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Komatsu PC220LC -8 User Manual

Komatsu PC220LC -8
397 pages
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HYDRAULIC
EXCAVATOR
TEN00354-01
PC200
-8
PC200LC
-8
PC220
-8
PC220LC
-8
SERIAL NUMBERS
PC200-315312
PC220- 80361
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

Table of Contents

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Komatsu PC220LC -8 Specifications

General IconGeneral
BrandKomatsu
ModelPC220LC -8
CategoryExcavators
LanguageEnglish

Summary

FOREWORD

CALIFORNIA Proposition 65 Warning

Safety warning regarding chemicals in California.

BEFORE READING THIS MANUAL

Ensuring Safe Operation

Guidelines for safe operation by trained personnel, following manual instructions.

SAFETY INFORMATION

Signal Words and Symbols

Explains DANGER, WARNING, CAUTION, NOTICE, and REMARKS for safety messages.

INTRODUCTION

USE OF MACHINE

Lists the primary intended uses of the Komatsu hydraulic excavator.

PRODUCT INFORMATION

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

Location and importance of the machine's identification plate for service.

SAFETY

SAFETY LABELS

Explains the purpose and care of warning and safety labels on the machine.

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Emphasizes appropriate attire and PPE for safe operation and maintenance.

FIRE PREVENTION

PRECAUTIONS TO PREVENT FIRE

Details measures to prevent fires caused by fuel, oil, or accumulated materials.

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE

Instructions for safe mounting and dismounting using designated points.

DO NOT GET CAUGHT IN WORK EQUIPMENT

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

Importance of ROPS/FOPS and seatbelt usage for operator protection.

UNAUTHORIZED MODIFICATION

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

Warnings regarding unauthorized attachments and their impact on safety and performance.

PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR JOBSITE

Guidelines for assessing and ensuring safety conditions at the worksite.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

ENSURE GOOD VISIBILITY

Importance of maintaining clear visibility and using signalmen in poor conditions.

BEWARE OF ASBESTOS DUST

STARTING ENGINE

Procedures and safety warnings for starting the machine's engine.

INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE

PRECAUTIONS WHEN STARTING ENGINE

Specific safety measures to follow during the engine starting process.

OPERATION

CHECKS BEFORE OPERATION

Daily pre-operation checks to ensure machine performance and safety.

PRECAUTIONS WHEN TRAVELING

TRAVELING ON SLOPES

Critical safety guidelines for operating the machine on inclines.

PROHIBITED OPERATIONS

Sudden Lever or Pedal Shifting High Speed Travel

Warnings against sudden movements and abrupt changes in direction or speed.

PARKING MACHINE

TRANSPORTATION

Guidelines and safety precautions for transporting the machine.

LOADING AND UNLOADING WITH TRAILER

TOWING

Procedures and safety warnings for towing a disabled machine.

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE

Essential safety steps before commencing any maintenance work.

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

Safety procedures when maintenance requires the engine to be operational.

PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT

PROPER TOOLS

Emphasizes using the correct and well-maintained tools for safety.

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

HANDLING BATTERY

Safety guidelines for handling and maintaining the machine's battery.

PRECAUTIONS WITH HIGH-PRESSURE OIL

PRECAUTIONS WITH HIGH-PRESSURE FUEL

Safety warnings related to high-pressure fuel systems during maintenance.

PRECAUTIONS FOR HIGH VOLTAGE

PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION

Specific safety measures for track tension adjustment involving high-pressure grease.

DO NOT DISASSEMBLE RECOIL SPRING

HANDLING ACCUMULATOR AND GAS SPRING

Safety instructions for handling accumulators and gas springs due to high pressure.

DISPOSING OF WASTE MATERIALS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

Importance of timely replacement of safety-critical components.

OPERATION

MACHINE VIEW ILLUSTRATIONS

Visual identification of major machine components.

CONTROLS AND GAUGES

Machine monitor

Explanation of the machine's central information display and its indicators.

DETAILED CONTROLS AND GAUGES

MONITORING SYSTEM

Detailed breakdown of the machine's monitoring system screens and indicators.

Basic Operation of Machine Monitor

Starting Engine When Situation is Normal

Step-by-step guide for starting the engine under standard conditions.

If Any Abnormality Occurs During Operation

Emergency Monitors

Identifies critical warning indicators that require immediate attention.

Caution Monitors

Fuel Level Monitor

Explains the fuel level warning indicator and action required.

Basic Check Monitors

Radiator Coolant Level Monitor

Describes the coolant level warning indicator and necessary actions.

Meter Display Portion

Pilot Display

Explanation of the pilot lamps used to confirm function actuation.

Monitor Switches Portion

Working Mode Selector Switch

How to select and change the machine's working modes for different operations.

Auto-deceleration Switch

Travel Speed Selector Switch

How to adjust and display the machine's travel speed settings.

SWITCHES

Starting Switch

Details on operating the starting switch for engine control.

CONTROL LEVERS AND PEDALS

Lock Lever

Function and operation of the lock lever for securing work equipment.

