Page 1 Operation & UENAM00902 Maintenance Manual PC210 PC210LC PC210 DEMOLITION BASE SPEC PC210LC DEMOLITION BASE SPEC HYDRAULIC EXCAVATOR SERIAL NUMBERS PC210-10 - K60001 and up PC210LC-10 - K60001 and up PC210-10 - 450120 and up PC210LC-10 - 450120 and up WARNING...
Page 3: Foreword
FOREWORD:ALL-0000-001K00A SAFETY WARNING Komatsu recommends that any service parts used for mainte- nance, 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.
Page 4 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. In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
Page 5 FOREWORD SAFETY INFORMATION 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.
Page 6 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.
Page 7: Noise (Pc210-10, Pc210Lc-10)
FOREWORD SAFETY INFORMATION NOISE (PC210-10, PC210LC-10) Two labels indicating the machine noise level are affixed on the machine. Sound pressure level at the operator’s station, meas- ured according to ISO 6396 (Dynamic test method, sim- ulated 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...
Page 8 ISO 7096 For PC210-10, PC210LC-10 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...
Page 9: Introduction
FOREWORD INTRODUCTION INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: Digging work Levelling work Ditching work Loading work Demolition work See the section RECOMMENDED APPLICATIONS (3-198) for further details. DIRECTIONS OF MACHINE (A) Front...
Page 10: Product Information
PRODUCT INFORMATION FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION:ALL-0000-20EK00A 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.
Page 11: Service Meter Location
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: KOMATSU UK Ltd. Address: Durham Road Birtley Chester-Le-Street County Durham DH3 2QX United Kingdom Distributor name:...
Page 12: Serial Plate
PRODUCT INFORMATION FOREWORD 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...
Page 13 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...
Page 14 PRODUCT INFORMATION FOREWORD 1–12...
Page 15: Table Of Contents
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 ..............
Page 16: Contents
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........................
Page 17 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 ........................
Page 18 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...
Page 19: Safety
SAFETY SAFETY SAFETY:ALL-0000-001K01A SAFETY WARNING Please read and make sure that you fully understand the pre- cautions described in this manual and the safety labels on the machine. When operating or servicing the machine, always fol- low these precautions strictly. 2–1...
Page 20 SAFETY SAFETY SAFETY Safety:PC220-1210-002A00A SAFETY..............................SAFETY LABELS ..........................LOCATION OF SAFETY LABELS ....................SAFETY LABELS..........................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....................
Page 21 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............................
Page 22: Safety Labels
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.
Page 23: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS Location of safety labels:PC220_KU-Q5L0-04DK00A KS000651 a: if equipped 2–5...
Page 24: Safety Labels
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.
Page 25 SAFETY SAFETY LABELS 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.
Page 26 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 com- pletely to the ground, set lock lever (1) securely to the LOCK position (L), then stop the engine.
Page 27 SAFETY SAFETY LABELS 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.
Page 28 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.
Page 29 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.
Page 30 SAFETY LABELS SAFETY (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.
Page 31 SAFETY SAFETY LABELS (b) Always wear safety glasses when working with batteries. (c) Keep children away from batteries. (d) Caution battery acid. (e) Read the operator’s manual before working with batteries. (f) Caution - explosive gases. (16) Caution when replacing fresh air filter (208-00-71261) q After replacing fresh air filter remember to remove key from cover as the key may get damaged when cab door is opened.
Page 32 If any modification is applied to the ROPS, it may affect the strength and may not comply with the standard. Consult your Komatsu Distributor before altering. q ROPS may provide less protection if it has been structurally damaged or involved in roll-over.
Page 33: General Precautions Common To Operation And Maintenance
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE General precautions common to operation and maintenance:ALL-1130-010A00A Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 34: Preparations For Safe Operation
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY PREPARATIONS FOR SAFE OPERATION Preparations for safe operation:ALL-0000-001K08A SAFETY-RELATED EQUIPMENT Safety-related equipment:ALL-0000-127K00A q Be sure that all guards, covers, cameras, and mirrors are in their proper position. Have them repaired immedi- ately if they are damaged. q Understand the method of use of safety features and use them properly.
Page 35: Provide Fire Extinguisher And First Aid Kit
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Provide fire extinguisher and first aid kit:ALL-Q5G5-012K00A Always follow the precautions below to prepare for action if any injury or fire should occur. q Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies.
Page 36: Fire Prevention
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY FIRE PREVENTION Fire prevention:ALL-0000-001K09A ACTION IF FIRE OCCURS Action if fire occurs:ALL-0000-17AK00A q Turn the start switch OFF to stop the engine. q Use the handrails and steps to get off the machine. q Do not jump off the machine.
Page 37 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE q Fire around the machine due to highly heat exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust gas discharged during purification process (regeneration) can be at higher temperature than that from existing models.
Page 38: Precautions When Getting On Or Off Machine
Do not climb on the step if it is damaged. q Damaged steps must be repaired immediately. Please call your Komatsu distributor and ask for repair or replacement of the step. q Always face the machine and maintain at least three-point...
Page 39: When Standing Up From Operator's Seat
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE WHEN STANDING UP FROM OPERATOR’S SEAT When standing up from operator’s seat:PC-0000-17GK00A Before standing up from the operator's seat, such as when opening or closing the front window or ceiling window, when removing or installing the bottom window, or adjusting the posi- tion of the seat, always lower the work equipment completely to the ground, set lock lever (1) to lock position (L), and stop the...
Page 40: Do Not Get Caught In Work Equipment
In such cases, always contact your Komatsu distributor for advice on the method of repair. q Even if the protective structure is installed, always fasten your seat belt properly when operating the machine.
Page 41: Protection Against Falling, Flying, Or Intruding Objects
No attempt should be made to repair these parts as this may have an adverse effect on component strength or durability. If such a repair is undertaken without authorisation from Komatsu there is a danger that a problem might occur that will lead to serious personal injury.
Page 42: Precautions Related To Attachments And Options
The machine weight will not exceed the ROPS certified value as long as the optional attachments written in the attachment combination table of this manual are installed. When installing optional attachments other than written in this manual, their weight may exceed the certified value, so please contact your Komatsu distributor before installing.
Page 43: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION Precautions for operation:ALL-1140-001A00A PRECAUTIONS FOR JOBSITE Precautions for jobsite:PC-0000-001K08A INVESTIGATE AND CONFIRM JOBSITE CONDITIONS Investigate and confirm jobsite conditions:ALL-0000-17RK00A On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera- tions, always check the following to confirm that there is no danger on the jobsite.
Page 44: Do Not Go Close To High-Voltage Cables
If the machine is equipped with cameras, clean off any dirt from the lens and make sure that the camera gives a clear view. If there is any problem with the camera and the rear view cannot be displayed, contact your Komatsu distributor immediately and ask for repairs to be carried out. 2–26...
Page 45: Check Signs And Signalman's Signals
Do not allow other persons to approach during the opera- tion. q Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. 2–27...
Page 46: Safety Machine Operation
SAFETY MACHINE OPERATION SAFETY SAFETY MACHINE OPERATION STARTING ENGINE Starting engine:ALL-0000-001K05A USE WARNING TAGS USE WARNING TAGS::PC220_KU-0000-17YK00A If there is any "DANGER! Do NOT operate!" warning tag dis- played, it means that someone is carrying out inspection and maintenance of the machine. If the warning sign is ignored and the machine is operated, there is danger that the person carry- ing out inspection or maintenance may be caught in the rotat- ing parts or moving parts and suffer serious personal injury or...
Page 47: When Starting Engine
SAFETY SAFETY MACHINE OPERATION q Before starting the engine, check that lock lever (1) is in LOCK position (L). q Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. When adjusting, see "Mirrors adjustment (3-154)". q Adjust the angle of each camera so that the surrounding area can be seen clearly from the operator's seat.
Page 48: Start Engine With Booster Cables
SAFETY MACHINE OPERATION SAFETY START ENGINE WITH BOOSTER CABLES Start engine with booster cables:ALL-AW10-14JK00A If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always observe the following. q Always wear protective eyeglasses and rubber gloves when starting the engine with booster cable.
Page 49: When Operating
SAFETY SAFETY MACHINE OPERATION WHEN OPERATING When operating:ALL-0000-001K11A CHECKS BEFORE OPERATION CHECKS BEFORE OPERATION:PC-0000-184K00A If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.
Page 50: When Travelling
SAFETY MACHINE OPERATION SAFETY WHEN TRAVELLING WHEN TRAVELING:PC-0000-186K00A Serious personal injury can result from tipping over of the travelling machine or its accidental contact. Always observe the following. q When travelling or carrying out operations, always keep a safe distance from people, structures, or other machines to avoid coming into contact with them.
Page 51 SAFETY SAFETY MACHINE OPERATION q When travelling up a steep slope, extend the work equip- ment to the front to improve the balance, keep the work equipment approximately 20 to 30 cm above the ground, and travel at low speed. q When travelling downhill, lower the engine speed, keep the travel lever close to the NEUTRAL position, and travel at low speed.
Page 52: When Operating On Slopes
SAFETY MACHINE OPERATION SAFETY WHEN OPERATING ON SLOPES When operating on slopes:PC-0000-188K01A q When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.
Page 53 SAFETY SAFETY MACHINE OPERATION q When carrying out demolition work, do not carry out demoli- tion work under the front of the machine. This makes the ground unstable, and there is a hazard of the machine fall- ing. q When carrying out demolition work, do not carry out demoli- tion work above your head.
Page 54: When Operating On Snow Or Frozen Surfaces
SAFETY MACHINE OPERATION SAFETY q In the operation using the fork or grapple, do not attempt to pick up an object with their tips. There is a danger of damage to the machine or personal injury, as the picked - up object can easily slip off. WHEN OPERATING ON SNOW OR FROZEN SURFACES When operating on snow or frozen surfaces:PC-0000-18AK00A q Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the...
Page 55 SAFETY SAFETY MACHINE OPERATION q If it is necessary to park the machine on a slope, always do as follows. Set the work equipment on the downhill side and dig it into the ground. In addition, put blocks under the tracks to prevent the machine from moving.
Page 56: Transportation
The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. When transporting the machine, please contact your Komatsu distributor to have the work carried out.
Page 57: Towing
SAFETY SAFETY MACHINE OPERATION TOWING Towing:ALL-0000-001K15A SAFETY RULES FOR TOWING SAFETY RULES FOR TOWING:ALL-0000-147K00A Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or tow- ing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For towing, see "Towing machine (3-230)".
Page 58: Lifting Objects With Bucket Link Lifting Device (Optional Equipment)
SAFETY MACHINE OPERATION SAFETY LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) SAFETY RULES FOR LIFTING OBJECTS q Determine the signals to be used and place a signalman in position. q To prevent the machine from tipping over or falling, carry out the operation on flat ground. q To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker inside the area.
Page 59 SAFETY SAFETY MACHINE OPERATION q Do not use the work equipment or swing to pull the load in any direction. There is a danger that the lifting eye may be damaged due to abnormal loading making it unsafe to lift. q The operator or person attaching the sling should inspect the bucket link lifting device and all components in the load line (e.g.
Page 60: Safety Rules For Lifting Objects
SAFETY MACHINE OPERATION SAFETY LIFTING OBJECTS WITH BUCKETS SAFETY RULES FOR LIFTING OBJECTS q Determine the signals to be used and place a signalman in position. q To prevent the machine from tipping over or falling, carry out the operation on flat ground. q To prevent the danger of contact with a raised load or the danger from a falling load, do not allow any worker inside the area.
