NOTICE
Komatsu has Operation & Maintenance Manuals written in
some other languages. If a foreign language manual is
necessary, contact your local distributor for availability.
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing 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.
SEAM002407
PC200, 200LC-6
PC210, 210LC-6 MIGHTY
PC220, 220LC-6
PC230, 230LC-6 MIGHTY
HYDRAULIC EXCAVATOR
SERIAL NUMBERS and up
PC200, 200LC- 102209
PC210, 210LC- 31425
PC220, 220LC- 53526
PC230, 230LC- 10247
0-1
1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
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.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
WARNING
‡ Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
‡ Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the luggage box to the rear of the operator’s seat, and have all personnel
involved in working on the machine read the manual periodically.
‡ Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
‡ The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
‡ 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 operating the machine.
‡ The description of safety is given in SAFETY INFORMATION on page 0-2 and in SAFETY from page
1-1.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
0-2
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
DANGER – This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
WARNING – This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
CAUTION – This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
NOTICE – This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page 1-1.
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 precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu
distributor.
0-3
3. INTRODUCTION
3.1 INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work:
‡ Digging work
‡ Smoothing work
‡ Ditching work
‡ Loading work
See the section “12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.
3.2 FEATURES
‡ This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced
electronics system.
fi The monitor panel greatly facilitates daily maintenance and self-diagnosis.
fi Working mode, travel speed, and active mode are selectable.
fi Digging and lifting force can be increased by light-touch control.
(For details, see operation section.)
‡ Adjustable wrist control levers make operations smooth and easy.
‡ Air-conditioned operator's cab assures comfortable operation.
‡ Low noise level and smart urban-style design and coloring.
‡ Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.
‡ Low fuel consumption controlled by an electronic control system provides an environment-friendly
machine.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
‡ Idle the engine for 5 minutes after starting it up.
‡ Avoid operation with heavy loads or at high speeds.
‡ Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
0-4
4.1 MACHINE SERIAL NO. PLATE POSITION
On the front bottom right of the operator's cab
4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
4.2 ENGINE SERIAL NO. PLATE POSITION
On the upper side of the engine cylinder head cover
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARKS
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
AN112910
0-5
5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
2. Safety information ............................................................................................................................ 0- 2
3. Introduction ........................................................................................................................................ 0- 3
4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 4
SAFETY
6. General precautions .......................................................................................................................... 1- 2
7. Precautions during operation .......................................................................................................... 1- 9
7.1 Before starting engine ............................................................................................................ 1- 9
7.2 After starting engine ............................................................................................................... 1-11
7.3 Transportation .......................................................................................................................... 1-18
7.4 Battery ....................................................................................................................................... 1-19
7.5 Towing ...................................................................................................................................... 1-21
7.6 Lifting operations .................................................................................................................... 1-21
8. Precautions for maintenance ........................................................................................................... 1-22
8.1 Before carrying out maintenance .......................................................................................... 1-22
8.2 During maintenance ................................................................................................................ 1-26
9. Position for attaching safety labels ................................................................................................ 1-32
OPERATION
10. General view ...................................................................................................................................... 2- 2
10.1 General view of machine ....................................................................................................... 2- 2
10.2 General view of controls and gauges .................................................................................. 2- 3
11. Explanation of components ............................................................................................................. 2- 4
11.1 Machine monitor ..................................................................................................................... 2- 4
11.2 Switches ................................................................................................................................... 2-15
11.3 Control levers, pedals ............................................................................................................. 2-19
11.4 Ceiling window ........................................................................................................................ 2-24
11.5 Front window ........................................................................................................................... 2-25
11.6 Door lock .................................................................................................................................. 2-27
11.7 Cap, cover with lock ............................................................................................................... 2-28
11.8 Hot/Cool box ............................................................................................................................ 2-29
11.9 Luggage box ............................................................................................................................ 2-29
11.10 Ashtray ...................................................................................................................................... 2-29
11.11 Air conditioner ......................................................................................................................... 2-30
11.12 Car radio ................................................................................................................................... 2-33
11.13 Fuse ........................................................................................................................................... 2-38
11.14 Fusible link ............................................................................................................................... 2-39
11.15 Controllers ................................................................................................................................ 2-39
11.16 Tool box ................................................................................................................................... 2-39