Work Equipment Control Lever

Arm control

Instructions for operating the arm using the control lever.

WORKING MODE

P mode

Explanation of the P mode for heavy-load operations emphasizing production.

PROHIBITED OPERATIONS

Sudden Lever or Pedal Shifting High Speed Travel

Warnings against sudden movements and abrupt changes in direction or speed.

GENERAL OPERATION INFORMATION

Traveling

General guidelines for safe machine travel and obstacle avoidance.

TRAVELING ON SLOPES

Engine Stopped on Slope

Procedures to follow if the engine stops while the machine is on a slope.

ESCAPE FROM MUD

Tracks on Both Sides Stuck

Steps to take if the machine becomes stuck in mud on both tracks.

RECOMMENDED APPLICATIONS

Backhoe Work

Guidance on using the backhoe attachment for optimal excavation.

BUCKET REPLACEMENT AND INVERSION

Replacement

Detailed procedure for replacing bucket teeth, including safety.

PARKING MACHINE

MACHINE INSPECTION AFTER DAILY WORK

Daily post-operation checks to ensure machine condition and safety.

LOCKING

TRANSPORTATION

General procedures and safety requirements for transporting the machine.

LOADING AND UNLOADING WITH TRAILER

Securing Machine

Steps to properly secure the machine onto a trailer for safe transport.

LIFTING MACHINE

Standard Specification Machine

Procedure for lifting the standard machine configuration safely.

COLD WEATHER OPERATION

Fuel and Lubricants

Recommendations for fuel and lubricants suitable for cold weather conditions.

AFTER DAILY WORK COMPLETION

AFTER COLD WEATHER SEASON

Actions to take when transitioning from cold weather to warmer conditions.

LONG TERM STORAGE

BEFORE STORAGE

Procedures to follow before storing the machine for an extended period.

TROUBLES AND ACTIONS

RUNNING OUT OF FUEL

Steps for restarting the engine after the fuel tank has been emptied.

TOWING THE MACHINE

LIGHTWEIGHT TOWING HOLE

Information on using the towing hole for lighter objects and permissible loads.

DISCHARGED BATTERY

Battery Removal and Installation

Detailed instructions for safely removing and installing the machine's battery.

Battery Charges

Starting Engine with Booster Cables

Step-by-step guide and safety warnings for jump-starting the engine.

OTHER TROUBLE

Electrical System

Common electrical system problems, their causes, and remedies.

Chassis

Speed of travel, swing, boom, arm, bucket is slow

Troubleshooting slow operation of travel, swing, boom, arm, and bucket.

Engine

Engine oil pressure monitor lights up

Diagnosis and remedy for the engine oil pressure warning light.

Electronic Control System

Machine Monitoring System

Explains error codes and corresponding actions for the machine monitoring system.

MAINTENANCE

MAINTENANCE INFORMATION

General guidelines and precautions for performing machine maintenance.

Dusty Jobsite

Avoid Mixing Lubricants

Instructions on proper lubricant handling to prevent contamination and issues.

OUTLINE OF SERVICE

GREASE

Procedures and recommendations for greasing machine components.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA ANALYSIS ITEMS

Details the types of oil analysis performed by KOWA for early failure detection.

FILTERS

ELECTRIC SYSTEM MAINTENANCE

Maintenance checks for the machine's electrical system components.

WEAR PARTS

WEAR PARTS LIST

A list of wear parts and their recommended replacement intervals.

RECOMMENDED FUEL, COOLANT, AND LUBRICANT

Specified capacity

Table detailing the specified oil capacities for various machine components.

TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE LIST

Table of torque specifications for various nuts and bolts.

SAFETY CRITICAL PARTS

SAFETY CRITICAL PARTS LIST

List of parts requiring periodic replacement for safety and fire prevention.

MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE CHART

Overview of maintenance intervals for various service items.

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER

Replace hydraulic filter element

Recommendations for replacing the hydraulic filter element based on breaker usage.

MAINTENANCE PROCEDURE

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)

First scheduled maintenance for new machines after 250 hours.

WHEN REQUIRED

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

Procedure for cleaning, checking, and replacing the air cleaner element.

CLEAN INSIDE OF COOLING SYSTEM

Coolant density table

Table showing required coolant density based on minimum ambient temperature.

CHECK AND TIGHTEN TRACK SHOE BOLTS

Adjustment

Instructions for adjusting and increasing track tension.

REPLACE BUCKET TEETH (VERTICAL PIN TYPE)

ADJUST BUCKET CLEARANCE

Procedure for adjusting the clearance between the bucket and adapter.

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

Mixture Ratio of Pure Washer Fluid and Water

Table detailing washer fluid and water proportions based on temperature.

CHECK AND MAINTENANCE AIR CONDITIONER

Check Level of Refrigerant (gas)

How to check the refrigerant level in the air conditioner system.

WASH WASHABLE FLOOR

Method of Washing

Steps for washing the machine's floor mat and interior.

Method of Setting Machine at Angle

Method Using Slope

How to position the machine on a slope for stability during operations.