Page 61: Precautions For Maintenance
Guards are installed in the area of the engine to protect personnel from moving parts. These guards should only be removed by a Komatsu service engineer unless specific instructions are given in this manual. END OF SERVICE LIFE q For safe dismantling of the machine at end of service life, please contact you Komatsu Distributor. 2–43...
Page 62: Appoint Leader When Working With Others
(After turning off the starting switch, wait for approximately 1 minute and press the horn switch. If the horn does not sound, power is not conducted.) q Put blocks under the track to prevent the machine from moving. q Allow Komatsu Diesel Particulate Filter to cool. 2–44...
Page 63: Two Workers For Maintenance When Engine Is Running
SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING:PC220-0000-2ACK00A To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and observe the following. q One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 64: Work On Machine
PRECAUTIONS FOR MAINTENANCE SAFETY WORK ON MACHINE WORK ON MACHINE:PC-0000-2AWK00A q When carrying out maintenance work on the machine, maintain the foothold clean and orderly to prevent falling. Always observe the followings. Avoid spilling of oil and grease. Do not litter the tools. Watch your step when walking around on the machine.
Page 65: Precautions For Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE Precautions for inspection and maintenance:ALL-0000-001K06A TURN OFF THE BATTERY DISCONNECT SWITCH TURN OFF THE BATTERY DISCONNECT SWITCH:ALL-AW1P-012K00A In the following cases, set the starting switch to the OFF position and confirm that the system operating lamp is off.
Page 66: When Using Hammer
PRECAUTIONS FOR MAINTENANCE SAFETY When removing the battery cables, turn the starting switch to OFF position and, after checking that the sys- tem operating lamp goes out, set the battery disconnect switch key to OFF position and pull it out. When removing the battery cables, remove the ground cable (negative (-) cable) first.
Page 67: High-Pressure Oil
If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 68: Noise
If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. It is necessary to disassemble the recoil spring assem- bly, always ask your Komatsu distributor to carry out the opera- tion. 2–50...
Page 69: Accumulator And Gas Spring
Do not make holes in it, weld it, or use a cutting torch. q Do not hit it, roll it, or subject it to any impact. q When disposing of the accumulator or gas spring, the gas must be released. Ask your Komatsu distributor to perform this work. COMPRESSED AIR...
Page 70: Periodic Replacement Of Safety Critical Parts
Replace or repair safety-critical parts if any defect is found, even when they have not reached the specified replacement time. q The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine.
Page 71: Operation
OPERATION OPERATION OPERATION:ALL-0000-001K02A OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section. 3–1...
Page 72: General View
GENERAL VIEW OPERATION GENERAL VIEW General view:PC-0000-001K01A GENERAL VIEW OF MACHINE GENERAL VIEW OF MACHINE:PC220-0000-04DK00A Bucket Sprocket Bucket cylinder Track frame Track shoe Arm cylinder (10) Idler Boom (11) Handrail Boom cylinder 3–2...
Page 73 OPERATION GENERAL VIEW (11) KDPF (16) Battery (12) KCCV ventilator (17) Grease pump holder (13) Disconnect switch (18) Toolbox (14) System operating lamp (19) Engine hood (15) Fusible link 3–3...
Page 74: General View Of Cab
GENERAL VIEW OPERATION GENERAL VIEW OF CAB GENERAL VIEW OF CAB:PC220_KU-K000-04DK00A Ceiling window Ashtray Front window Power outlet Emergency escape hammer Fuse 1 Door unlock lever (10) Fuse 2 Drink box (11) Fire extinguisher (if equipped) Magazine box, Cup holder 3–4...
Page 75 OPERATION GENERAL VIEW 3–5...
Page 76: General View Of Controls And Gauges
GENERAL VIEW OPERATION GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW OF CONTROLS AND GAUGES:PC220_KU-K190-04DK00A 3–6...
Page 77 OPERATION GENERAL VIEW Radio (20) Swing brake cancel switch Lock lever (21) Engine shutdown secondary switch L.H. work equipment control lever (22) AUX One-touch power max. switch (23) Lower wiper switch Travel pedals (24) Seat heater switch Travel levers (25) Additional lamps switch (if equipped) Horn switch (26) 1st attachment proportional control switch Machine monitor...
Page 78 GENERAL VIEW OPERATION Machine monitor AA: Standard screen, BB: Check before starting screen, CC: Maintenance interval warning screen Wiper switch (20) Radiator coolant level monitor Buzzer cancel switch (21) Message monitor Auto-deceleration switch (22) Air conditioner monitor Engine coolant temperature monitor (23) Wiper monitor Engine coolant temperature gauge (24) Swing lock monitor...
Page 79: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS Explanation of components:ALL-0000-043K00A The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operating the equipment, and the meanings of the displays. MACHINE MONITOR Machine monitor:PC220-Q180-04DK00A AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen...
Page 80 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR:PC220-Q180-044K00A STARTING ENGINE WHEN SITUATION IS NORMAL When the starting switch is turned to the ON position, the opening screen GG is displayed. After the opening screen GG is displayed for 2 seconds, the screen switches to the check before starting screen BB.
Page 81 When the starting switch is turned to the OFF position, ending screen JJ or KK is displayed for 5 seconds, then the display goes out. Ending Screen with Message If there is any message from your Komatsu distributor, it is dis- played on the ending screen. In this case, turned the starting switch to the ON position to re- check the message, and if it is the message requesting response, send back your reply.
Page 82 EXPLANATION OF COMPONENTS OPERATION IF THERE IS ABNORMALITY WHEN STARTING ENGINE If there is any abnormality when starting the engine, the check before starting screen BB changes to the main- tenance time warning screen CC, warning screen FF, or error screen EE. After displaying the check before starting screen BB for 2 seconds, the screen changes to the maintenance time warning screen CC.
Page 83 OPERATION EXPLANATION OF COMPONENTS IF ANY ABNORMALITY OCCURS DURING OPERATION If any abnormality occurs during operation, the standard screen AA changes to warning screen FF-(1) or the error screen EE. After displaying warning screen FF-(1) for 2 seconds, the screen automatically changes to warning screen FF- (2).
Page 84 EXPLANATION OF COMPONENTS OPERATION If there is any error existing, "!" is displayed on top of switch F5. Press switch F5 to check the detail of the error. Existing error list screen is displayed. 3–14...
Page 85 OPERATION EXPLANATION OF COMPONENTS WARNING DISPLAY WARNING DISPLAY:PC-Q1FB-043K00A NOTICE Appearance of any of action levels "L01" to "L04" on the machine monitor indicates presence of an abnormality on the machine. Take appropriate actions following the list of action level monitor displays and remedies. The alarm monitor that is lit in red when an action level is displayed urges you to stop the current work urgently, stop it in the normal procedure or pause it temporarily.
Page 86 │ Lights in red intermittently If the condition is not improved, ask your Komatsu distributor │ for inspection and maintenance. Part of the above functions may be restricted in some cases. However, it does not affect your work.
Page 87 OPERATION EXPLANATION OF COMPONENTS The alarm monitors and their colours are as follows. Display colour/Machine condition (Action level) Symbol Type of monitor Yellow White Blue High Engine coolant temperature temperature – Normal monitor temperature (L02) High Hydraulic oil temperature temperature –...
Page 88 EXPLANATION OF COMPONENTS OPERATION Display colour/Machine condition (Action level) Symbol Type of monitor Yellow White Blue Clogged Air cleaner clogging monitor – – – (L01) Air conditioner system state Abnormal – – – monitor (L01) Overload caution monitor Overload – –...
Page 89 OPERATION EXPLANATION OF COMPONENTS On the occurred error list screen, switches F1, F2 and F5 allow the following operations. F1: Displays next page. When on the last page, it displays the first page. F2: Displays the previous page. When on the first page, it dis- plays the last page.
Page 90 The monitor lights up yellow. Part of the above functions may be restricted in some cases. However, it does not affect your work. Whenever finished the work, carry out the inspection and maintenance. As needed, ask your Komatsu distributor for inspection and maintenance. 3–20...
Page 91 Part of the above functions may be restricted in some cases. However, it does not affect your work. Whenever finished the work, carry out the inspection and maintenance. As needed, ask your Komatsu distributor for inspection and maintenance. KDPF SYSTEM OPERATING MONITOR KDPF SYSTEM OPERATING MONITOR:PC-A9HD-043K00A This monitor warns about abnormality in the KDPF system.
Page 92 The monitor lights up yellow. Part of the above functions may be restricted in some cases. However, it does not affect your work. Whenever finished the work, carry out the inspection and maintenance. As needed, ask your Komatsu distributor for inspection and maintenance. 3–22...
Page 93 The alarm buzzer sounds intermittently. Charging cannot be made normally while the engine is running. Stop the engine and check if the fan belt is damaged, and then ask your Komatsu distributor for inspection and mainte- nance. For details, see "Other trouble (3-236)". 3–23...
Page 94 When condition is abnormal: The monitor lights up yellow and indicates action level "L01". The air conditioner system has abnormality. Please ask your Komatsu distributor for inspection and maintenance as soon as possible. MAINTENANCE MONITOR MAINTENANCE MONITOR:PC-Q1D3-043K00A This monitor displays notices and alarms concerning mainte- nance time.
Page 95 The lighting time of maintenance time notice (yellow) has been initially set to 30 hours, but you can change it. To change the initial setting, contact your Komatsu distribu- tors. For operations on the maintenance screen, see "MAINTE- NANCE SCREEN SETTING (3-65)".
Page 96 EXPLANATION OF COMPONENTS OPERATION METER DISPLAY METER DISPLAY:PC220-Q1LA-04DK00A Pilot display Gauge and Meter Engine preheating monitor (15) Engine coolant temperature gauge Swing lock monitor (16) Hydraulic coolant temperature gauge Wiper monitor (17) Fuel gauge Auto-deceleration monitor (18) Service meter, Clock Working mode monitor (19) ECO gauge Travel speed monitor...
Page 97 OPERATION EXPLANATION OF COMPONENTS SWING LOCK MONITOR Swing Lock Monitor::PC220_KU-JC5N-043K00A This monitor (2) informs that the swing lock is being actuated. Lighting: The swing lock is being actuated. When the swing lock switch is turned ON (ACTUATED), the monitor lights up. This lamp flashes when the swing brake cancel switch is set to the FREE position.
Page 98 Monitor lights up: Air conditioner ON Monitor goes out: Air conditioner OFF MESSAGE MONITOR MESSAGE MONITOR:PC-Q235-043K00A This monitor (9) lights up when Komatsu send out any informa- tion. To read the information, see the paragraph of "MESSAGE DIS- PLAY (3-73)".
Page 99 OPERATION EXPLANATION OF COMPONENTS SEAT BELT MONITOR SEAT BELT MONITOR:PC-K2S5-043K00A This monitor (10) is displayed when the seat belt is not fas- tened. It goes out when the seat belt is fastened. For how to fasten the seat belt, see "SEAT BELT (3-159)". ENGINE STOP MONITOR ENGINE STOP MONITOR:PC-AKHK-043K00A This monitor (11) is displayed while the engine is stopped.
Page 100 EXPLANATION OF COMPONENTS OPERATION KDPF REGENERATION STOP MONITOR KDPF REGENERATION STOP MONITOR:PC-A9HN-043K00A This monitor (13) lights up when KDPF is set not to be regener- ated. REMARK Even if no regeneration of KDPF is set, when the manual sta- tionary regeneration is necessary, accumulated soot monitor of KDPF lights up.If it lights up, cancel no regeneration setting and carry out manual stationary regeneration.
Page 101 OPERATION EXPLANATION OF COMPONENTS HYDRAULIC RELIEF DETERRENCE GUIDANCE (B) If the hydraulic oil is kept relieved for more than 3 seconds dur- ing operation, the hydraulic relief deterrence message is dis- played on the monitor. The hydraulic relief deterrence message goes out 10 sec- onds after or when switch F5 is pressed.