11.17 Grease pump holder ............................................................................................................... 2-39
11.18 Handling accumulator ............................................................................................................. 2-40
0-6
5. CONTENTS 5. CONTENTS
12. Operation ............................................................................................................................................ 2- 42
12.1 Check before starting engine ................................................................................................. 2- 42
12.2 Starting engine ........................................................................................................................ 2- 52
12.3 Operations and checks after starting engine ....................................................................... 2- 55
12.4 Moving machine off ................................................................................................................ 2- 61
12.5 Steering machine .................................................................................................................... 2- 64
12.6 Stopping machine ................................................................................................................... 2- 66
12.7 Swinging ................................................................................................................................... 2- 67
12.8 Operation of work equipment ............................................................................................... 2- 68
12.9 Handling active mode ............................................................................................................. 2- 69
12.10 Working mode selection ......................................................................................................... 2- 71
12.11 Prohibitions for operation ...................................................................................................... 2- 73
12.12 Precautions for operation ....................................................................................................... 2- 75
12.13 Precautions when traveling up or down hills ..................................................................... 2- 76
12.14 How to escape from mud ...................................................................................................... 2- 78
12.15 Work possible using hydraulic excavator ............................................................................ 2- 79
12.16 Replacement and inversion of bucket .................................................................................. 2- 80
12.17 Parking machine ...................................................................................................................... 2- 82
12.18 Check after finishing work ..................................................................................................... 2- 83
12.19 Stopping engine ...................................................................................................................... 2- 84
12.20 Check after stopping engine .................................................................................................. 2- 85
12.21 Locking ...................................................................................................................................... 2- 85
13. Transportation ................................................................................................................................... 2- 86
13.1 Loading, unloading work ........................................................................................................ 2- 86
13.2 Precautions for loading .......................................................................................................... 2- 88
13.3 Precautions for transportation ............................................................................................... 2- 89
14. Cold weather operation ................................................................................................................... 2- 90
14.1 Precautions for low temperature ........................................................................................... 2- 90
14.2 Precautions after completion of work .................................................................................. 2- 92
14.3 After cold weather ................................................................................................................... 2- 92
15. Long-term storage ............................................................................................................................ 2- 93
15.1 Before storage ......................................................................................................................... 2- 93
15.2 During storage ......................................................................................................................... 2- 94
15.3 After storage ............................................................................................................................ 2- 94
15.4 Starting machine after long-term storage ............................................................................ 2- 94
16. Troubleshooting ................................................................................................................................ 2- 95
16.1 Phenomena that are not failures ........................................................................................... 2- 95
16.2 Method of towing machine .................................................................................................... 2- 95
16.3 Using method for light-weight towing hole ........................................................................ 2- 95
16.4 Precautions on particular jobsites ......................................................................................... 2- 96
16.5 If battery is discharged ........................................................................................................... 2- 96
16.6 Other trouble ............................................................................................................................ 2-100
0-7
5. CONTENTS 5. CONTENTS
MAINTENANCE
17. Guides to maintenance .................................................................................................................... 3- 2
18. Outlines of service ............................................................................................................................ 3- 5
18.1 Outline of oil, fuel, coolant .................................................................................................... 3- 5
18.2 Outline of electric system ...................................................................................................... 3- 8
18.3 Outline of hydraulic system ................................................................................................... 3- 9
19. Wear parts list ................................................................................................................................... 3-10
20. Use of fuel, coolant and lubricants according to ambient temperature ................................... 3-12
21. Standard tightening torques for bolts and nuts .......................................................................... 3-16
21.1 Introduction of necessary tools ............................................................................................. 3-16
21.2 Torque list ................................................................................................................................ 3-17
22. Periodic replacement of safety critical parts ................................................................................. 3-18
23. Maintenance schedule chart ............................................................................................................ 3-22
23.1 Maintenance schedule chart .................................................................................................. 3-22
23.2 Maintenance interval when using hydraulic breaker .......................................................... 3-24
24. Service Procedure ............................................................................................................................. 3-25
