Komatsu PC210-10, PC210LC-10 Maintenance Manual
UENAM00902
Operation &
Maintenance Manual
PC210
PC210LC
PC210
PC210LC
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
PC210-10 - K60001
PC210LC-10 - K60001
-10
-10
-10
DEMOLITION BASE SPEC
-10
and up
and up
DEMOLITION BASE SPEC
.
.
PC210-10 - 450120
PC210LC-10 - 450120
WARNING
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 inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
and up
and up
ORIGINAL INSTRUCTIONS
FOREWORD
k WARNING
FOREWORD:ALL-0000-001K00A
FOREWORD
SAFETY
Komatsu recommends that any service parts used for maintenance, repair or replacement of emission control systems be
genuine new Komatsu or Komatsu approved rebuilt parts or
assemblies or others parts of equivalent quality, and that the
engine be serviced by an authorized Komatsu distributor. Failure to follow these recommendations could result in ineffective
service, damage to the product or safety risks (including personal injury or death).
1–1
FOREWORD FOREWORD
k WARNING
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
q Read the safety messages and safety labels given in this manual carefully so that they should be understood
fully.
q Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all
personnel involved in working on the machine can consult it periodically.
q In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to
obtain a new copy.
q When you sell the machine, make sure that this manual should be provided to the new owner together with the
machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose,
weight units used in the past are also displayed in ().
Storage location for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.
1–2
FOREWORD SAFETY INFORMATION
k WARNING
k DANGER
k WARNING
k CAUTION
SAFETY INFORMATION
SAFETY INFORMATION:ALL-1110-010A00A
To enable you to use the machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding
such situations.
Signal Words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage
Example of safety message using signal word
When standing up from the operator’s seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause serious injury or death.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
NOTICE
REMARKS
This precaution is given where the machine may be damaged or the service life reduced
if the precaution is not followed.
This word is used for information that is useful to know.
1–3
SAFETY INFORMATION FOREWORD
Part No.
SAFETY LABELS
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using pictograms” to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side and the method of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual
Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions
regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in () in the text. (For example: -> (1))
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, 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 distributor before
operating the machine.
1–4
FOREWORD SAFETY INFORMATION
69
NOISE (PC210-10, PC210LC-10)
Two labels indicating the machine noise level are affixed on the machine.
q Sound pressure level at the operator’s station, meas-
ured according to ISO 6396 (Dynamic test method, simulated working cycle).
The maximum value of the standard deviation of the
measured time-averaged A-weighted emission sound
pressure level at the operator’s position is 2.5dB, in
accordance with ISO 11201.
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 1.0 dB.
1–5
SAFETY INFORMATION FOREWORD
VIBRATION LEVELS
q When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the
operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance
with ISO 7096
q For PC210-10, PC210LC-10
q The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s², the uncertainty for this
value is 0.53 m/s² according to EN12096:1997.
q The actual acceleration value for the body is less than or equal to 0.5 m/s², the uncertainty for this value is
0.28 m/s² according to EN12096:1997.
q These values were determined using a representative machine and measured during the typical operating
condition indicated below according to the measurement procedures that are defined in the standards ISO
2631/1 and ISO 5349.
q Operating condition:
q Excavating (Digging-loading-rotating-unloading-rotating)
q Guide to Reduce Vibration Levels on Machine
q The following guides can help an operator of this machine to reduce the whole body vibration levels:
q Use the correct equipment and attachments.
q Maintain the machine according to this manual
q Tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
q Keep the terrain where the machine is working and travelling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain condi-
tions
q Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
q Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
q Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of travelling path as large as possible
q Travel at low speed when travelling around sharp curves
q Minimize vibrations for long work cycle or long distance travelling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
q The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good health.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1–6
FOREWORD INTRODUCTION
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Levelling work
q Ditching work
q Loading work
q Demolition work
q See the section RECOMMENDED APPLICATIONS (3-198) for further details.