Page 102 EXPLANATION OF COMPONENTS OPERATION GAUGES AND METER Gauges and Meter:ALL-Q1LB-001K00A ENGINE COOLANT TEMPERATURE GAUGE Engine coolant temperature gauge:PC220_KU-BA80-043K00A This meter (15) shows the engine coolant temperature. During normal operations, the indicator should be in the green range. If the indicator goes beyond red range (A) during opera- tions, the overheat prevention system is actuated.
Page 103 OPERATION EXPLANATION OF COMPONENTS Display (G) at low temperatures: Monitor background (K) is white Display (H) at correct temperatures: Monitor background (K) is blue Display (J) when condition is abnormal: Monitor back- ground (K) is red FUEL GAUGE FUEL GAUGE:PC-AER3-043K00A This meter (17) shows the amount of fuel remaining in the fuel tank.
Page 104 EXPLANATION OF COMPONENTS OPERATION Clock display (24-hour display) When the standard screen is being displayed, if function switch F4 is pressed, it is possible to switch between the clock display and the service meter display. REMARK If the battery is disconnected for a long period for storage etc., the time information may be lost.
Page 105 OPERATION EXPLANATION OF COMPONENTS MONITOR SWITCH PORTION MONITOR SWITCH PORTION:PC220-Q1C0-04DK00A Function switches Wiper switch Working mode selector switch Window washer switch Auto-deceleration switch Buzzer cancel switch Travel speed selector switch Air conditioner switch GUIDANCE ICONS, FUNCTION SWITCHES GUIDANCE ICONS, FUNCTION SWITCHES:PC-Q1C1-043K00A Function switches (1) at the bottom of the monitor display consist of 6 switches (F1 to F6).
Page 106 EXPLANATION OF COMPONENTS OPERATION (A) Switch F3: Camera screen selector switch. (B) Switch F4: Service meter/time display selector switch (C) Switch F5: Occurred error list display switch (While the alarm monitor is displayed) (D) Switch F5: Energy saving (ECO) guidance erase switch (While Energy saving (ECO) guidance is displayed) (E) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance...
Page 107 OPERATION EXPLANATION OF COMPONENTS (H) Switch F3: To move downward (forward) by 1 space. (An icon at the extreme end moves to the top.) (I) Switch F4: To move upward (backward) by 1 space. (An icon at the top moves to the extreme end.) (J) Switch F5: To cancel any change and return to the previous screen.
Page 108 If you press F5 (No), the system starts up in E mode. If you want to have automatic setting of the P, E, L, B, ATT/P or ATT/E mode when starting (optional default setting), please ask your Komatsu distributor to change the setting. PROCEDURE FOR OPERATION 1.
Page 109 OPERATION EXPLANATION OF COMPONENTS After 2 seconds, the screen returns to the standard screen. The monitor display highlighted in yellow in Step 4 returns to blue. REMARK When setting the working mode to B mode, to ensure safety, the buzzer sounds and at the same time, the message in the illustration on the right is displayed.
Page 110 EXPLANATION OF COMPONENTS OPERATION 1. When auto-deceleration switch (3) is pressed and the auto- deceleration function is turned ON, the mode is displayed in the centre of the monitor display, and after two seconds, the screen returns to the standard screen. 2.
Page 111 OPERATION EXPLANATION OF COMPONENTS TRAVEL SPEED SELECTOR SWITCH TRAVEL SPEED SELECTOR SWITCH:PC220-C6T7-043K00A WARNING When loading or unloading from a trailer, always travel at low speed (with travel speed selector switch (4) at the Lo position). Never operate travel speed selector switch (4) while loading or unloading. If the travel speed is switched between Hi and Lo when the machine is travelling, the machine may deviate to one side, even when travelling in a straight line.
Page 112 EXPLANATION OF COMPONENTS OPERATION WIPER SWITCH WIPER SWITCH:PC-K751-043K00A This switch (5) actuates the front window wiper. Each time the switch is pressed, it changes ON to INT to Stop (monitor goes out). Wiper monitor INT lights up: Wiper operates intermittently Wiper monitor ON lights up: Wiper operates continuously Wiper monitor goes out: Wiper stops REMARK...
Page 113 OPERATION EXPLANATION OF COMPONENTS WINDOW WASHER SWITCH WINDOW WASHER SWITCH:PC-K7DA-043K00A This switch (6) is kept continuously pressed, window washer fluid is sprayed out on the front glass. When the switch is released, the spray stops. If switch (6) is kept pressed when the wiper is stopped, the window washer fluid will spray, and at the same time, the wiper will be actuated continuously.
Page 114 EXPLANATION OF COMPONENTS OPERATION AIR CONDITIONER SWITCH AIR CONDITIONER SWITCH:PC-K5FK-04DK00A The air conditioner switches (8) consist of 9 switches. For explanation of each switch, see "Handling air conditioner (3-104)". 3–44...
Page 115 A maximum of three cameras can be installed. If you want to install another camera, please consult your Komatsu distributor. OPERATION OF ONE CAMERA IMAGE DISPLAY SCREEN The following explanation describes the method of operation when it is desired to display only one camera screen on the monitor.
Page 116 EXPLANATION OF COMPONENTS OPERATION Press switch F5 to return to the standard screen. OPERATION OF IMAGE DISPLAY SCREEN WHEN TWO CAMERA IMAGES ARE SHOWN SIMULTA- NEOUSLY The following explanation describes the method of operation when it is desired to display two camera screens at the same time on the monitor.
Page 117 OPERATION EXPLANATION OF COMPONENTS It is possible to change the working mode by pressing the working mode selector switch. For details of the method of using the working mode selector switch, see "WORKING MODE SELECTOR SWITCH (3- 37)". When the working mode is changed, the screen returns automatically to the camera image screen.
Page 118 EXPLANATION OF COMPONENTS OPERATION Press the wiper switch and washer switch to operate the wipers and washer. Even if the wiper switch or washer switch is pressed, the camera image display screen does not switch to another screen or return to the standard screen display. ACTIONS AGAINST WARNING DURING CAMERA DISPLAY If an error or alarm occurs while the camera image is being displayed, the error monitor or alarm monitor is displayed at...
Page 119 OPERATION EXPLANATION OF COMPONENTS USER MENU SELECTOR SWITCH USER MENU SELECTOR SWITCH:PC220-Q1C3-100K00A When switch F6 is pressed on the standard screen, the user menu screen will be displayed on which you can make various settings for the machine in the monitor display. 3–49...
Page 120 EXPLANATION OF COMPONENTS OPERATION USER MENU USER MENU:PC220-Q1C3-100K01A The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens. (a): ECO guidance (b): Machine settings (c): KDPF regeneration (d): Maintenance (e): Monitor setting (f): Mail check...
Page 121 OPERATION EXPLANATION OF COMPONENTS F1: Moves to the left menu. When on the left-end menu, it moves to the right-end menu. F2: Moves to the right menu. When on the right-end menu, it moves to the left-end menu. F3: Moves to next item (1 line down). When on the last line, it moves to the top line on the next page.
Page 122 EXPLANATION OF COMPONENTS OPERATION OPERATING RECORD Select operating record (1) from the ECO guidance menu screen, then press switch F6. Using the operating record menu, display the operating hours, average fuel consumption, actual operating hours, fuel con- sumption in actual operating hours, fuel consumption in the period, idling hours and E mode time ratio on daily basis or on a split measurement period basis.
Page 123 OPERATION EXPLANATION OF COMPONENTS REMARK Energy saving (ECO) guidance denotes displaying the guid- ance for energy saving operation. This display may appear on the standard screen while the machine is in operation. For details, see "ECO GUIDANCE (3-30)". FUEL CONSUMPTION RECORD Select fuel consumption record (3) from the ECO guidance menu screen, then press switch F6.
Page 124 EXPLANATION OF COMPONENTS OPERATION SWITCHING OF A DISPLAYED GRAPH On the fuel consumption record screen, it is possible to change the currently displayed graph to another with switch F2. REMARK There are two types of graphs. One shows hourly average fuel consumption during the last 12 hours and the other is daily average fuel consumption during the last one week.
Page 125 OPERATION EXPLANATION OF COMPONENTS DISPLAY SETTING Select display setting (4) from the ECO guidance menu screen, then press switch F6. From the display setting menu, following operations are availa- ble. Setting the fuel consumption gauge Switching Display/Non-display of ECO Gauge Setting the Target Fuel Consumption Value Displayed in the ECO Gauge Switching Display/Non-display of Energy Saving (ECO)
Page 126 EXPLANATION OF COMPONENTS OPERATION 2. The display setting of fuel consumption gauge screen appears. 1 day Displays the average fuel consumption from 0:00 a.m. of the day to 0:00 a.m. of the next day. Split Displays the average fuel consumption during the split measurement period.
Page 127 OPERATION EXPLANATION OF COMPONENTS 1. Select the ECO gauge display (8) from the display setting screen, then press switch F6. 2. The ECO gauge display setting screen appears. ON: Displays the ECO gauge (7) on the standard screen. OFF: Does not display ECO gauge (7) on the standard screen.
Page 128 EXPLANATION OF COMPONENTS OPERATION SWITCHING DISPLAY/NON-DISPLAY OF ENERGY SAVING (ECO) GUIDANCE It is possible to change the setting of Display/Non-display of energy saving (ECO) guidance (10). 1. Select energy saving (ECO) guidance display (11) from the display setting screen, then press switch F6. 2.
Page 129 OPERATION EXPLANATION OF COMPONENTS SWITCHING DISPLAY/NON-DISPLAY OF GUIDANCE WHEN THE STARTING KEY IS TURNED OFF It is possible to change the setting of Display/Non-display of guidance (12) when the starting key is turned off. 1. Select guidance display when starting key is OFF (13) from the display setting screen, then press switch F6.
Page 130 EXPLANATION OF COMPONENTS OPERATION MACHINE SETTINGS Machine settings:PC-Q1C9-100K00A On this menu (b), it is possible to set items of machine. ECONOMY MODE ADJUSTMENT Select economy mode adjustment (1) on the machine setting menu screen, then press switch F6. On the economy mode adjustment menu, it is possible to adjust the engine output in E mode.
Page 131 OPERATION EXPLANATION OF COMPONENTS BREAKER SETTING 1. Move to the machine setting menu (b) on the user menu. 2. Select the breaker setting menu (2), then press switch F6. 3. On the breaker setting screen shown on the right, select breaker and press switch F6.
Page 132 EXPLANATION OF COMPONENTS OPERATION CHANGING BREAKER OIL FLOW SETTING 1. On the breaker setting screen, select a breaker to change its oil flow, then press switch F2. 2. The breaker oil flow setting screen is displayed. On the breaker oil flow setting screen, it is possible to carry out the following operations with switches F3 to F6.
Page 133 OPERATION EXPLANATION OF COMPONENTS 1. Select an attachment to change its name on the attachment setting screen, then press switch F6. 2. The attachment name setting screen is displayed. On the attachment name setting screen, it is possible to carry out the following operations with switches F1 to F6. F1: "CLEAR"...
Page 134 EXPLANATION OF COMPONENTS OPERATION ATTACHMENT 2 SETTING Attachment 2 Setting:PC220_KU-PT5X-100K00A If installing 2nd attachment line as a field kit ask distributor to change monitor setting to allow 2 attachments (as shown below). On machines equipped with 2 attachment lines it is possible on the attachment 2 settings menu to adjust the oil flow in ATT mode to match the attachment installed.
