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.

Run the engine at idling for 15 seconds after starting it.  During this time, do not operate the control levers or
fuel control dial.

Idle the engine for 5 minutes after starting it up.

Avoid operation with heavy loads or at high speeds.

Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

PRODUCT INFORMATION

FOREWORD

1-8

PRODUCT INFORMATION

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.

PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL
NO. PLATE

On the bottom right of the operator's cab

The design of the nameplate differs according to the territory.

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION

On the top of the No.1 cylinder head cover (The EPA auxiliary nameplate is on the top of the No. 5 cylinder head
cover.)

EPA: Environmental Protection Agency, U.S.A.

FOREWORD

PRODUCT INFORMATION

1-9

SERVICE METER LOCATION

On top of the machine monitor

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR

Machine serial No.

Engine serial No.

Product identification number (PIN)

Distributor name

Address

Service Personal

Phone/Fax

CONTENTS

FOREWORD

1-10

CONTENTS

FOREWORD

FOREWORD ......................................................................................................................................................... 1-2

SAFETY INFORMATION...................................................................................................................................... 1-5

INTRODUCTION................................................................................................................................................... 1-7

DIRECTIONS OF MACHINE ...................................................................................................................... 1-7

BREAKING-IN THE NEW MACHINE ......................................................................................................... 1-7

PRODUCT INFORMATION .................................................................................................................................. 1-8

PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE....................................... 1-8

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ......................................................................... 1-8

SERVICE METER LOCATION ................................................................................................................... 1-9

YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ..................................................................... 1-9

SAFETY

SAFETY INFORMATION...................................................................................................................................... 2-2

POSITION FOR ATTACHING SAFETY LABELS................................................................................................ 2-4

POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 2-4

SAFETY LABELS ....................................................................................................................................... 2-5

SAFETY INFORMATION.................................................................................................................................... 2-11

SAFETY MACHINE OPERATION ...................................................................................................................... 2-20

STARTING ENGINE ................................................................................................................................. 2-20

OPERATION ............................................................................................................................................. 2-22

TRANSPORTATION ................................................................................................................................. 2-28

BATTERY ................................................................................................................................................. 2-29

TOWING ................................................................................................................................................... 2-31

LIFTING OBJECTS WITH BUCKET ......................................................................................................... 2-32

SAFETY MAINTENANCE INFORMATION ........................................................................................................ 2-33

OPERATION

GENERAL VIEW .................................................................................................................................................. 3-2

GENERAL VIEW OF MACHINE ................................................................................................................. 3-2

GENERAL VIEW CONTROLS AND GAUGES........................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-4

MACHINE MONITOR ................................................................................................................................. 3-4

BASIC CHECK ITEMS................................................................................................................................ 3-5

SWITCHES ............................................................................................................................................... 3-17