DIRECTIONS OF MACHINE
(A) Front (D) Right
(B) Rear (E) Operator’s seat
(C) Left (F) Sprocket
In this manual, the terms front, rear, left and right refer to the travel direction as seen from the operator’s seat
when the operator’s seat is facing the front and the sprocket is at the rear of the machine.
OPERATOR PROTECTIVE STRUCTURE
This machine is ROPS compliant to ISO12117-2:2008 when a ROPS plate is installed - see Location of safety
labels (2-5) for location of ROPS plate.
VISIBILITY FOR OPERATOR
This machine complies with the visibility standard (ISO 5006).
This machine maintains a close visibility of a height of 1.5 m at a point 1 m away from the outside surface of the
machine and a visibility for a radius of 12m.
1–7
PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION:ALL-00 00-20EK00A
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN) / MACHINE SERIAL NO. PLATE
PRODUCT IDENTIFICATION NUMBER (PIN)?MACHINE SERIAL NO. PLATE:PC-0000-20RK00A
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE
EPA regulations, engine number plate:PC220-0000-20SK00A
On the top of the engine cylinder head cover.
(The EPA auxiliary nameplate is on the top of the engine cylinder head cover).
EPA: Environmental Protection Agency, U.S.A.
1–8
FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION
Service meter location: PC-0000-20TK00A
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Your machine serial numbers and distributor:ALL-0000-20EK01A
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturers name:
Address:
KOMATSU UK Ltd.
Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
United Kingdom
Distributor name:
Address:
Service Personnel
Phone/Fax
1–9
PRODUCT INFORMATION FOREWORD
A
B
D
F
G
C
E
SERIAL PLATE
A MACHINE DESIGNATION TYPE E ENGINE POWER
B SERIAL F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D WEIGHT
1–10
FOREWORD PRODUCT INFORMATION
DECLARATION OF CONFORMITY
The manufacturer:
KOMATSU UK Ltd
Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
Declares that this machine:
PC210-10, PC210LC-10
Fulfils all the relevant provisions of the following EC Directives.
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC
1–11
PRODUCT INFORMATION FOREWORD
1–12
CONTENTS
CONTENTS
FOREWORD........................................................................................................................................ 1-1
FOREWORD................................................................................................................................... 1-2
SAFETY INFORMATION................................................................................................................ 1-3
NOISE (PC210-10, PC210LC-10) ............................................................................................. 1-5
INTRODUCTION ............................................................................................................................ 1-7
DIRECTIONS OF MACHINE ..................................................................................................... 1-7
OPERATOR PROTECTIVE STRUCTURE ............................................................................... 1-7
VISIBILITY FOR OPERATOR ................................................................................................... 1-7
PRODUCT INFORMATION ............................................................................................................ 1-8
PRODUCT IDENTIFICATION NUMBER (PIN) / MACHINE SERIAL NO. PLATE .................... 1-8
EPA REGULATIONS, ENGINE NUMBER PLATE .................................................................... 1-8
SERVICE METER LOCATION .................................................................................................. 1-9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR .................................................... 1-9
SERIAL PLATE........................................................................................................................ 1-10
CONTENTS .................................................................................................................................. 1-13
SAFETY ............................................................................................................................................... 2-1
SAFETY.......................................................................................................................................... 2-2
SAFETY LABELS ........................................................................................................................... 2-4
LOCATION OF SAFETY LABELS............................................................................................. 2-5
SAFETY LABELS ...................................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................ 2-15
PRECAUTIONS BEFORE STARTING OPERATION.............................................................. 2-15
PREPARATIONS FOR SAFE OPERATION ........................................................................... 2-16
FIRE PREVENTION ................................................................................................................ 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ................................................... 2-20
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................... 2-22
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.............................................. 2-22
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS ........................... 2-23
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES .................................. 2-23
UNAUTHORIZED MODIFICATION ......................................................................................... 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ......................................... 2-24
PRECAUTIONS RELATED TO CAB GLASS .......................................................................... 2-24
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ........................................... 2-24
PRECAUTIONS FOR OPERATION ............................................................................................. 2-25
PRECAUTIONS FOR JOBSITE .............................................................................................. 2-25
SAFETY MACHINE OPERATION ................................................................................................ 2-28
STARTING ENGINE ................................................................................................................ 2-28
WHEN OPERATING................................................................................................................ 2-31
TRANSPORTATION................................................................................................................ 2-38