Page 135 (initial setting value), the remaining time display (c) is highlighted in yellow. If the time remaining to the mainte- nance is less than 0 hour, display (c) is highlighted in red. If you want to change the setting for the maintenance interval or maintenance interval notice time (initial set- ting: 30 hours), please consult your Komatsu distributor. 3–65...
Page 136 EXPLANATION OF COMPONENTS OPERATION OPERATIONS ON THE MAINTENANCE INTERVAL RESET SCREEN On the maintenance menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the maintenance interval reset screen. Reset the remaining time to the maintenance on this screen. 1.
Page 137 OPERATION EXPLANATION OF COMPONENTS MONITOR SETTING Monitor setting:PC-Q193-110K00A Each item of this menu (e) is to make settings for the monitor. SCREEN ADJUSTMENT SCREEN ADJUSTMENT:PC-Q19C-100K00A Use the screen adjustment menu to adjust brightness of the monitor screen. 1. Select screen adjustment (1) on the monitor setting menu screen, then press switch F6.
Page 138 EXPLANATION OF COMPONENTS OPERATION 1. Select screen adjustment (camera) (2) on the monitor set- ting menu screen, then press switch F6. 2. Use switches F2 to F6 to adjust brightness the screen. F2: Resets an adjusted value to initial value F3: Moves the indicator to the left by one notch F4: Moves the indicator to the right by one notch F5: Cancels the change and returns to the monitor setting...
Page 139 OPERATION EXPLANATION OF COMPONENTS GPS SYNCHRONIZATION On machines equipped with KOMTRAX, turning the GPS Syn- chronization menu ON enables automatic setting of the moni- tor's date and time in accordance with the GPS's clock. F3: Selects the next item (a line down below the current one). When on the last line, it moves to the top line on the next page.
Page 140 EXPLANATION OF COMPONENTS OPERATION 3. When month display (B) is highlighted in yellow, operate the switches as follows to change month display (B). If it is not necessary to change the month, press switch F6. F3: Calendar goes back one month F4: Calendar advances one month F5: Cancels change and returns to the year setting screen.
Page 141 OPERATION EXPLANATION OF COMPONENTS 1. Select Time (c) on the clock adjustment screen, then press switch F6. 2. The time setting screen is displayed. When hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D). If it is not necessary to change the hour setting, press switch F6.
Page 142 EXPLANATION OF COMPONENTS OPERATION 12H/24H MODE Choose either a 12-hour display (am/pm) or a 24-hour display. 24-hour display 12-hour display (am/pm) 1. Select 12h/24h Mode (d) on the clock adjustment screen, then press switch F6. 2. 12h/24h Mode screen appears. F3: Selects the next item (a line down below the current one).
Page 143 MESSAGE DISPLAY:PC-Q235-100K00A On machines equipped with KOMTRAX, it is possible to see the messages from your Komatsu distributor on this menu (f). When any massage is available, the message monitor at the left end of the standard screen lights up.
Page 144 EXPLANATION OF COMPONENTS OPERATION MESSAGE CONFIRMING METHOD 1. On the standard screen, press switch F6. When there is any message, press switch F6, and the mail confirmation menu directly opens. 2. Select mail confirmation menu (f), and you can read the arrived message.
Page 145 OPERATION EXPLANATION OF COMPONENTS REPLYING METHOD TO A MESSAGE 1. When replying to a message, input the selected item num- ber in ten-key input value column (2). The selected item number is written in place (3) of the message text. Input the number by using the monitor panel switch.
Page 146: Switches
EXPLANATION OF COMPONENTS OPERATION SWITCHES SWITCHES:PC220_KU-Q13C-04DK00A Starting switch (12) Ceiling window wiper switch (if equipped) Fuel control dial (13) Engine shutdown secondary switch Cigarette lighter (14) Lower wiper switch (if equipped) Swing lock switch (15) Seat heater switch Lamp switch (16) Quick coupler switch Horn switch (17) Quick coupler switch...
Page 147 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting Switch:ALL-AKB0-043K00A Starting switch (1) is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electrical system (except room lamp), are all turned off and the engine is stopped. (B): ON position electric current flows through the charging and lamp circuits.
Page 148 EXPLANATION OF COMPONENTS OPERATION SWING LOCK SWITCH Swing Lock Switch:PC-JC5P-043K00A WARNING When not using the swing operation, e.g. when travelling, put the swing lock switch to the ON posi- tion. On slopes, even when the swing lock switch is at the ON position, the weight of the work equipment may cause the upper structure to swing if the swing control lever is operated in the downhill direction, so always carry out operations carefully.
Page 149 OPERATION EXPLANATION OF COMPONENTS ONE-TOUCH POWER MAX. SWITCH One-Touch Power Max. Switch::PC220_KU-PT5H-043K00A This switch (7) on the left work equipment control lever is used to actuate the power max functions. Press once (single click) and keep the switch pressed. The one-touch power max.
Page 150 EXPLANATION OF COMPONENTS OPERATION SWING BRAKE CANCEL SWITCH SWING BRAKE CANCEL SWITCH:PC220-JA16-043K00A NOTICE This switch (10) makes it possible to perform swing operations for a short time even when there is a prob- lem in the swing holding brake electric system. DO NOT use this switch except in emergencies. Repair the problem as soon as possible.
Page 151 OPERATION EXPLANATION OF COMPONENTS CEILING WINDOW WIPER SWITCH CEILING WINDOW WIPER SWITCH:PC220_KU-K77F-043K00A (if equipped) This switch (12) is used to actuate the ceiling window wiper and spray the washing water. (a) Wiper position: To actuate the ceiling window wiper (b) Washer position: While depressing the switch, the washing water for the ceiling window is sprayed and wiper actuates at the same time.
Page 152 EXPLANATION OF COMPONENTS OPERATION ENGINE SHUTDOWN SECONDARY SWITCH ENGINE SHUTDOWN SECONDARY SWITCH:PC-AKHL-100K00A NOTICE Do not use this switch (13) except in emergencies. Ask for repair of the problem as soon as possible. If this switch is moved to the "STOP ENGINE" position by mistake while the machine is operating nor- mally, "ENGINE SHUTDOWN SECONDARY SWITCH ON"...
Page 153 OPERATION EXPLANATION OF COMPONENTS LOWER WIPER SWITCH LOWER WIPER SWITCH:PC220_KU-K77H-043K00A (if equipped) When this switch (14) is pressed, the lower wiper is turned on. (a) ON: Lower wiper operates. (b) OFF: Lower wiper stops. SEAT HEATER SWITCH Seat heater switch:PC220_KU-K313-043K00A This switch (15) is used to warm the seat.
Page 154 EXPLANATION OF COMPONENTS OPERATION ADDITIONAL LAMPS SWITCH ADDITIONAL LAMPS SWITCH:PC220_KU-Q6BC-043K00A (if equipped) Switch (21) is used to turn on the cab front lamps, cab rear lamps and extra boom lamps (NB If fitted by customer). (a) ON: Lamps light up. (b) OFF: Lamps go out.
Page 155: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS CONTROL LEVERS AND PEDALS:PC220_KU-K191-04DK00A Lock lever (3) Left work equipment control lever (with auto- deceleration system) Travel levers (4) Right work equipment control lever (with pedal and auto-deceleration system) LOCK LEVER Lock Lever:PC-Q5J0-043K00A WARNING When leaving the operator's seat, set the lock lever securely to the LOCK position.
Page 156 EXPLANATION OF COMPONENTS OPERATION TRAVEL LEVERS Travel Levers:PC-C6W1-043K00A WARNING If you carry out operations with your foot on the pedal, the machine may suddenly start if you depress the pedal by mistake, and this may lead to serious personal injury. Be extremely careful when using the pedal for travel and steering operations, and do not put your foot on the pedal when it is not neces- sary.
Page 157: Ceiling Window
OPERATION EXPLANATION OF COMPONENTS Right work equipment control lever (4) is used to operate the boom and bucket. Boom control (a): Boom RAISE (b): Boom LOWER Bucket control (c): Bucket DUMP (d): Bucket CURL N (NEUTRAL): The boom and bucket are held in position and do not move. CEILING WINDOW CEILING WINDOW:PC220_KU-K18H-100K00A The operator cab is provided with a fixed clear ceiling window...
Page 158: Opening And Closing Cab Front Window
EXPLANATION OF COMPONENTS OPERATION OPENING AND CLOSING CAB FRONT WINDOW Opening and closing cab front window:PC220-K181-100K00A WARNING When opening or closing the front window, bottom window, or door, always set the lock lever to the LOCK position. If the lock lever is at the FREE position and the control lever or control pedal is touched by mistake, this may lead to a serious personal accident.
Page 159 OPERATION EXPLANATION OF COMPONENTS 3–89...
Page 160 EXPLANATION OF COMPONENTS OPERATION 5. Hold lower handle (C) with your left hand from inside the operator's cab, and with your right hand, grip top handle (D), pull it up, and push it against lock catch (E) at the rear of the cab securely to lock the window.
Page 161 OPERATION EXPLANATION OF COMPONENTS CLOSING CAUTION When closing the window, lower it slowly and be careful not to get your hand caught. 1. Stop the machine on level ground, lower the work equip- ment completely to the ground, then stop the engine. 2.
Page 162 EXPLANATION OF COMPONENTS OPERATION 5. When the bottom of the window reaches the top of lower side window, push the top of the window to the front to push it against right and left lock catches (G) and engage the lock.
Page 163: Emergency Escape Hammer
OPERATION EXPLANATION OF COMPONENTS EMERGENCY ESCAPE HAMMER Emergency escape hammer:ALL-Q5K1-043K00A CAUTION If it is necessary to break the window glass with the hammer, be extremely careful not to injure your- self on the flying pieces of broken glass. To prevent injury, remove the broken pieces of glass remaining in the frame before escaping through the window.
Page 164: Door Lock
OPERATION E X P L A N A T I O N O F C O M P O N E N T S DOOR LOCK Door lock:PC-K164-043K00A WARNING Before the releasing the door lock, always stop the machine on level ground. Never release the door lock on a slope.
Page 165: Opening And Closing Engine Hood
OPERATION EXPLANATION OF COMPONENTS OPENING AND CLOSING ENGINE HOOD Opening and closing engine hood:PC-H540-100K00A CAUTION When opening or closing the engine hood, stop the machine on level ground, lower the work equip- ment to the ground, stop the engine, then carry out the operation. When opening the engine hood, do not release the handle until the stay is set in the lock position securely.
Page 166 EXPLANATION OF COMPONENTS OPERATION REMARK To open the engine hood fully, hold handle (D) and pull up the engine hood. Stay (E) stops first at branch portion (3) of the guide groove. Then, while pushing stay (E) in the direction of the arrow, open the engine hood and set stay (E) in LOCK posi- tion (2).
Page 167 OPERATION EXPLANATION OF COMPONENTS WHEN CLOSING (NORMAL CASE: INTERMEDIATE LOCK POSITION) 1. While holding handle (D) to support the hood, push stay (E) in the direction of the arrow and take it off from intermediate LOCK position (1). Check that stay (E) is set in guide groove (4), and then lower the engine hood.
Page 168 EXPLANATION OF COMPONENTS OPERATION Do not lower the engine hood while stay (E) is not set in guide grooves (4) and (5). If you do so, stay (E) may be deformed. Do not release handle (D) until the engine hood is lowered fully.
Page 169: Caps And Covers With Lock
OPERATION EXPLANATION OF COMPONENTS CAPS AND COVERS WITH LOCK Caps and covers with lock:ALL-Q8E0-043K00A Use the starting switch key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see "LOCKING (3-206)". Insert the key as far as it will go to the shoulder (A).