24.1 Initial 250 hours service ......................................................................................................... 3-25
24.2 When required ......................................................................................................................... 3-26
24.3 Check before starting .............................................................................................................. 3-44
24.4 Every 100 hours service ......................................................................................................... 3-49
24.5 Every 250 hours service ......................................................................................................... 3-52
24.6 Every 500 hours service ......................................................................................................... 3-58
24.7 Every 1000 hours service ....................................................................................................... 3-63
24.8 Every 2000 hours service ....................................................................................................... 3-66
24.9 Every 4000 hours service ....................................................................................................... 3-69
24.10 Every 5000 hours service ....................................................................................................... 3-70
SPECIFICATIONS
25. Specifications ..................................................................................................................................... 4- 2
0-8
5. CONTENTS 5. CONTENTS
OPTIONS, ATTACHMENTS
26. General precautions .......................................................................................................................... 5- 2
26.1 Precautions related to safety ................................................................................................. 5- 2
26.2 Precautions when installing attachments ............................................................................. 5- 3
27. Handling bucket with hook ............................................................................................................. 5- 4
27.1 Checking for damage to bucket with hook .......................................................................... 5- 4
27.2 Prohibited operations .............................................................................................................. 5- 4
27.3 Precautions during operations ............................................................................................... 5- 4
28. Using seat belt .................................................................................................................................. 5- 5
28.1 Seat belt ................................................................................................................................... 5- 5
29. Handling car heater .......................................................................................................................... 5- 7
29.1 Explanation of components ................................................................................................... 5- 7
29.2 Preparing car heater ............................................................................................................... 5- 8
30. Machines ready for attachments .................................................................................................... 5- 9
30.1 Explanation of components ................................................................................................... 5- 9
30.2 hydraulic circuit ....................................................................................................................... 5-11
30.3 Attachment mounting/dismounting procedure .................................................................... 5-13
30.4 Operation .................................................................................................................................. 5-15
30.5 Long-term storage ................................................................................................................... 5-16
30.6 Specifications ........................................................................................................................... 5-16
31. Introduction of attachments ............................................................................................................ 5-17
31.1 Specification, use .................................................................................................................... 5-17
31.2 Attachment installation combination table .......................................................................... 5-19
31.3 Selection of track shoes ......................................................................................................... 5-22
31.4 Selection of bucket teeth ........................................................................................................ 5-23
31.5 Handling rubber pad shoe ..................................................................................................... 5-24
31.6 Handling trapezoidal bucket ................................................................................................... 5-26
31.7 Handling extension arm ......................................................................................................... 5-27
31.8 Handling clamshell bucket ..................................................................................................... 5-28
31.9 Handling variable 2-piece boom, rotating arm ................................................................... 5-29
32. Extending machine service life ....................................................................................................... 5-38
32.1 Hydraulic breaker .................................................................................................................... 5-38
32.2 Power ripper ............................................................................................................................ 5-42
32.3 Fork grab .................................................................................................................................. 5-43
32.4 Grapple bucket ......................................................................................................................... 5-44
32.5 Scrap grapple ........................................................................................................................... 5-45
32.6 Crusher & cutter ...................................................................................................................... 5-46
32.7 Hydraulic pile driver ................................................................................................................ 5-47
32.8 Hydraulic excavator with multi-purpose crane .................................................................... 5-48
1-1
¤ WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional equip-
ment and attachments.
SAFETY
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Description
MACHINE MODEL SERIAL NUMBERS
- PC200/200LC-6 - 102209 and up
- PC210/210LC-6 - 31425 and up
- PC220/220LC-6 - 53526 and up
- PC230/230LC-6 - 10247 and up
Service Repair Manual Covers:
- FOREWORD
- SAFETY INFORMATION
- INTRODUCTION
- LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- CONTENTS
- SAFETY
- GENERAL PRECAUTIONS
- PRECAUTIONS DURING OPERATION
- PRECAUTIONS FOR MAINTENANCE
- POSITION FOR ATTACHING SAFETY LABELS
- OPERATION
- GENERAL VIEW
- EXPLANATION OF COMPONENTS
- OPERATION
- TRANSPORTATION
- COLD WEATHER OPERATION
- LONG-TERM STORAGE
- TROUBLESHOOTING
- MAINTENANCE
- GUIDES TO MAINTENANCE
- OUTLINES OF SERVICE
- WEAR PARTS LIST
- USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS
- GENERAL PRECAUTIONS
- HANDLING BUCKET WITH HOOK
- USING SEAT BELT
- HANDLING CAR HEATER
- MACHINES READY FOR ATTACHMENTS
- INTRODUCTION OF ATTACHMENTS
- EXTENDING MACHINE SERVICE LIFE
- And More......
File Format:
- Compatible: All Versions of Windows & Mac
- Language: English
- Requirements: Adobe Reader & Win
NO waiting, Buy from responsible seller and get INSTANT access, Without wasting your hard-owned money on uncertainty or surprise! All pages are printable. It is great to have KOMATSU PC200-6, PC200LC-6, PC210-6, PC210LC-6, PC220-6, PC220LC-6, PC230-6, PC230LC-6 Operation & Maintenance.