TOWING .................................................................................................................................. 2-39
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) ..... 2-40
SAFETY RULES FOR LIFTING OBJECTS ............................................................................. 2-40
PRECAUTIONS FOR MAINTENANCE ........................................................................................ 2-43
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ......................... 2-43
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ................................................... 2-47
OPERATION........................................................................................................................................ 3-1
GENERAL VIEW............................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................ 3-2
GENERAL VIEW OF CAB ......................................................................................................... 3-4
GENERAL VIEW OF CONTROLS AND GAUGES ................................................................... 3-6
EXPLANATION OF COMPONENTS .............................................................................................. 3-9
MACHINE MONITOR ................................................................................................................ 3-9
SWITCHES.............................................................................................................................. 3-76
CONTROL LEVERS AND PEDALS ........................................................................................ 3-85
CEILING WINDOW.................................................................................................................
OPENING AND CLOSING CAB FRONT WINDOW ................................................................ 3-88
EMERGENCY ESCAPE HAMMER ......................................................................................... 3-93
.3-87
1–13
CONTENTS
DOOR LOCK ........................................................................................................................... 3-94
CAB DOOR HINGE ................................................................................................................. 3-94
OPENING AND CLOSING ENGINE HOOD ............................................................................ 3-95
CAPS AND COVERS WITH LOCK ......................................................................................... 3-99
DRINK BOX ........................................................................................................................... 3-102
MAGAZINE BOX ................................................................................................................... 3-102
CUP HOLDER ....................................................................................................................... 3-102
ASHTRAY.............................................................................................................................. 3-103
HANDLING AIR CONDITIONER ........................................................................................... 3-104
HANDLING RADIO................................................................................................................ 3-116
SPACE FOR RADIO CASSETTE.......................................................................................... 3-120
AUXILIARY ELECTRIC POWER........................................................................................... 3-121
FUSE ..................................................................................................................................... 3-122
FUSIBLE LINK....................................................................................................................... 3-124
CONTROLLER ...................................................................................................................... 3-125
TOOL BOX ............................................................................................................................ 3-125
GREASE PUMP HOLDER .................................................................................................... 3-126
FIRE EXTINGUISHER........................................................................................................... 3-126
BATTERY DISCONNECT SWITCH ...................................................................................... 3-127
SYSTEM OPERATING LAMP ............................................................................................... 3-128
HANDLING KDPF.................................................................................................................. 3-129
HANDLING KCCV ................................................................................................................. 3-138
HANDLING MACHINES EQUIPPED WITH KOMTRAX........................................................ 3-139
MACHINE OPERATIONS AND CONTROLS ............................................................................. 3-141
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ............................................ 3-141
STARTING ENGINE.............................................................................................................. 3-163
OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................ 3-166
STOPPING ENGINE ............................................................................................................. 3-177
MACHINE OPERATION ........................................................................................................ 3-178
STEERING MACHINE........................................................................................................... 3-182
SWINGING MACHINE........................................................................................................... 3-184
WORK EQUIPMENT CONTROLS AND OPERATIONS ....................................................... 3-185
WORKING MODE ................................................................................................................. 3-187
PROHIBITED OPERATIONS ................................................................................................ 3-190
RULES FOR OPERATION .................................................................................................... 3-193
TRAVELLING ON SLOPES................................................................................................... 3-195
ESCAPE FROM MUD ........................................................................................................... 3-197