Page 170 EXPLANATION OF COMPONENTS OPERATION OPEN AND CLOSE COVERS WITH LOCK OPEN AND CLOSE COVERS WITH LOCK:PC-Q8E2-100K00A OPENING THE COVER (LOCKED COVER)) 3. Insert the key into the key slot. 4. Turn the key counterclockwise and open the cover by pull- ing the cover handle.
Page 171 OPERATION EXPLANATION OF COMPONENTS LOCK AND UNLOCK CAB DOOR LOCK AND UNLOCK CAB DOOR:PC-K164-100K00A OPENING THE DOOR (LOCKED DOOR) 5. Insert the key into the key slot. 6. Turn the key clockwise to unlock the key, then open the door handle. Position (A): OPEN Position (B): LOCK LOCKING THE DOOR...
Page 172: Drink Box
EXPLANATION OF COMPONENTS OPERATION DRINK BOX Drink box:ALL-K821-043K00A This is on the right side at the rear of the operator's seat. It keeps drinks and other things hot or cold. Hot or cold air blows into the box according to the setting of the air conditioner.
Page 173: Ashtray
OPERATION EXPLANATION OF COMPONENTS ASHTRAY Ashtray:ALL-K851-043K00A This is on top of the console box on the left side of the opera- tor's seat. Always put out your cigarette before putting it in the ashtray and be sure to close the lid. NOTICE While removing the ashtray, if it is stuck in the console cover and hard to remove, open the lid (A) of ashtray, then...
Page 174: Handling Air Conditioner
EXPLANATION OF COMPONENTS OPERATION HANDLING AIR CONDITIONER Handling air conditioner:ALL-K500-001K00A AIR CONDITIONER CONTROL PANEL Air Conditioner Control Panel:PC-K5V0-04DK00A OFF switch FRESH/RECIRC selector switch Fan switch Display monitor Temperature control switch Air conditioner switch Vent selector switch Sunlight sensor Auto switch OFF SWITCH OFF Switch:ALL-K5V4-043K00A Switch (1) is used to stop the fan and air conditioner.
Page 175 OPERATION EXPLANATION OF COMPONENTS FAN SWITCH Fan Switch:ALL-K5V5-043K00A Switch (2) is used to adjust the air flow. The air flow can be adjusted to six levels. Press the E switch to increase the air flow; press the R switch to decrease the air flow. During auto operation, the air flow is automatically adjusted.
Page 176 EXPLANATION OF COMPONENTS OPERATION VENT SELECTOR SWITCH VENT SELECTOR SWITCH:PC220-K5V7-043K00A Switch (4) is used to select the vents. When switch (4) is pressed, the display on monitor display (7) switches and air blows out from the vents displayed. During automatic operation, the vents are automatically selected.
Page 177 OPERATION EXPLANATION OF COMPONENTS AUTO SWITCH Auto Switch:ALL-K5V8-043K00A With switch (5), the air flow, vents, and air source (FRESH/ RECIRC) are automatically selected according to the set tem- perature. Press switch (5), then use temperature control switch (3) to set the temperature, and run the air conditioner under auto- matic control.
Page 178 EXPLANATION OF COMPONENTS OPERATION SUNLIGHT SENSOR Sunlight Sensor:PC-K5FH-043K00A This sensor (9) automatically adjusts the flow of air from the vents to match the strength of the sun's rays. In addition, it automatically detects changes in the temperature inside the cab caused by changes in the strength of the sun's rays before- hand and automatically adjusts the temperature.
Page 179 OPERATION EXPLANATION OF COMPONENTS AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The monitors for the set temperature (a) and air flow (b) are also displayed. 2. Use temperature set switch (3) to set to the desired temper- ature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated automatically to provide the set temperature.
Page 180 EXPLANATION OF COMPONENTS OPERATION MANUAL OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on monitor (7). 2. Turn air conditioner switch (8) ON. 3.
Page 181 OPERATION EXPLANATION OF COMPONENTS 5. Press RECIRC/FRESH selector switch (6) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH). STOP MANUAL OPERATION Press OFF switch (1). Operation stops. OPERATION WITH COLD AIR BLOWING TO THE FACE AND WARM AIR BLOWING TO THE FEET To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows.
Page 182 EXPLANATION OF COMPONENTS OPERATION 2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in the diagram on the right. 3. Turn air conditioner switch (8) ON. 4. Adjust fan switch (2), temperature setting switch (3) and RECIRC/FRESH selector switch (6) to the desired posi- tions.
Page 183 OPERATION EXPLANATION OF COMPONENTS 2. Press vent selector switch (4) and set vent display on the display monitor to (f) or (g) as shown in diagram on the right. 3. Press RECIRC/FRESH selector switch (6) and set it to take in fresh air.
Page 184 EXPLANATION OF COMPONENTS OPERATION 5. Adjust vents (A), (B1), and (B2) so that the air blows onto the window glass. (Vents (C) and (D) are fixed and cannot be adjusted.) When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (8) ON.
Page 185 If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system state monitor lights up on the monitor screen. If the air condi- tioner system state monitor lights up, please ask your Komatsu distributor for inspection and repair. 3–115...
Page 186: Handling Radio
EXPLANATION OF COMPONENTS OPERATION HANDLING RADIO Handling radio:PC-K860-001K00A RULES FOR USING RADIO Rules for using radio:ALL-K860-170K00A To ensure safety, always keep the sound to a level where it is possible to hear outside sounds during opera- tion. If water gets into the speaker case or radio, it may lead to an unexpected failure, so be careful not to get water on the equipment.
Page 187 OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS:PC-K860-043K00A Power button Preset station buttons (1,2,3,4,5,6) Band selection button Display selection button Volume control button Sound adjust button Tuning/time adjust button Display POWER BUTTON Press this power button (1) to supply the power to the radio and the frequency is shown on the display (8). Press the button again to turn the power off.
Page 188 EXPLANATION OF COMPONENTS OPERATION DISPLAY (A): Band name, "AUX", frequency, time and other character/ numeric information are displayed. (B): Frequencies are displayed in step of 50 kHz in certain areas. (C): Lights up when a stereo broadcasting is heard while a FM station is selected.
Page 189 OPERATION EXPLANATION OF COMPONENTS OPERATION METHOD Antenna:PC-K861-822K00A FREQUENCY ADJUSTMENT Antenna:PC-K861-822K00A 1. Press band selection button (2) and select FM or AM. 2. In this condition, press the E button of the tuning/time adjust button (4), and the frequency becomes higher. Also, press the R button, and the frequency becomes lower.
Page 190: Space For Radio Cassette
EXPLANATION OF COMPONENTS OPERATION 4. Flash the item to be adjusted, and press the tuning/time adjust button (4) and start the adjustment. 5. If display selection button (6) is pressed during the minute adjustment, the time adjustment will be released and the time display will resume.
Page 191: Auxiliary Electric Power
OPERATION EXPLANATION OF COMPONENTS AUXILIARY ELECTRIC POWER Auxiliary electric power:ALL-K890-001K00A 24V POWER SOURCE 24V Power Source:PC-K891-043K00A NOTICE Do not use this as the power supply for 12 V equipment. It will cause failure of the equipment. If the cigarette lighter is removed, the socket can be used as a power source.
Page 192: Fuse
EXPLANATION OF COMPONENTS OPERATION FUSE Fuse::PC220_KU-Q6G0-043K00A NOTICE Before replacing a fuse, be sure to turn the starting switch to the OFF position, then turn the battery dis- connect switch to the OFF position. The fuse holders are installed for fuse 1 (a) at the rear right and for fuse 2 (b) at the rear left of the operator's seat, It protects the electrical equipment and wiring from burning out.
Page 193 OPERATION EXPLANATION OF COMPONENTS FUSE CAPACITIES AND CIRCUIT NAMES Fuse 1 Fuse Name of circuit 10 A Lamp relay, emergency switch 30 A Solenoid valve PPC hydraulic lock solenoid 10 A Window washer, Cigarette lighter 10 A Horn Auto pre-heater relay 10 A Revolving warning lamp Radio, Speaker, Left knob switch, Right...
Page 194: Fusible Link
EXPLANATION OF COMPONENTS OPERATION REMARK Spare fuses are installed in the back of the fuse holder lid (A) at the rear right of the operator's seat. After using spare fuses, replenish them immediately. One spare fuse is installed for each 5 A, 10 A, 20 A, 25 A, and 30 A.
Page 195: Controller
Be careful not to get water, mud or juice on the controller . This will cause failures. If any problem occurs in the controller, do not disassemble it yourself. Contact your Komatsu distributor for repairs. TOOL BOX Tool box:PC-Q8G1-043K00A Store the tools in this box.
Page 196: Grease Pump Holder
EXPLANATION OF COMPONENTS OPERATION GREASE PUMP HOLDER Grease pump holder::PC220_KU-Q8A6-043K00A This is installed in the door at rear left of the machine. Keep the grease pump hooked on this holder while it is not used. FIRE EXTINGUISHER Fire extinguisher:PC-Q5G1-043K00A (if equipped) A fire extinguisher is prepared at the rear part inside the opera- tor's cab.
Page 197: Battery Disconnect Switch
OPERATION EXPLANATION OF COMPONENTS BATTERY DISCONNECT SWITCH BATTERY DISCONNECT SWITCH:PC-AW1P-043K00A CAUTION If you have turned the battery disconnect switch to the OFF position, be sure to pull out the switch key. If someone turns the key to the ON position carelessly, this is extremely dangerous. NOTICE Keep this switch in the ON position, except the following cases.
Page 198: System Operating Lamp
If the data are lost, when the engine is tried to be started next time, "L04" is displayed on the monitor panel and the engine may not start. Ask your Komatsu distributor to carry out inspection and repair. REMARK Even if the starting switch is in the OFF position, the controller may operate. The lamp lights up at this point, but it is not a failure.
Page 199: Handling Kdpf
KDPF. For the setting procedure, see "KDPF regeneration disable procedure". KDPF (Komatsu Diesel Particulate Filter) is a device to capture soot in the exhaust gas to purify the exhaust gas. If soot is accumulated to a certain level in the filter, a purifica- tion process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 200 EXPLANATION OF COMPONENTS OPERATION 1. When level of urgency is low If KDPF soot accumulation monitor (2) lights up yellow (Action level monitor (3): L01), screen (A) is displayed first. The action level monitor goes out 2 seconds after and the screen changes to standard screen (B).
Page 201 Always use Komatsu genuine engine oil for KDPF. If the engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the engine such as lubricating function reduction by deteriorated oil, and it may cause failure.
Page 202 EXPLANATION OF COMPONENTS OPERATION OPERATION PROCEDURE OF MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase higher than the current models during KDPF regeneration. Avoid getting near the exhaust pipe outlet to prevent being burnt. Also, keep flammables away from the exhaust pipe outlet to pre- vent a fire.
Page 203 OPERATION EXPLANATION OF COMPONENTS REMARK After switch F6 is pressed in Step 6, the screen shown at right may be displayed. This indicates that the operations in Steps 1 - 4 were not performed correctly or there is trouble other than KDPF soot accumulation abnormality.
Page 204 EXPLANATION OF COMPONENTS OPERATION 7. This screen is displayed during the manual stationary regeneration. It may take more than 40 minutes to complete the manual stationary regeneration. Do not switch any screen or operate fuel control dial until the regeneration is complete and the standard screen appears again.
Page 205 OPERATION EXPLANATION OF COMPONENTS WHILE REGENERATION IS NOT BEING PERFORMED: SETTING FOR REGENERATION DISABLE (When KDPF regeneration monitor is not lighting on standard screen) 1. On the standard screen, press switch F6. 2. Operate switches F1 and F2 to select KDPF regeneration menu (C) and display the KDPF regeneration screen.
