Komatsu PC200-7, Operator'S Maintenance Manual

Page 1: ...ecessary 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 www komatsupartsbook com Cou...

Page 2: ...1 1 FOREWORD 11 www komatsupartsbook com Courtesy of Machine Market ...

Page 3: ... 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...

Page 4: ...FOREWORD FOREWORD 1 3 www komatsupartsbook com Courtesy of Machine Market ...

Page 5: ...ÚÑÎÛÉÑÎÜ ÚÑÎÛÉÑÎÜ ïóì www komatsupartsbook com Courtesy of Machine Market ...

Page 6: ...tion 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...

Page 7: ...ethod 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 respons...

Page 8: ... 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 ...

Page 9: ...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 www komatsupartsbook com Courtesy of Machine Market ...

Page 10: ...ATION 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 www komatsupartsbook com Courtesy of Machine Market ...

Page 11: ...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 VIE...

Page 12: ...E 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 AFTE...

Page 13: ... 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...

Page 14: ...IT 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 ...

Page 15: ... 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...

Page 16: ...ke 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 www komatsupartsbook com Courtesy of Machine Market ...

Page 17: ...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 GRO...

Page 18: ... 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 NO...

Page 19: ...d 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...

Page 20: ...ABELS 2 5 SAFETY LABELS 1 Precautions for operation inspection and maintenance 09651 A0641 2 Precautions for before operation 09802 03000 3 Warning for leaving operator s seat 09654 A0641 www komatsupartsbook com Courtesy of Machine Market ...

Page 21: ...HING SAFETY LABELS SAFETY 2 6 4 Warnings for high voltage 09801 A0641 5 Warnings when opening front window 09839 03000 6 Warnings when stowing front window 09308 A0481 www komatsupartsbook com Courtesy of Machine Market ...

Page 22: ...for high temperature coolant and hydraulic oil 09653 A0481 8 Precautions when handling accumulator 09659 A057B 9 Precautions when adjusting track tension 09657 A0881 10 Precautions when handling cable 09808 A0881 www komatsupartsbook com Courtesy of Machine Market ...

Page 23: ...ABELS SAFETY 2 8 11 Stop rotation when performing testing and adjusting 09667 A0481 12 Explanation of methods for emergency escape 20Y 00 31170 13 Roll over precautions 09805 A0881 www komatsupartsbook com Courtesy of Machine Market ...

Page 24: ...ION FOR ATTACHING SAFETY LABELS 2 9 14 Roll over precautions 09805 C0881 15 Prohibited to enter within swing range 09133 A3281 16 Beware of equipment 09134 A1681 www komatsupartsbook com Courtesy of Machine Market ...

Page 25: ...N FOR ATTACHING SAFETY LABELS SAFETY 2 10 17 Precautions for broken or becomes dislodged to the window 20U 98 21910 18 Prohibition of jump start 09842 A0481 www komatsupartsbook com Courtesy of Machine Market ...

Page 26: ... has been cor rected WORKING WEAR AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories There is a hazard that they may catch on control levers or other pro truding parts If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful not to let it get caught Always wear a hard hat and safety...

Page 27: ...es of your shoes If you operate the pedal with mud or oil affixed to your shoes your foot may slip and this may cause a serious acci dent Do not leave parts or tools lying around the operator s compartment Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire Do not use cellular telephones inside the operator s compartment when driving or operating the machine...

Page 28: ... face the machine and maintain three point contact both feet and one hand or both hands and one foot with the handrails and steps including the track shoe to ensure that you support yourself Do not grip the control levers or lock lever when getting on or off the machine Never climb on the engine hood or covers where there are no non slip pads Before getting on or off the machine check the handrail...

Page 29: ...when checking or draining the coolant wait for the water to cool to a temperature where it is possible to touch the radi ator cap by hand before starting the operation Even when the coolant has cooled down loosen the cap slowly to relieve the pressure inside the radiator before removing the cap Hot oil To prevent burns from hot oil spurting out when checking or draining the oil wait for the oil to...

Page 30: ...ntain flammable liquids Fire caused by accumulation of flammable material Remove any dry leaves chips pieces of paper dust or any other flammable materials accumulated or affixed around the engine exhaust manifold muffler or battery or inside the undercovers Fire coming from electric wiring Short circuits in the electrical system can cause fire Always keep electric wiring connections clean and sec...

Page 31: ...optional parts or attachments there may be problems with safety or legal restrictions so please contact your Komatsu distributor for advice Any injuries accidents or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu When installing and using optional attachments read the instruction manual for the attachment and the gen eral info...

Page 32: ...or any injuries accidents or product failures resulting from modifications made without authorization from Komatsu SAFETY AT JOBSITE Before starting operations thoroughly check the area for any unusual conditions that could be dangerous When carrying out operations near combustible materials such as thatched roofs dry leaves or dry grass there is a hazard of fire so be careful when operating Check...

Page 33: ...e the table on the right between the machine and the electric cable Check with the local power company about safe operating procedure before starting operations To prepare for any possible emergencies wear rubber shoes and gloves Lay a rubber sheet on top of the seat and be careful not to touch the chassis with any exposed part of your body Use a signalman to give warning if the machine approaches...

Page 34: ... open the rear window and use it as an emergency escape For details see EMERGENCY EXIT FROM OPERATOR S CAB PAGE 3 31 in this manual ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste Always observe the following Spray water to keep do...

Page 35: ... engine oil pan check for clogging of the air cleaner and check for damage to the electric wiring Adjust the operator s seat to a position where it is easy to carry out operations and check that there is no dam age or wear to the seat belt or mounting clamps Check the operation of the instruments and gauges check the angle of the mirror and check that the control levers are all at the Neutral posi...

Page 36: ...ATHER Carry out the warming up operation thoroughly If the machine is not thoroughly warmed up before the control levers are operated the reaction of the machine will be slow and this may lead to unexpected accidents If the battery electrolyte is frozen do not charge the battery or start the engine with a different power source There is a hazard that this will ignite the battery Before charging or...

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Page 38: ... when possible If the machine has to travel over an obstacle keep the work equipment close to the ground and travel at low speed Never travel over obstacles which make the machine tilt strongly to one side When traveling or carrying out operations always keep a safe distance from people structures or other machines to avoid coming into contact with them When passing over bridges or structures chec...

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