RECOMMENDED APPLICATIONS....................................................................................... 3-198
REPLACING AND INVERTING BUCKET ............................................................................. 3-200
WHEN PARKING MACHINE ................................................................................................. 3-204
AFTER DAILY WORK COMPLETION................................................................................... 3-206
LOCKING............................................................................................................................... 3-206
TRANSPORTATION................................................................................................................... 3-207
TRANSPORTATION PROCEDURE...................................................................................... 3-207
LOADING AND UNLOADING WITH TRAILER ..................................................................... 3-208
LIFTING MACHINE ............................................................................................................... 3-223
COLD WEATHER OPERATION................................................................................................. 3-225
COLD WEATHER OPERATION INFORMATION ................................................................. 3-225
AFTER DAILY WORK COMPLETION................................................................................... 3-226
AFTER COLD WEATHER SEASON ..................................................................................... 3-226
LONG-TERM STORAGE............................................................................................................ 3-227
BEFORE STORAGE ............................................................................................................. 3-227
DURING STORAGE .............................................................................................................. 3-227
AFTER STORAGE ................................................................................................................ 3-228
STARTING MACHINE AFTER LONG-TERM STORAGE ..................................................... 3-228
TROUBLES AND ACTIONS ....................................................................................................... 3-229
RUNNING OUT OF FUEL ..................................................................................................... 3-229
PHENOMENA THAT ARE NOT FAILURES.......................................................................... 3-229
1–14
CONTENTS
TOWING MACHINE .............................................................................................................. 3-230
LIGHTWEIGHT TOWING HOLE ........................................................................................... 3-231
SEVERE JOB CONDITION ................................................................................................... 3-231
DISCHARGED BATTERY ..................................................................................................... 3-232
OTHER TROUBLE ................................................................................................................ 3-236
MAINTENANCE................................................................................................................................... 4-1
RULES FOR MAINTENANCE ........................................................................................................ 4-2
SERVICE METER READING .................................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS....................................................................... 4-2
KOMATSU GENUINE LUBRICANTS ........................................................................................ 4-2
ALWAYS USE CLEAN WASHER FLUID .................................................................................. 4-2
FRESH AND CLEAN LUBRICANTS ......................................................................................... 4-2
CHECK DRAINED OIL AND USED FILTER ............................................................................. 4-2
FUEL STRAINER ...................................................................................................................... 4-2
WELDING INSTRUCTIONS ...................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ............................................................................ 4-2
DUSTY WORKSITES ................................................................................................................ 4-3
AVOID MIXING OIL ................................................................................................................... 4-3
LOCKING INSPECTION COVERS ........................................................................................... 4-3
BLEEDING AIR FROM HYDRAULIC CIRCUIT......................................................................... 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ................................................... 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE ............................................................ 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ................................ 4-3
CLOSE ENGINE HOOD SECURELY........................................................................................ 4-3
OUTLINE OF SERVICE.................................................................................................................. 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................... 4-4
HANDLING ELECTRICAL COMPONENTS .............................................................................. 4-7
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.................................................... 4-8
TIGHTENING TORQUE LIST.................................................................................................... 4-8
MAINTENANCE SCHEDULE ......................................................................................................... 4-9
MAINTENANCE SCHEDULE TABLE........................................................................................ 4-9
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ................................................... 4-11
MAINTENANCE SCHEDULE TABLE........................................................................................... 4-12
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) .................. 4-12
WHEN REQUIRED.................................................................................................................. 4-12
CHECKS BEFORE STARTING ............................................................................................... 4-39