Page 206 EXPLANATION OF COMPONENTS OPERATION WHILE REGENERATION IS BEING PERFORMED: STOPPING REGENERATION (When KDPF regeneration monitor (3) is lighting on standard screen) 1. If switch F6 is pressed on the standard screen, the KDPF regeneration screen is displayed. 2. Select regeneration disable and then press switch F6, and the regeneration stops.
Page 207 OPERATION EXPLANATION OF COMPONENTS KDPF REGENERATION DISABLE CANCEL PROCEDURE CAUTION When cancelling the regeneration disable, move the machine to a safe place and check that there is no person or combustible matter around. And start the cancel opera- tion. 1. If switch F6 is pressed on the standard screen, the KDPF regeneration screen is displayed.
Page 208: Handling Kccv
"REPLACE KCCV FILTER ELEMENT (4-71)". If the engine is operated without the KCCV filter ele- ment or if a filter element other than the Komatsu genu- ine one is used, the engine sucks oil and foreign matter which can cause a trouble. Always use Komatsu genu- ine KCCV filter element.
Page 209: Handling Machines Equipped With Komtrax
KOMTRAX stop at the same time. For details of the operation of the battery disconnect device, see BATTERY DISCONNECT SWITCH (3-127). Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof. REMARK The KOMTRAX equipment uses wireless communications, so it cannot be used inside tunnels, underground, inside buildings, or in mountain areas where radio waves cannot be received.
Page 210 When Komatsu judges that KOMTRAX is used by an unregistered user. When Komatsu judges that KOMTRAX is used in a country or region not allowing the use of KOMTRAX. In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX communication.
Page 211: Machine Operations And Controls
10. Seat belt and mounting clamps Check the seat belt and mounting clamps for any abnormality. If any damage is found, ask your Komatsu distrib- utor to replace it with new one.
Page 212 14. Checking gas leakage in the space around KDPF Check the pipe connecting KDPF to turbocharger and also KDPF connection for leakage of gas (and deposition of soot). If any problem is found, ask your Komatsu distributor for repair. 3–142...
Page 213 When not in use, fully close the hose strainer valve cap (H) to prevent leakage or spillage. If there is any malfunction of the refuel automatic shut-off system, consult your Komatsu Distributor and do not use the system until the problem is rectified.
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION 1. When the machine is operated on sites with no fuel con- tainer and pump, the machine may be refuelling pump from fuel barrels. The refuelling pump is located in the right hand rear pump compartment of the machine.
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS 4. After refuelling is complete: 5. Push float gauge (G) straight down with fuel filler cap (F), be careful not to get the float gauge (G) caught in the tab of the fuel filler cap (F) and tighten fuel filler cap (F) securely. 6.
Page 216 MACHINE OPERATIONS AND CONTROLS OPERATION CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER:PC220-AEB0-220K00A 1. Open the pump room door on the right side of the machine. 2. It is possible to judge the water level and amount of sedi- ment by looking through transparent cap (2).
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUSTING DRAIN VALVE Adjusting drain valve:PC220-AEB4-270K00A If drain valve (4) is stiff, coat the O-ring portion of the drain valve with grease to make the movement smooth. 1. Turn the valve (6) at the bottom of the fuel tank to the CLOSE position (S).
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL:PC220-PM30-212K00A WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before starting the work.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS CHECK COOLANT LEVEL, ADD COOLANT CHECK COOLANT LEVEL, ADD COOLANT:PC220-B000-216K00A WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
Page 220 If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove immediately. CHECK FUEL LEVEL, ADD FUEL CHECK FUEL LEVEL, ADD FUEL:PC220-AD10-211K00A WARNING When adding fuel, never spill the fuel or let it overflow. It will cause fire. If any fuel has spilled, wipe it up completely.
Page 222 Check that the working lamps and lamps inside the instruments light up properly. Check also that there is no dirt or damage. If any lamp does not light up, the bulb is probably blown up or there is a disconnection, so ask your Komatsu dis- tributor for repair.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUSTMENT Adjustment:ALL-K000-001K01A SEAT ADJUSTMENT SEAT ADJUSTMENT:PC220_KU-K2Q0-270K00A WARNING When adjusting the position of the operator's seat, always set the lock lever to the LOCK position to pre- vent any accidental contact with the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. Adjust the operator's seat so control levers and switches can be operated freely and easily with the operator's back against the backrest.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Adjusting armrest angle Angle of armrest (7) can be adjusted vertically by turning adjustment dial (8) at the bottom of the armrest. Armrest angle adjustment: 9° in lower direction and, 4° in upper direction (E) Lumber adjustment Rotate knob (9) in direction shown to increase the amount of lumber support.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS The specified positions of the mirror and the stay are as fol- lows: Stay (1) Mounting position (2): 77mm Mounting angle (3): 89deg. Mounting angle (4): 107 deg. Tightening torque of mounting bolt (5): 15.0 to 19.6 Nm {1.52 to 2 kgm} Mirror (6) Tightening torque of mounting bolt (7): 6.0 to 7.0 Nm {0.61...
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION The specified positions of the mirror and the stay are as fol- lows: Stay (9) Mounting position (10): 590 mm Mounting angle (11): 77deg. Mounting angle (12): 17deg. Tightening torque of mounting bolt (13): 15.0 to 19.6 Nm {1.52 to 2 kgm} Mirror (14) Tightening torque of mounting bolt (15): 6.0 to 7.0 Nm {0.61...
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS ADJUST REAR VIEW CAMERA ANGLE ADJUST REAR VIEW CAMERA ANGLE:PC220-Q162-270K00A WARNING Be sure to adjust the camera before starting work. If it is not adjusted properly, you cannot secure the visibil- ity and may be injured or may injure someone seri- ously.
Page 228 MACHINE OPERATIONS AND CONTROLS OPERATION If the image on the monitor is not aligned correctly, adjust mounting angle (A) of the rear view camera in the following procedure. Angle (A) can be adjusted within the range from 32 to 53 degrees.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS SEAT BELT SEAT BELT:PC-K2Q3-100K00A WARNING Before fitting the seat belt, check that there is no problem in the belt mount bracket or mounting belt. If it is worn or damaged, replace it. Even if no problem can be seen in the belt, replace the seat belt every 3 years from starting usage or 5 years after manufacture whichever comes sooner.
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK If the tongue is not inserted in the buckle, the seat belt monitor is displayed at the left top of the monitor panel. If it is displayed, fasten the seal belt. OPERATIONS AND CHECKS BEFORE STARTING ENGINE OPERATIONS AND CHECKS BEFORE STARTING ENGINE:PC220_KU-0000-12DK00A WARNING When starting the engine, check that the lock lever is securely at the LOCK position.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS 1. Check that battery disconnect switch (S) is in ON position (I). 2. Check that lock lever (1) is at LOCK position (L). 3. Check that all control levers and control pedals are at the NEUTRAL position.
Page 232 After inputting the password, press enter switch F6 (3). REMARK Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the password. 1) The buzzer sounds for approximately 2 seconds, then the monitor or meter lights up for approximately 2 sec- onds.
Page 233: Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS AUTOMATIC GREASE SYSTEM Check Automatic Grease System is normal, see section Maintenance - AUTOMATIC GREASE SYSTEM (6-7) STARTING ENGINE STARTING ENGINE:PC220_KU-0000-132K00A WARNING Start the engine only while sitting 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 personal injury or fire.
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION 3. Turn the key in starting switch (3) to ON position (B). If the ambient temperature is low, the preheating monitor lights up and automatic preheating is carried out. Keep the key in starting switch (3) at ON position (B) until the preheating monitor goes out.
Page 235 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK Regardless of the ambient temperature, it is possible to start the engine preheating manually. 1. Turn the key in starting switch (3) to the left from OFF posi- tion (A). The preheating monitor lights up and engine preheat- ing starts.
Page 236: Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 237 BREAK-IN THE NEW MACHINE:PC-0000-138K00A NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How- ever, operating the machine under full load before breaking in the machine may adversely affect the per- formance and shorten the machine life.
Page 238 MACHINE OPERATIONS AND CONTROLS OPERATION 1. This machine is equipped with an automatic engine warm- up system, so if the engine coolant temperature is below 30°C after the engine is started, the engine warm-up opera- tion starts automatically. When the engine automatic warm- up operation starts, the engine speed is maintained at a speed higher than the normal low idling speed.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS 1. Turn fuel control dial (2) to the full speed (MAX) position and hold it for three seconds. 2. When fuel control dial (2) is returned to the low idle (MIN) position, the engine speed will drop. HYDRAULIC SYSTEM WARM-UP OPERATION HYDRAULIC SYSTEM WARM-UP OPERATION:PC220_KU-0000-13EK00A WARNING...
Page 240 MACHINE OPERATIONS AND CONTROLS OPERATION 1. Check that engine coolant temperature monitor (1) displays the proper temperature. Display (A) when temperature is proper: Monitor back- ground (C) is blue Display (B) when temperature is low: Monitor back- ground (C) is white If it displays low temperature, carry out additional warm up of the engine until engine coolant temperature monitor (1) displays the proper temperature.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS 5. Turn fuel control dial (4) to a 2/3 position between low idle (MIN) and full speed (MAX). NOTICE When the work equipment is operated, take care that it does not interfere with the machine body or ground.
Page 242 Fuel level monitor (18): Displays appropriate level 14. Check for abnormal exhaust gas colour, noise, or vibration. If any problem is found, contact your Komatsu distributor. In cold temperatures [ambient temperature below 0°C], even when the hydraulic oil temperature monitor displays the proper temperature, carry out additional Step 15 to warm up all the hydraulic equipment.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS 16. Before starting the work, check that fuel control dial (4) is at a 2/3 position between low idling (MIN) and full speed (MAX). If it is not at a 2/3 position, set it to the midway position and run the engine at 2/3 speed between MIN and MAX before operating.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Attachment operation: One way (A)ioOther way (B) 19. Check that hydraulic oil temperature monitor (7) displays the proper temperature. If the hydraulic oil temperature monitor is not displaying the correct temperature (it is displaying low temperature), repeat Steps 6 to 10 until the display is the correct temperature.
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS 1) P mode For heavy-duty operations 2) E mode For operations with emphasis on fuel economy 3) L mode For operations requiring fine control 4) B mode For breaker operations 3–175...
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION 5) ATT/P mode For operations with crusher or other double-acting action attachment 6) ATT/E mode For operations with crusher or other double-acting action attachment (operations with emphasis on fuel consumption) 3–176...
Page 247: Stopping Engine
OPERATION MACHINE OPERATIONS AND CONTROLS STOPPING ENGINE STOPPING ENGINE:PC220-0000-13GK00A WARNING Keep away from the exhaust pipe just after stopping the engine. NOTICE If the engine is stopped abruptly, the service lives of com- ponent parts of the engine may be considerably reduced. Do not stop the engine abruptly except the case in an emergency.
Page 248: Machine Operation
MACHINE OPERATIONS AND CONTROLS OPERATION MACHINE OPERATION MACHINE OPERATION::PC220_KU-0000-13HK00A WARNING Before operating the travel levers or travel pedals, check the direction of the track frame. If the track frame is facing the rear (if the sprocket is at the front), the machine moves in the opposite direction to the direction of the operation of the travel levers or travel pedals (front and rear travel are reversed, left and right steering are reversed).
Page 249 Start the machine either by pulling lever (5) backwards slowly or by depressing the rear part of pedal (6) slowly. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, contact your Komatsu distrib- utor for repair.
