KOMATSU PC200-250001, PC220-65001. Manual - part 2

FOREWORD

CONTENTS

1-11

CONTROL LEVERS, PEDALS ................................................................................................................. 3-22

CEILING WINDOW................................................................................................................................... 3-25

FRONT WINDOW..................................................................................................................................... 3-26

EMERGENCY EXIT FROM OPERATOR'S CAB ..................................................................................... 3-31

DOOR LOCK ............................................................................................................................................ 3-31

CAP, COVER WITH LOCK....................................................................................................................... 3-32

HOT AND COOL BOX .............................................................................................................................. 3-33

MAGAZINE BOX....................................................................................................................................... 3-33

ASHTRAY ................................................................................................................................................. 3-33

AIR CONDITIONER CONTROLS............................................................................................................. 3-34

RADIO....................................................................................................................................................... 3-48

FUSE ........................................................................................................................................................ 3-53

FUSIBLELINK ........................................................................................................................................... 3-54

CONTROLLER (COMPUTER) ................................................................................................................. 3-55

TOOLBOX................................................................................................................................................. 3-55

GREASE GUN HOLDER .......................................................................................................................... 3-55

HANDLING ACCUMULATOR................................................................................................................... 3-56

MACHINE OPERATIONS AND CONTROLS..................................................................................................... 3-57

BEFORE STARTING ENGINE ................................................................................................................. 3-57

STARTING ENGINE ................................................................................................................................. 3-71

AFTER STARTING ENGINE .................................................................................................................... 3-75

IN COLD WEATHER AREAS ................................................................................................................... 3-77

STOPPING THE ENGINE ........................................................................................................................ 3-80

MACHINE OPERATION ........................................................................................................................... 3-81

STEERING THE MACHINE...................................................................................................................... 3-85

SWINGING ............................................................................................................................................... 3-87

WORK EQUIPMENT CONTROLS AND OPERATIONS .......................................................................... 3-88

OPERATING WORKING MODE .............................................................................................................. 3-90

PROHIBITED OPERATIONS ................................................................................................................... 3-91

GENERAL OPERATION INFORMATION ................................................................................................ 3-93

TRAVELING ON SLOPES........................................................................................................................ 3-94

ESCAPE FROM MUD............................................................................................................................... 3-96

RECOMMENDED APPLICATIONS.......................................................................................................... 3-97

REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 3-99

PARKING MACHINE .............................................................................................................................. 3-102

CHECK AFTER SHUT OFF ENGINE..................................................................................................... 3-103

MACHINE INSPECTION AFTER DAILY WORK .................................................................................... 3-103

LOCKING................................................................................................................................................ 3-104

TRANSPORTATION......................................................................................................................................... 3-105

TRANSPORTATION PROCEDURE....................................................................................................... 3-105

LOADING AND UNLOADING WITH TRAILER ...................................................................................... 3-106

LIFTING MACHINE................................................................................................................................. 3-113

COLD WEATHER OPERATION ...................................................................................................................... 3-115

COLD WEATHER OPERATION INFORMATION................................................................................... 3-115

AFTER DAILY WORK COMPLETION.................................................................................................... 3-117

AFTER COLD WEATHER SEASON ...................................................................................................... 3-118

CONTENTS

FOREWORD

1-12

LONG TERM STORAGE .................................................................................................................................. 3-119

BEFORE STORAGE............................................................................................................................... 3-119

DURING STORAGE ............................................................................................................................... 3-119

AFTER STORAGE.................................................................................................................................. 3-120

TROUBLESHOOTING...................................................................................................................................... 3-121

AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-121

PHENOMENA THAT ARE NOT FAILURES ........................................................................................... 3-121

TOWING THE MACHINE ....................................................................................................................... 3-122

LIGHTWEIGHT TOWING HOOK............................................................................................................ 3-123

PRECAUTIONS ON PARTICULAR JOBSITES ..................................................................................... 3-123

DISCHARGED BATTERY ...................................................................................................................... 3-124

OTHER TROUBLE ................................................................................................................................. 3-128

MAINTENANCE

MAINTENANCE INFORMATION ......................................................................................................................... 4-2

OUTLINE OF SERVICE........................................................................................................................................ 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................... 4-5

ELECTRIC SYSTEM MAINTENANCE ....................................................................................................... 4-9

WEAR PARTS LIST ........................................................................................................................................... 4-10

RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-11

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............. 4-12

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR
PRODUCTS OTHER THAN KOMATSU GENUINE OIL .......................................................................... 4-13

TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 4-14

TIGHTENING TORQUE LIST ................................................................................................................... 4-14

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-15

SAFETY CRITICAL PARTS...................................................................................................................... 4-15

MAINTENANCE SCHEDULE ............................................................................................................................. 4-16

MAINTENANCE SCHEDULE CHART...................................................................................................... 4-16

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................................................... 4-18

MAINTENANCE PROCEDURE.......................................................................................................................... 4-19

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ................................... 4-19

INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ............................... 4-19

WHEN REQUIRED ................................................................................................................................... 4-20