EVERY 100 HOURS MAINTENANCE .................................................................................... 4-40
EVERY 250 HOURS MAINTENANCE .................................................................................... 4-41
EVERY 500 HOURS MAINTENANCE .................................................................................... 4-45
EVERY 1000 HOURS MAINTENANCE .................................................................................. 4-59
EVERY 2000 HOURS MAINTENANCE .................................................................................. 4-65
EVERY 4000 HOURS MAINTENANCE .................................................................................. 4-74
EVERY 4500 HOURS MAINTENANCE .................................................................................. 4-78
EVERY 5000 HOURS MAINTENANCE .................................................................................. 4-79
EVERY 8000 HOURS MAINTENANCE .................................................................................. 4-80
END OF SERVICE LIFE ............................................................................................................... 4-81
SPECIFICATIONS ............................................................................................................................... 5-1
SPECIFICATIONS .......................................................................................................................... 5-2
EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC-10
1-PIECE BOOM......................................................................................................................... 5-4
ATTACHMENTS AND OPTIONS ........................................................................................................ 6-1
GENERAL PRECAUTIONS FOR SAFETY .................................................................................... 6-2
PRECAUTIONS WHEN SELECTING ....................................................................................... 6-2
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY ............................ 6-2
PRECAUTIONS WHEN REMOVING OR INSTALLING ............................................................ 6-2
PRECAUTIONS WHEN USING ................................................................................................ 6-2
HANDLING QUICK COUPLER....................................................................................................... 6-4
AUTOMATIC GREASE SYSTEM ................................................................................................... 6-7
1–15
CONTENTS
CHECK AUTO-GREASING SYSTEM ..................................................................................... 6-10
BUCKET WITH HOOK.................................................................................................................. 6-13
HOOK CONDITION ................................................................................................................. 6-13
PROHIBITED OPERATIONS .................................................................................................. 6-13
MACHINE READY FOR INSTALLATION OF ATTACHMENT ..................................................... 6-14
EXPLANATION OF COMPONENTS ....................................................................................... 6-14
HYDRAULIC CIRCUIT ............................................................................................................ 6-18
REMOVAL AND INSTALLATION OF ATTACHMENT ............................................................ 6-25
ATTACHMENT OPERATIONS................................................................................................ 6-28
LONG-TERM STORAGE......................................................................................................... 6-31
SPECIFICATIONS................................................................................................................... 6-32
ARM/PIN INFORMATION........................................................................................................ 6-32
ATTACHMENTS AND OPTIONS ................................................................................................. 6-33
ATTACHMENT COMBINATIONS ........................................................................................... 6-33
TRACK SHOES SELECTION.................................................................................................. 6-34
BUCKET TEETH SELECTION ................................................................................................ 6-35
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ..................................................... 6-36
HANDLING TRAPEZOIDAL BUCKET..................................................................................... 6-38
HANDLING EXTENSION ARM ............................................................................................... 6-40
HANDLING CLAMSHELL BUCKET ........................................................................................ 6-41
RECOMMENDED ATTACHMENT OPERATIONS....................................................................... 6-42
HYDRAULIC BREAKER.......................................................................................................... 6-42
REPLACEMENT PARTS ..................................................................................................................... 7-1
SAFETY CRITICAL PARTS............................................................................................................ 7-2
SAFETY CRITICAL PARTS LIST.............................................................................................. 7-2
CONSUMABLE PARTS.................................................................................................................. 7-3
CONSUMABLE PARTS LIST .................................................................................................... 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .............................................................. 7-4
LUBRICATION CHART ............................................................................................................. 7-5
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE............ 7-7
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER
THAN KOMATSU GENUINE OIL .............................................................................................. 7-8
INDEX .................................................................................................................................................. 8-1
1–16
SAFETY
k WARNING
SAFETY:ALL-0000-001K01A
SAFETY
SAFETY
Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the
machine. When operating or servicing the machine, always follow these precautions strictly.