CHECK GAS SPRING

BLEEDING AIR FROM HYDRAULIC SYSTEM

Procedures for removing air from the hydraulic system's pump, cylinders, and motor.

CHECK BEFORE STARTING

Drain water and sediment from fuel tank

Steps to drain water and sediment from the fuel tank.

EVERY 100 HOURS MAINTENANCE

LUBRICATING

Greasing points and procedures for 100-hour maintenance.

EVERY 250 HOURS MAINTENANCE

CHECK LEVEL OF BATTERY ELECTROLYTE

Procedure for checking and maintaining battery electrolyte levels.

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST

EVERY 500 HOURS MAINTENANCE

Maintenance tasks required every 500 hours, including lubrication.

LUBRICATING

LUBRICATE SWING CIRCLE

Specific instructions for lubricating the machine's swing circle.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

REPLACE FUEL PRE-FILTER CARTRIDGE

Step-by-step guide for replacing the fuel pre-filter cartridge.

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS

CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS

Instructions for cleaning the air conditioner's fresh and recirculated air filters.

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK

CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL

Procedure for checking and adding oil to the swing machinery case.

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

EVERY 1000 HOURS MAINTENANCE

Maintenance tasks required every 1000 hours.

REPLACE HYDRAULIC OIL FILTER ELEMENT

CHANGE OIL IN SWING MACHINERY CASE

Procedure for changing the oil in the swing machinery case.

CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS

CHECK FAN BELT TENSION AND REPLACE FAN BELT

Instructions for checking fan belt tension and replacing the belt.

EVERY 2000 HOURS MAINTENANCE

CHANGE OIL IN FINAL DRIVE CASE

Procedure for changing the oil in the final drive case.

CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)

CHECKING FUNCTION OF ACCUMULATOR

How to check the function and pressure of the hydraulic accumulator.

METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT

CHECK ALTERNATOR

Guidance on checking the alternator's condition.

EVERY 4000 HOURS MAINTENANCE

CHECK WATER PUMP

Procedures for checking the water pump for leaks and proper function.

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)

CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER

Checks for secure high-pressure piping clamps and rubber condition.

CHECK OPERATING CONDITION OF COMPRESSOR

EVERY 5000 HOURS MAINTENANCE

Maintenance tasks required every 5000 hours.

CHANGE OIL IN HYDRAULIC TANK

EVERY 8000 HOURS MAINTENANCE

Maintenance tasks required every 8000 hours.

REPLACE HIGH-PRESSURE PIPING CLAMP

REPLACE FUEL SPRAY PREVENTION CAP

Procedure for replacing the fuel spray prevention cap.

SPECIFICATIONS

Working ranges

Table detailing the machine's digging and working range dimensions.

ATTACHMENTS, OPTIONS

GENERAL PRECAUTIONS FOR SAFETY

Essential safety guidelines for installing and using attachments or options.

BUCKET WITH HOOK

PROHIBITED OPERATIONS

Warnings against unsafe operations when using a bucket with a hook.

MACHINE READY FOR ATTACHMENT

LOCATIONS

Diagrams showing the locations of attachment-related components.

Stop Valve

Selector Valve

Function of the selector valve for switching hydraulic oil flow.

Attachment Control Pedal

Lock Pin

How to use the lock pin to secure the attachment control pedal.

Accumulator

HYDRAULIC CIRCUIT

Explanation of the hydraulic circuit and its configurations for attachments.

Switching Hydraulic Circuit

Adjusting Oil Flow

How to adjust hydraulic oil flow based on the attachment type.

Replace Additional Breaker Filter Element

ATTACHMENT REMOVAL AND INSTALLATION

Step-by-step instructions for removing and installing attachments.

ATTACHMENT OPERATIONS

When Using Breaker

Specific operating procedures and precautions for using the hydraulic breaker attachment.

When Using General Attachment Such as Crusher

Precautions when using

General safety guidelines for operating attachments like crushers.

ATTACHMENT GUIDE

ATTACHMENT COMBINATIONS

Table showing compatible attachments with different machine arm configurations.

TRACK SHOES SELECTION

Selection

Guidance on selecting the appropriate track shoes based on operating conditions.

BUCKET TEETH SELECTION

Teeth Selection

Information on different types of bucket teeth and their applications.

HANDLING OF RUBBER PAD SHOE AND ROAD LINER

Storage and Maintenance

Instructions for storing and maintaining rubber pad shoes and road liners.

TRAPEZOIDAL BUCKET

Digging Work

Method for performing digging operations using a trapezoidal bucket.

HANDLING EXTENSION ARM

HANDLING CLAMSHELL BUCKET

Instructions for using and maintaining a clamshell bucket.

RECOMMENDED ATTACHMENT OPERATIONS

HYDRAULIC BREAKER

Guidelines for operating the hydraulic breaker attachment safely and effectively.

Prohibited Works

Pecking operations

Prohibited methods of operation for the hydraulic breaker to prevent damage.

HANDLING MACHINES EQUIPPED WITH KOMTRAX

BASIC PRECAUTIONS

Safety warnings related to the KOMTRAX system and its components.

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