CHECK BEFORE STARTING .................................................................................................................. 4-46

EVERY 100 HOURS MAINTENANCE...................................................................................................... 4-47

EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-49

EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-54

EVERY 1000 HOURS MAINTENANCE.................................................................................................... 4-61

EVERY 2000 HOURS MAINTENANCE.................................................................................................... 4-65

EVERY 4000 HOURS MAINTENENCE.................................................................................................... 4-67

FOREWORD

CONTENTS

1-13

EVERY 5000 HOURS MAINTENANCE.................................................................................................... 4-68

SPECIFICATIONS

SPECIFICATIONS ................................................................................................................................................ 5-2

ATTACHMENTS AND OPTIONS

GENERAL PRECAUTIONS FOR SAFETY.......................................................................................................... 6-2

PRECAUTIONS WHEN SELECTING......................................................................................................... 6-2

READ THE INSTRUCTION MANUAL THOROUGHLY.............................................................................. 6-2

PRECAUTIONS WHEN REMOVING OR INSTALLING ............................................................................. 6-2

PRECAUTIONS WHEN USING.................................................................................................................. 6-3

BUCKET WITH HOOK ......................................................................................................................................... 6-4

HOOK CONDITION .................................................................................................................................... 6-4

PROHIBITED OPERATIONS ..................................................................................................................... 6-4

MACHINES READY FOR ATTACHMENTS ........................................................................................................ 6-5

EXPLANATION OF COMPONENTS .......................................................................................................... 6-5

HYDRAULIC CIRCUIT................................................................................................................................ 6-8

ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE .................................................................. 6-12

OPERATION............................................................................................................................................. 6-14

LONG-TERM STORAGE.......................................................................................................................... 6-16

SPECIFICATIONS .................................................................................................................................... 6-16

HANDLING SCSH BUSHING............................................................................................................................. 6-17

EVERY 500 HOURS MAINTENANCE...................................................................................................... 6-17

ATTACHMENT GUIDE....................................................................................................................................... 6-19

COMBINATIONS OF WORK EQUIPMENT.............................................................................................. 6-19

SELECTION OF TRACK SHOES............................................................................................................. 6-22

SELECTION OF BUCKET TEETH ........................................................................................................... 6-23

STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH........... 6-23

HANDLING OF RUBBER PAD SHOE AND ROAD LINER ...................................................................... 6-24

HANDLING TRAPEZOIDAL BUCKET...................................................................................................... 6-26

HANDLING EXTENSION ARM................................................................................................................. 6-27

HANDLING CLAMSHELL BUCKET ......................................................................................................... 6-28

HANDLING HEATER................................................................................................................................ 6-29

RECOMMENDED ATTACHMENT OPERATIONS ............................................................................................ 6-41

HYDRAULIC BREAKER ........................................................................................................................... 6-41

CONTENTS

FOREWORD

1-14

MULTI-MONITOR SPECIFICATION

OPERATION

CONTENTS .......................................................................................................................................................... 7-2

GENERAL VIEW .................................................................................................................................................. 7-3

GENERAL VIEW CONTROLS AND GAUGES........................................................................................... 7-3

EXPLANATION OF COMPONENTS.................................................................................................................... 7-4

MACHINE MONITOR ................................................................................................................................. 7-4

BASIC CHECK ITEMS................................................................................................................................ 7-7

MACHINE OPERATIONS AND CONTROLS..................................................................................................... 7-28

BEFORE STARTING ENGINE ................................................................................................................. 7-28

STARTING ENGINE ................................................................................................................................. 7-31

AFTER STARTING ENGINE .................................................................................................................... 7-35

IN COLD WEATHER AREAS ................................................................................................................... 7-38

MACHINE OPERATION ........................................................................................................................... 7-42

SWINGING ............................................................................................................................................... 7-45

OPERATING WORKING MODE .............................................................................................................. 7-46

GENERAL OPERATION INFORMATION ................................................................................................ 7-47

CHECK AFTER SHUT OFF ENGINE ....................................................................................................... 7-48

MACHINE INSPECTION AFTER DAILY WORK ...................................................................................... 7-48

TRANSPORTATION........................................................................................................................................... 7-49

TRANSPORTATION PROCEDURE ......................................................................................................... 7-49

LOADING AND UNLOADING WITH TRAILER ........................................................................................ 7-50

MAINTENANCE

MAINTENANCE PROCEDURE.......................................................................................................................... 7-57

WHEN REQUIRED ................................................................................................................................... 7-57

INDEX ................................................................................................................................................................... 8-1

2-1

SAFETY

21

WARNING

Please read and make sure that you fully understand pre-
cautions described in this manual and the safety labels on
the machine.  When operating or servicing the machine,
always follow these precautions strictly.