2–1
SAFETY SAFETY
SAFETY
Safety:PC220-1210-002A00A
SAFETY................................................................................................................................................. 2-2
SAFETY LABELS .................................................................................................................................. 2-4
LOCATION OF SAFETY LABELS ................................................................................................... 2-5
SAFETY LABELS............................................................................................................................. 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ................................. 2-15
PRECAUTIONS BEFORE STARTING OPERATION ...................................................................... 2-15
ENSURING SAFE OPERATION ................................................................................................ 2-15
UNDERSTANDING THE MACHINE ........................................................................................... 2-15
PREPARATIONS FOR SAFE OPERATION .................................................................................... 2-16
SAFETY-RELATED EQUIPMENT.............................................................................................. 2-16
INSPECTING MACHINE ............................................................................................................ 2-16
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ...................................... 2-16
KEEP MACHINE CLEAN ............................................................................................................ 2-16
INSIDE OPERATOR’S COMPARTMENT .................................................................................. 2-16
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ............................................................. 2-17
IF ANY PROBLEM IS FOUND.................................................................................................... 2-17
FIRE PREVENTION......................................................................................................................... 2-18
ACTION IF FIRE OCCURS ........................................................................................................ 2-18
PREVENT FIRE.......................................................................................................................... 2-18
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................ 2-20
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE .............................. 2-20
NO JUMPING ON OR OFF MACHINE ....................................................................................... 2-20
LIFTING OF PERSONNEL PROHIBITED .................................................................................. 2-20
NO PEOPLE ON ATTACHMENTS ............................................................................................. 2-20
WHEN STANDING UP FROM OPERATOR’S SEAT ................................................................. 2-21
WHEN LEAVING MACHINE....................................................................................................... 2-21
EMERGENCY EXIT FROM OPERATOR’S CAB ....................................................................... 2-21
ELECTROMAGNETIC INTERFERENCE ................................................................................... 2-21
DO NOT GET CAUGHT IN WORK EQUIPMENT............................................................................ 2-22
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...................................................... 2-22
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS .................................... 2-23
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES .......................................... 2-23
UNAUTHORIZED MODIFICATION.................................................................................................. 2-23
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................. 2-24
PRECAUTIONS RELATED TO CAB GLASS .................................................................................. 2-24
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING .................................................... 2-24
PRECAUTIONS FOR OPERATION ...................................................................................................... 2-25
PRECAUTIONS FOR JOBSITE ....................................................................................................... 2-25
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS .......................................................... 2-25
WORK ON LOOSE GROUND .................................................................................................... 2-25
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ................................................................. 2-26
ENSURE GOOD VISIBILITY ...................................................................................................... 2-26
CHECK SIGNS AND SIGNALMAN’S SIGNALS......................................................................... 2-27
BEWARE OF ASBESTOS DUST ............................................................................................... 2-27
SAFETY MACHINE OPERATION ......................................................................................................... 2-28
STARTING ENGINE ........................................................................................................................ 2-28
USE WARNING TAGS ............................................................................................................... 2-28
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ................................................. 2-28
WHEN STARTING ENGINE ....................................................................................................... 2-29
IN COLD AREAS ........................................................................................................................ 2-29
START ENGINE WITH BOOSTER CABLES ............................................................................. 2-30
WHEN OPERATING ........................................................................................................................ 2-31
CHECKS BEFORE OPERATION ............................................................................................... 2-31
WHEN TRAVELING IN FORWARD OR REVERSE AND SWINGING....................................... 2-31
WHEN TRAVELLING.................................................................................................................. 2-32
WHEN TRAVELLING ON SLOPES ............................................................................................ 2-32
2–2
SAFETY SAFETY
WHEN OPERATING ON SLOPES ............................................................................................. 2-34
PROHIBITED OPERATIONS ..................................................................................................... 2-34
WHEN OPERATING ON SNOW OR FROZEN SURFACES ..................................................... 2-36
WHEN PARKING MACHINE ...................................................................................................... 2-36
TRANSPORTATION ........................................................................................................................ 2-38