Page 250 Start the machine either by pushing lever (5) forward slowly or by depressing the front part of pedal (6) slowly. 3. Check that the travel alarm sounds properly. If the travel alarm does not sound, contact your Komatsu distrib- utor for repair.
Page 251 OPERATION MACHINE OPERATIONS AND CONTROLS 3–181...
Page 252: Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION STEERING MACHINE Steering machine:PC-0000-001K12A STEERING Pivot turn:PC-0000-13PK01A WARNING Before operating the travel levers or travel pedals, check the direction that the track frame is facing (the position of the sprocket). When the sprocket is at the front, the directions of operations of the travel levers or control pedals are the opposite to the direction of movement of the machine.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS CHANGE DIRECTION OF THE MACHINE Change Direction of the Machine:PC-0000-13PK02A When turning to the left: If the left travel lever is returned to the NEUTRAL position, the machine will turn to the left. (A): Forward left turn (B): Reverse left turn REMARK When turning to the right, operate the right travel lever in the...
Page 254: Swinging Machine
MACHINE OPERATIONS AND CONTROLS OPERATION SWINGING MACHINE SWINGING MACHINE:PC220_KU-0000-13TK00A WARNING The tail of the machine extends outside the tracks. Before operating the swing, check that the area around the machine is safe. If the lever is operated when the engine speed is decreased by the auto-deceleration function, the engine speed will suddenly increase.
Page 255: Work Equipment Controls And Operations
OPERATION MACHINE OPERATIONS AND CONTROLS WORK EQUIPMENT CONTROLS AND OPERATIONS WORK EQUIPMENT CONTROLS AND OPERATIONS:PC-0000-13UK00A WARNING If the lever is operated when the engine speed is decreased by the auto-deceleration function, the engine speed will suddenly increase. Operate the levers carefully. Use the control levers to operate the work equipment.
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION If the work equipment control levers are returned to the NEUTRAL position when the machine is stopped, even if the fuel control dial is set to FULL, the auto-deceleration mechanism works to reduce the engine speed to a low- range speed.
Page 257: Working Mode
OPERATION MACHINE OPERATIONS AND CONTROLS WORKING MODE WORKING MODE:PC-0000-100K00A WORKING MODE WORKING MODE:PC220-PT5W-100K00A Use working mode selector switch (1) to select the working mode that matches the operating conditions or pur- pose. This will make it possible to carry out operations efficiently. Use the following procedure to select the most efficient working mode.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION 1. When working mode selector switch (1) is pressed, the screen switches to the working mode selection screen. 2. Press the working mode selector switch or, switches F3 or F4 to select the appropriate mode. 3.
Page 259 OPERATION MACHINE OPERATIONS AND CONTROLS ONE-TOUCH POWER MAX. SWITCH Operations Using Travel Force:PC-0000-189K02A The one-touch power max. switch can be used during operations to increase the power. Make effective use of this function whenever necessary in combination with the working mode. Press the left knob switch and keep it pressed.
Page 260: Prohibited Operations
MACHINE OPERATIONS AND CONTROLS OPERATION PROHIBITED OPERATIONS Prohibited operations:PC-0000-001K15A WARNING Do not operate the work equipment control lever when the machine is travelling. If any lever is operated when the auto-deceleration is being actuated, the engine speed will suddenly increase, so be careful when operating. OPERATIONS USING SWING FORCE Operations Using Swing Force:PC-0000-189K01A Do not use the swing force to compact soil or break objects.
Page 261 OPERATION MACHINE OPERATIONS AND CONTROLS OPERATIONS USING BUCKET DROPPING FORCE Operations Using Bucket Dropping Force:PC-0000-189K04A Do not use the dropping force of the machine for digging, nor use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will drastically reduce the life of the machine. OPERATIONS USING MACHINE DROPPING FORCE Operations Using Machine Dropping Force:PC-0000-189K05A Do not use the dropping force of the machine for digging.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION LONG-TIME CONTINUOUS TRAVEL OPERATIONS Long-Time Continuous Travel Operations:PC-0000-189K08A Do not travel continuously at high speed for one and a half hours or more. The lubricating oil inside the track rollers and final drive will rise to a high temperature. And there is a danger that this will cause damage to the oil seal or leakage of oil.
Page 263: Rules For Operation
OPERATION MACHINE OPERATIONS AND CONTROLS RULES FOR OPERATION RULES FOR OPERATION:PC-0000-001K13A TRAVELLING Traveling:PC-0000-186K01A Travelling over boulders, tree stumps, or other obstacles will cause a big shock to the machine (and in particular to the undercarriage), and this will cause damage to the machine. For this reason, always remove any obstacles or travel around them, or take other steps to avoid travelling over such obsta- cles as far as possible.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION PERMISSIBLE WATER DEPTH Permissible Water Depth:PC-0000-18NK00A NOTICE When driving the machine out of water, if the angle of the machine exceeds 15°, the rear of the upper structure will go under water, and water will be thrown up by the cooling fan.
Page 265: Travelling On Slopes
OPERATION MACHINE OPERATIONS AND CONTROLS TRAVELLING ON SLOPES Travelling on slopes:PC-0000-187K01A WARNING Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over, so avoid such operations. It is particularly dangerous to swing downhill when the bucket is loaded.
Page 266 MACHINE OPERATIONS AND CONTROLS OPERATION 1. When travelling down steep hills, use the travel lever and fuel control dial to keep the travel speed low. When travelling down a steep hill of more than 15°, set the work equipment to the posture shown in the figure on the right, and lower the engine speed.
Page 267: Escape From Mud
MACHINE OPERATIONS AND CONTROLS O P E R A T I O N ESCAPE FROM MUD ESCAPE FROM MUD:PC-0000-14CK00A Always operate carefully to avoid getting stuck in mud. If the machine does get stuck in mud, do as follows to get the machine out.
Page 268: Recommended Applications
MACHINE OPERATIONS AND CONTROLS OPERATION RECOMMENDED APPLICATIONS RECOMMENDED APPLICATIONS:PC-0000-13VK00A In addition to the following, it is possible to further increase the range of applications by using various attach- ments. BACKHOE WORK Backhoe Work:PC-0000-13WK00A A backhoe is suitable for excavating areas that are lower than the machine.
Page 269 OPERATION MACHINE OPERATIONS AND CONTROLS LOADING WORK Loading Work:PC-0000-13ZK00A In places where the swing angle is narrow, work efficiency can be enhanced by locating the dump truck in a place easily visi- ble to the operator. When loading the soil into dump truck body, it is easier to load from the rear of the dump body than to load from the side of the dump body, and more soil can be loaded as well.
Page 270: Replacing And Inverting Bucket
MACHINE OPERATIONS AND CONTROLS OPERATION REPLACING AND INVERTING BUCKET REPLACING AND INVERTING BUCKET:PC-LBK0-928K00A WARNING When pins are knocked in with a hammer, pieces of metal may fly and cause serious injury. When carrying out this operation, always wear goggles, hard hat, gloves, and other protective equip- ment.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When installing the bucket, for arm pin portion (A), fit O-ring (3) to bucket (4) in the position shown in the figure on the right. After inserting the pin, fit it in the regular groove. For link pin portion (B), install the bucket with O-ring (3) fitted in the regular groove.
Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION 3. After removing the bucket, reverse it. 4. Align the pin hole of arm (5) with replacement bucket hole (1), then align the pin hole of link (6) with hole (2), coat pins (A) and (B) with grease, and install. REMARK When inverting, do not install O-rings.
Page 273 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK Machines with Automatic Grease System require one time lubrication each time the bucket is changed. Lubricate at the bucket linkage and at the grease metering valve as indicated until grease comes out from the end faces.
Page 274: When Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION WHEN PARKING MACHINE When parking machine:PC220_KU-0000-160K00A WARNING Avoid stopping suddenly. Stop the machine gradually. Park the machine on flat hard ground. Avoid to park the machine on a slope. If it is unavoidably necessary to park the machine on a slope, put blocks to the track shoes.
Page 275 OPERATION MACHINE OPERATIONS AND CONTROLS 3. Lower the bucket horizontally until the bottom touches the ground. 4. Set lock lever (3) in the LOCK position (L). 5. Check the engine coolant temperature and engine oil pres- sure with the machine monitor. If the coolant temperature gauge is in the red range, allow it to cool until the indicator enters the green range, then stop the engine.
Page 276: After Daily Work Completion
MACHINE OPERATIONS AND CONTROLS OPERATION AFTER DAILY WORK COMPLETION After daily work completion:ALL-3330-200A00A 1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. 2.
Page 277: Transportation
Note that the weight and dimension given in SPECIFICATIONS (weight and dimension) may differ according to the type of shoe or arm, or other attachments. Consult your Komatsu distributor for details of the procedure for transporting machines with a protective guard installed for the operator's cab.
Page 278: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER LOADING AND UNLOADING WITH TRAILER:PC-0000-830K00A WARNING Always observe the following when loading or unloading the machine from a trailer. Select firm, level ground when loading or unloading the machine. Maintain a safe distance from the edge of a road. Always turn the auto-deceleration switch OFF (cancel).
Page 279 OPERATION TRANSPORTATION LOADING Loading:PC220-0000-831K00A 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of centre (3) of the trailer.
Page 280 TRANSPORTATION OPERATION 8. When loading or unloading a machine with the work equip- ment installed, at the point where the tracks are on both the ramps and the ground surface, turn the swing lock switch OFF, then swing the upper structure slowly 180°. After doing that, drive slowly in reverse and load the machine onto the trailer.
Page 281 OPERATION TRANSPORTATION SECURE MACHINE SECURE MACHINE:PC220-0000-821K00A NOTICE Stow the radio antenna. Reassemble the mirrors so that they are within the width of the machine. To prevent damage to the bucket cylinder during transportation, put a wooden block under the tip of the bucket link to prevent the bucket cylinder from touching the floor.
Page 282 TRANSPORTATION OPERATION Securing the machine when using tie-down point Tie one end of each chain or wire rope of appropriate strength to the tie-down holes on the track frame. X : 50 mm minimum up to 100 mm. (chain clearance to track) NOTE: Do not use tie down lugs for towing.
Page 283 OPERATION TRANSPORTATION INSTALLATION AND REMOVAL OF MIRRORS Installation and removal of mirrors:PC220_KA-K810-924K00A The mirrors are at the positions shown in the diagram on the right. If they are damaged, or are to be removed for shipment, or are to be installed again, use the following procedure. After installing the mirrors, be sure to adjust them, referring toMirrors adjustment (3-154).
Page 284 Remove and install handrail:PC220-H5H0-924K00A Depending on the height of the trailer platform, the handrail part might exceed the high limit. Accordingly, contact your Komatsu distributor for handling of the handrail transportation. WARNING After transporting the machine, be sure to install the handrails before inspection and maintenance.
Page 285 OPERATION TRANSPORTATION REMOVAL OF HANDRAILS 1. Remove bolts (1), then remove handrail (A). 2. Remove bolts (2), then remove handrail (B) and cover (3). INSTALLATION OF HANDRAILS 1. Install handrail (B) and cover (3), then tighten them with bolt (2). 2.
Page 286 TRANSPORTATION OPERATION REMOVE AND INSTALL REVOLVING WARNING LAMP REMOVE AND INSTALL REVOLVING WARNING LAMP:PC-Q5D0-822K00A REMOVAL OF REVOLVING WARNING LAMP 1. Remove connector (A) of the revolving warning lamp. When removing the connector, pull it out while pressing the claw in the centre of the connector. 2.
Page 287 OPERATION TRANSPORTATION INSTALLATION OF REVOLVING WARNING LAMP 1. Insert bracket (C) of the revolving warning lamp to claw (F) of mounting portion (E) and fix it with lock (D). REMARK If the reaction force of lock (D) is large, try it again by shifting bracket (C).