SAFETY INFORMATION

SAFETY

2-2

SAFETY INFORMATION

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

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

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

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

SAFETY RULES ....................................................................................................................................... 2-11
IF ABNORMALITIES ARE FOUND .......................................................................................................... 2-11
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ................................................................... 2-11
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................ 2-11
SAFETY EQUIPMENT.............................................................................................................................. 2-12
KEEP MACHINE CLEAN .......................................................................................................................... 2-12
KEEP OPERATOR'S COMPARTMENT CLEAN ...................................................................................... 2-12
LEAVING OPERATOR'S SEAT WITH LOCK ........................................................................................... 2-12
HANDRAILS AND STEPS ........................................................................................................................ 2-13
MOUNTING AND DISMOUNTING ........................................................................................................... 2-14
NO PERSONS ON ATTACHMENTS........................................................................................................ 2-14
BURN PREVENTION ............................................................................................................................... 2-14
FIRE PREVENTION AND EXPLOSION PREVENTION........................................................................... 2-15
ACTION IF FIRE OCCURS ...................................................................................................................... 2-16
WINDSHIELD WASHER FLUID ............................................................................................................... 2-16
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ......................... 2-16
ATTACHMENT INSTALLATION ............................................................................................................... 2-16
ATTACHMENT COMBINATIONS............................................................................................................. 2-17
CAB WIDOW GLASSES........................................................................................................................... 2-17
UNAUTHORIZED MODIFICATIONS ........................................................................................................ 2-17
SAFETY AT JOBSITE .............................................................................................................................. 2-17
WORKING ON LOOSE GROUND............................................................................................................ 2-18
DISTANCE TO HIGH VOLTAGE CABLES............................................................................................... 2-18
ENSURE GOOD VISIBILITY .................................................................................................................... 2-18
VENTILATION FOR ENCLOSED AREA .................................................................................................. 2-19
SIGNALMAN'S SIGNAL AND SIGNS....................................................................................................... 2-19
EMERGENCY EXIT FROM OPERATOR'S CAB...................................................................................... 2-19
ASBESTOS DUST HAZARD PREVENTION............................................................................................ 2-19

SAFETY

SAFETY INFORMATION

2-3

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

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

CHECKS BEFORE STARTING ENGINE ................................................................................................. 2-20
SAFETY RULES FOR STARTING ENGINE ............................................................................................ 2-21
STARTING ENGINE IN COLD WEATHER .............................................................................................. 2-21

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

CHECKS AFTER STARTING ENGINE .................................................................................................... 2-22
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS ................................................................. 2-22
SAFETY RULES FOR TRAVELING ......................................................................................................... 2-23
TRAVELING ON SLOPES........................................................................................................................ 2-24
OPERATIONS ON SLOPES..................................................................................................................... 2-25
PROHIBITED OPERATIONS ................................................................................................................... 2-25
OPERATIONS ON SNOW........................................................................................................................ 2-27
PARKING MACHINE ................................................................................................................................ 2-27

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

LOADING AND UNLOADING................................................................................................................... 2-28
SHIPPING THE MACHINE ....................................................................................................................... 2-28

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

BATTERY HAZARD PREVENTION ......................................................................................................... 2-29
STARTING ENGINE WITH BOOSTER CABLES ..................................................................................... 2-30

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

SAFETY RULES FOR TOWING............................................................................................................... 2-31

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

SAFETY RULES FOR LIFTING OBJECTS .............................................................................................. 2-32

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

WARNING TAG ........................................................................................................................................ 2-33
KEEP WORK PLACE CLEAN AND TIDY................................................................................................. 2-33
APPOINT LEADER WHEN WORKING WITH OTHERS .......................................................................... 2-33
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................. 2-34
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................................. 2-35
PROPER TOOLS...................................................................................................................................... 2-35
ACCUMULATOR ...................................................................................................................................... 2-36
PERSONNEL............................................................................................................................................ 2-36
ATTACHMENTS ....................................................................................................................................... 2-36
WORK UNDER THE MACHINE ............................................................................................................... 2-36
NOISE....................................................................................................................................................... 2-37
WHEN USING HAMMER.......................................................................................................................... 2-37
WELDING WORKS................................................................................................................................... 2-37
REMOVING BATTERY TERMINALS ....................................................................................................... 2-37
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION .............. 2-38
DO NOT DISASSEMBLE RECOIL SPRINGS .......................................................................................... 2-38
SAFETY RULES FOR HIGH-PRESSURE OIL......................................................................................... 2-38
SAFETY HANDLING HIGH-PRESSURE HOSES.................................................................................... 2-39
WASTE MATERIALS................................................................................................................................ 2-39
AIR CONDITIONER MAINTENANCE....................................................................................................... 2-39
COMPRESSED AIR ................................................................................................................................. 2-39
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................................. 2-40

POSITION FOR ATTACHING SAFETY LABELS

SAFETY

2-4

POSITION FOR ATTACHING SAFETY LABELS

The following warning signes and safety labels are used on this machine.

Be sure that you fully understand the correct position and content of labels.

To ensure that the content of labels can be read properly. Be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline, there may cause the labels to
peel off.

There are also other labels in addition to the warning signes and safety labels. Handle those labels in the
same way.

If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITION FOR ATTACHING SAFETY LABELS