SAFETY RULES FOR LOADING AND UNLOADING ................................................................ 2-38
SHIPPING THE MACHINE ......................................................................................................... 2-38
TOWING........................................................................................................................................... 2-39
SAFETY RULES FOR TOWING................................................................................................. 2-39
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) .............. 2-40
SAFETY RULES FOR LIFTING OBJECTS ..................................................................................... 2-40
SAFETY RULES FOR LIFTING OBJECTS ................................................................................ 2-42
PRECAUTIONS FOR MAINTENANCE ................................................................................................. 2-43
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE.................................. 2-43
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ................................ 2-43
KEEP WORKPLACE CLEAN AND TIDY.................................................................................... 2-43
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ................................... 2-43
ONLY AUTHORIZED PERSONNEL........................................................................................... 2-43
STABILITY.................................................................................................................................. 2-43
GUARDS..................................................................................................................................... 2-43
END OF SERVICE LIFE .............................................................................................................2-43
APPOINT LEADER WHEN WORKING WITH OTHERS ............................................................ 2-44
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE .................... 2-44
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................... 2-45
INSTALLING, REMOVING, OR STORING ATTACHMENTS..................................................... 2-45
WORK AT HIGH PLACES .......................................................................................................... 2-45
WORK ON MACHINE.................................................................................................................2-46
WORK UNDER MACHINE OR WORK EQUIPMENT ................................................................ 2-46
PROPER TOOLS........................................................................................................................ 2-46
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ............................................................ 2-47
TURN OFF THE BATTERY DISCONNECT SWITCH ................................................................ 2-47
WELDING INSTRUCTIONS ....................................................................................................... 2-47
BATTERY ................................................................................................................................... 2-47
WHEN USING HAMMER............................................................................................................ 2-48
HIGH-TEMPERATURE COOLANT ............................................................................................ 2-48
HIGH-TEMPERATURE PARTS.................................................................................................. 2-48
HIGH-TEMPERATURE OIL........................................................................................................ 2-48
HIGH-PRESSURE OIL ...............................................................................................................2-49
HIGH-PRESSURE FUEL............................................................................................................ 2-49
HIGH-PRESSURE HOSES AND PIPING................................................................................... 2-49
HIGH VOLTAGE ......................................................................................................................... 2-49
NOISE......................................................................................................................................... 2-50
HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION ...................................... 2-50
DO NOT DISASSEMBLE RECOIL SPRING .............................................................................. 2-50
ACCUMULATOR AND GAS SPRING ........................................................................................ 2-50
COMPRESSED AIR ................................................................................................................... 2-51
MAINTENANCE OF AIR CONDITIONER................................................................................... 2-51
CHEMICAL HAZARD.................................................................................................................. 2-51
DISPOSE OF WASTE MATERIALS........................................................................................... 2-51
SELECT WINDOW WASHER FLUID ......................................................................................... 2-51
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................... 2-52
2–3
SAFETY LABELS SAFETY
SAFETY LABELS
SAFETY LABELS:ALL-Q5L0-043K00A
The following warning signs and safety labels are used on this machine.
q Be sure that you fully understand the correct position and content of labels.
q 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 petrol. These may cause the labels to
peel off.
q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
q 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.
2–4
SAFETY SAFETY LABELS
X
g
h
1
a
b
c
d
e
f
KS000651
X
LOCATION OF SAFETY LABELS
Location of safety labels:PC220_ KU-Q5L0-04DK00A
a: if equipped
2–5
SAFETY LABELS SAFETY
SAFETY LABELS
SAFETY LABELS:PC220_KU-Q5L1-012K00A
(1) (20Y-00–K2021)
q Warnings for operation, inspection and maintenance.
q Improper operation and maintenance can cause serious
injury or death.
q Read the manual and labels before operation and mainte-
nance.
Follow instructions and warnings in manual and in labels on
machine.
q Warning!
q a. Read the manual before operating, maintenance, disas-
sembly, assembly and transportation.
q b. Before standing up from operator’s seat.
q Lower work equipment to ground and move safety lock
lever (located near seat) to lock position to avoid hitting
unlocked operation levers.
q Sudden and unwanted machine movement can cause seri-
ous injury or death.
2–6
SAFETY SAFETY LABELS
k WARNING
q c. WARNING — No passengers
No passengers allowed to ride on machine while it is
moving.
q d. WARNING — DANGER OF FALLING OBJECTS
Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection.
q e. Caution for going close to electric cables.
q An electrocution hazard if the machine is brought too near
to electric power lines.
q Keep a safe distance from electric power lines.
q f. Control levers operational function diagram.
q In order to prevent an accident resulting in injury or
death caused by error-operation, confirm the machine
motion and indicated operating pattern, when operating machines. Pay attention to the circumference and
operate slowly when confirming the machine motion.
2–7
SAFETY LABELS SAFETY
q g. Caution when standing in operator cab
q Before standing up from the operator’s seat (such as when
opening or closing the front window or roof window, or when
removing or installing the bottom window, or when adjusting
the operator’s seat), always lower the work equipment completely to the ground, set lock lever (1) securely to the
LOCK position (L), then stop the engine. If you accidentally
touch the control levers (pedals) when they are not locked,
there is a hazard that the machine may suddenly move and
cause serious injury or property damage.
q (h) Caution when reversing
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:
q Sound horn to alert people nearby.
Be sure no one is on or near machine or in swing area.
Rotate cab for full view of travel path if it can be done safely.
Use spotter if view is obstructed.
Follow the above even if machine is equipped with travel alarm,
mirrors and rear view camera.
2–8
SAFETY SAFETY LABELS
k WARNING
To open or close the front or ceiling windows, never stand up from the operator’s seat before throwing
the safety lock lever to the LOCK position.
Inadvertently touching any of the working equipment control levers might cause the machine to start
moving all of a sudden, probably resulting in a serious injury.
(2) Caution when stowing front window (09803-A0481)
q Sign indicates a hazard from falling window.
q After raising window, be sure to lock it in place with lock
pins.
(3) Caution for high-temperature coolant and hydraulic oil
(09653-A0481)
q Never remove the cap when the engine is at operating
(high) temperature. Steam or high temperature oil blowing
up from the radiator or hydraulic tank, will cause personal
injury and/or burns.
q Never remove the radiator cap or hydraulic tank oil filler
when cooling water or hydraulic oil is at high temperature.
(4) Caution for handling accumulator and gas spring
(09659-A057B)
q There is a hazard of explosion causing injury.
q Do not disassemble the accumulator, make holes in it, weld
it, cut it, hit it, roll it or bring it near flame.
2–9
SAFETY LABELS SAFETY
(5) Caution when adjusting track tension (09657-A0881)
q Sign indicates a hazard of flying plug from track adjuster
that could cause injury.
q Read manual regarding adjusting track for safe and proper
handling.
(6) Caution when handling cable (09808-A0881)
q Sign indicates an electric hazard from handling the cable.
q Read manual for safe and proper handling.
(7) Stopping rotation for inspection and maintenance (09667A0481)
q Sign indicates a hazard of rotating parts, such as belt.
q Turn off before inspection and maintenance.
(8) Emergency escape (09844-00050)
2–10
SAFETY SAFETY LABELS
(9) Caution against falling (09805-C0481)
q Sign indicates a hazard of falling.
q Do not stand on this place here
(10) Prohibited to enter swing radius (09133-A3281)
q There is a danger of getting caught when upper structure
swings.
q Do not enter range of swing
(11) Keeping out of working range area (09134-A1681)
q Sign indicates a hazard of being hit by the working device of
the machine.
q Keep away from the machine during operation.
2–11
SAFETY LABELS SAFETY
k WARNING
(12) Prohibition of jump start (09842-A0481)
q Start the engine only after sitting down in the operator’s
seat.
Do not attempt to start the engine by short-circuiting the engine
starting circuit. Such an act may cause a serious bodily injury
or fire.
(13) Caution for use of hydraulic quick coupler piping system
(20J-00–11271)
q There is a danger of an exposed person being killed by fall-
ing attachment.
q Read the manual for safe operation.
(14) Caution when swinging or travelling in reverse
(09833-A0881)
q When swinging or backing up excavator, press button
to change display mode on monitor so you can see rear
and side of machine.
Before moving, look around and at mirror and monitor
to confirm that no one is around the machine. Failure to
do so can result in serious injury or death.
(15) Caution when handling batteries (09664-60001)
(a) Never smoke or use any naked flame near the batteries, no
sparks.
2–12
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