Page 288 TRANSPORTATION OPERATION 2. Removal of striker 1) Remove cap (7) from inside the door by picking the pro- trusion (a) of cap (7) with fingers. 2) Loosen the inside nuts (8) (2 pieces) to remove striker (3). Keep the removed parts and the removal procedure manual in the magazine box.
Page 289 OPERATION TRANSPORTATION 3. Covering stoppers and striker Cover the mounting holes of stoppers and striker with tape (b) etc. to prevent dust from entering the holes. HOW TO INSTALL CAB PARTS AFTER TRANSPORTATION 1. Removal of covering of stoppers and striker Completely remove the covering tapes (b) for mounting holes of stoppers and striker.
Page 290 TRANSPORTATION OPERATION 3. Installation of striker 1) Tighten nuts (8) (2 pieces) to install striker (3). 2) Install cap (7) to inside the door by picking protrusion (a) of cap (7) with fingers. Be careful to install cap (7) so that the part which has one claw (c) comes upside.
Page 291 OPERATION TRANSPORTATION UNLOADING UNLOADING:PC220-0000-841K00A 1. Load and unload on firm level ground only. Maintain a safe distance from the edge of a road. 2. Apply the trailer brakes securely, then put blocks (1) under the tires to prevent the trailer from moving. Set left and right ramps (2) parallel to each other and equally spaced to the left and right of centre (3) of the trailer.
Page 292 TRANSPORTATION OPERATION NOTICE When unloading the machine, always keep the arm and boom at an angle of 90° - 110°. If the machine is unloaded with the arm pulled in, it will cause damage to the machine. When moving onto the ramps, do not thrust the bucket into the ground.
Page 293: Lifting Machine
The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (5-2)". When lifting the machine, carry out the operation on flat ground as follows.
Page 294 TRANSPORTATION OPERATION STANDARD SPECIFICATION MACHINES STANDARD SPECIFICATION MACHINES:PC220-0000-816K00A 1. Start the engine, then the swing the upper structure so that the work equipment is on the side of sprocket (1). 2. Extend the bucket cylinder and arm cylinder fully, then lower the work equipment to the ground as shown in the fig- ure on the right using the boom cylinder.
Page 295: Cold Weather Operation
When changing the coolant or draining the coolant from the radiator during repairs, ask a qualified person to handle any coolant containing antifreeze, or contact your Komatsu distributor. Coolant is toxic, so never pour it into ditches or drain it onto the ground surface.
Page 296: After Daily Work Completion
COLD WEATHER OPERATION OPERATION AFTER DAILY WORK COMPLETION AFTER DAILY WORK COMPLETION:PC-0000-15AK00A WARNING Performing idle-running of the tracks is dangerous, stay well away from the tracks. To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions.
Page 297: Long-Term Storage
OPERATION LONG-TERM STORAGE LONG-TERM STORAGE LONG-TERM STORAGEALL-0000-870K00A BEFORE STORAGE Before storage:PC220-0000-870K01A NOTICE When storing the machine (one month or more), set the machine in the posture shown in the figure on the right to protect the cylinder rods. (To prevent rusting of the cylinder rods) When putting the machine in storage for a long time (more than one month), do as follows.
Page 298: After Storage
NOTICE If the machine is stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
Page 299: Troubles And Actions
OPERATION TROUBLES AND ACTIONS TROUBLES AND ACTIONS Troubles and actions:ALL-0000-001K14A RUNNING OUT OF FUEL RUNNING OUT OF FUEL:ALL-0000-14GK00A When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before stating. When bleeding air, see "REPLACE FUEL PRE-FILTER CARTRIDGE (4-49)"or "REPLACE FUEL MAIN FILTER CARTRIDGE (4-62)".
Page 300: Towing Machine
TROUBLES AND ACTIONS OPERATION TOWING MACHINE Towing machine:PC-0000-146K00A WARNING Any mistake in the selection of the wire rope or towing bar or in the method of towing, may lead to serious personal injury or death. Always check that the wire rope used for towing has ample strength for the weight of the machine being towed.
Page 301: Lightweight Towing Hole
OPERATION TROUBLES AND ACTIONS LIGHTWEIGHT TOWING HOLE Lightweight towing hole:PC220-0000-148K00A WARNING If tools such as a wire rope are selected inappropriately or working approaches such as towing method are executed inappropriately, serous personal injury can result. Select the appropriate tools and methods.
Page 302: Discharged Battery
TROUBLES AND ACTIONS OPERATION DISCHARGED BATTERY DISCHARGED BATTERY:PC-AW10-2A1K00A WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charging. When checking or handling the battery, stop the engine and turn the starting switch and battery disconnect switch keys to the OFF positions.
Page 303 OPERATION TROUBLES AND ACTIONS REMOVE AND INSTALL BATTERY Remove and install battery:PC-AW10-924K00A When removing the battery, remove the ground cable (nor- mally connected to the negative (-) terminal) first. If any tool touches the positive terminal of the battery and the chassis, there is a hazard of sparks being generated.
Page 304 TROUBLES AND ACTIONS OPERATION START ENGINE WITH BOOSTER CABLES Start Engine with Booster Cables:ALL-AW10-14BK00A When starting the engine with a booster cable, do as follows. CONNECT AND DISCONNECT BOOSTER CABLES CONNECT AND DISCONNECT BOOSTER CABLES:PC220-AW10-14BK00A WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals.
Page 305 OPERATION TROUBLES AND ACTIONS CONNECTION OF BOOSTER CABLES Set the starting switch and the battery disconnect switch of the failed machine, and the starting switch of the nor- mal machine to the OFF positions, and connect the booster cables as follows in the order of the numbers marked in the figure: 1.
Page 306: Other Trouble
ELECTRICAL SYSTEM ELECTRICAL SYSTEM:PC-AK50-400K00A As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu distribu- tor. In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Page 307 TROUBLES AND ACTIONS CHASSIS CHASSIS:PC220-RA15-400K00A As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu distribu- tor. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Page 308 OPERATION ENGINE ENGINE:PC-A000-400K00A As for the corrective actions indicated with (*) in the remedy column, be sure to contact your Komatsu distribu- tor. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
Page 309 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Exhaust gas is white or blue Water entry in KDPF Check, repair (*) Broken KDPF Replace KDPF (*) Too much oil in oil pan Set oil to specified level, see Check before staring. Improper fuel Change to specified fuel Exhaust gas occasionally turns...
Page 310 (emergency) position. After that, ask your Komatsu distributor for inspection and repair. If a display of "CA2249" or "CA559" appears on the occur-...
Page 311: Maintenance
MAINTENANCE MAINTENANCE MAINTENANCE:ALL-0000-001K03A MAINTENANCE WARNING Please read and make sure that you understand the SAFETY section before reading this section. 4–1...
Page 312: Rules For Maintenance
Komatsu recommends using Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS Komatsu Genuine Lubricants:ALL-0000-201K00A For lubrication of the machine, Komatsu recommends using the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Always use clean washer fluid:ALL-K7B3-200K00A Use ethyl alcohol window washer fluid, and be careful not to let any dirt get into it.
Page 313: Dusty Worksites
MAINTENANCE RULES FOR MAINTENANCE DUSTY WORKSITES Dusty worksites:ALL-0000-20HK00A When working at dusty worksites, do as follows: Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. Replace the fuel filter more frequently.
Page 314: Outline Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval.We recommend that you use the Komatsu oil clinic to check the characteristics of the oil in detail. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF.
Page 315 NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminium parts of the cooling system.
Page 316 Perform sampling at regular fixed intervals. Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORING OIL AND FUEL STORING OIL AND FUEL:ALL-RA19-876K00A Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 317: Handling Electrical Components
When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, contact your Komatsu distributor. Do not open packs of spare filters until just before they are to be used.
Page 318: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that is removed.
Page 319: Maintenance Schedule
250 hours. For detail, see the oil part number and notes in "RECOMMENDED FUEL, COOLANT, AND LUBRICANT (7-4)". Contact your Komatsu distributor for changing the maintenance interval of the machine monitor. MAINTENANCE SCHEDULE TABLE Maintenance schedule table:ALL-3130-001A00A INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ..........
Page 320 MAINTENANCE SCHEDULE MAINTENANCE CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER) ......4-64 EVERY 2000 HOURS MAINTENANCE EVERY 2000 HOURS MAINTENANCE:PC-33E0-002A00A CHANGE OIL IN FINAL DRIVE CASE ......................4-65 CLEAN HYDRAULIC TANK STRAINER......................4-66 CHECK CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT) ..4-67 CHECK ALTERNATOR .............................
Page 321: Maintenance Interval For Hydraulic Breaker
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER:PC220_KU-LG10-20CK00A On the machine equipped with a hydraulic breaker, the hydraulic oil and grease deteriorate faster than in normal bucket digging operations, so set the maintenance intervals as follows. Replace hydraulic filter element On a new machine, replace the element after the first 100 to 150 hours of operation, then carry out further replacement of...
Page 322: Maintenance Schedule Table
MAINTENANCE SCHEDULE TABLE MAINTENANCE MAINTENANCE SCHEDULE TABLE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) Carry out the following maintenance only after the first 250 hours of operation on new machines. Lubrication For details of the method of maintaining, see "LUBRICATING (4-40)".
Page 323 MAINTENANCE MAINTENANCE SCHEDULE TABLE CLEAN OUTER ELEMENT CLEAN OUTER ELEMENT:PC220-A92G-250K00A NOTICE Before and after cleaning the element, do not leave or keep it under direct sunlight. 1. Open the rear door on the left side of the machine, remove hooks (2) (four places), then remove cover (3). NOTICE Never remove the inner element (6).
Page 324 MAINTENANCE SCHEDULE TABLE MAINTENANCE 3) Remove one numbered tab from the decal whenever the element is cleaned. 8. If small holes or thinner parts are found on the element when it is checked by lightening inside the element it after cleaning, replace the element.
Page 325 MAINTENANCE MAINTENANCE SCHEDULE TABLE NOTICE When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is installed by force with hook (2), there is a danger that the hook and air cleaner body may be damaged, so be careful when installing.
Page 326 MAINTENANCE SCHEDULE TABLE MAINTENANCE NOTICE The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time. If the inner element is not installed properly and the outer element and cover are installed, there is a danger that the outer element is damaged.
Page 327: Clean Inside Of Cooling System
MAINTENANCE MAINTENANCE SCHEDULE TABLE NOTICE When inserting the element into the body, if the rubber at the tip is swollen or the outer element is not pushed in straight, and cover (3) is installed by force with hook (2), there is a danger that the hook and air cleaner body may be damaged, so be careful when installing.
Page 328 NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminium parts of the cooling system.
Page 329 MAINTENANCE MAINTENANCE SCHEDULE TABLE 1. Stop the machine on level ground, then stop the engine. 2. Open engine hood (1). 3. Check that the coolant temperature is low enough to make it possible to touch the radiator cap surface by hand, then turn radiator cap (2) slowly until it contacts the stopper to release the pressure.
Page 330 MAINTENANCE SCHEDULE TABLE MAINTENANCE 9. Move the lock lever slowly and steadily to FREE position (F), then raise the bucket from the ground. 10. Turn the fuel control dial to a 2/3 position between low idling (MIN) and full speed (MAX). NOTICE When the work equipment is operated, take care that it does not interfere with the machine body or ground.
Page 331 MAINTENANCE MAINTENANCE SCHEDULE TABLE 16. Stop the engine and open drain valve (3) to drain the water. 17. Drain the coolant in sub-tank (5). 18. After draining the water, clean the radiator with detergent. For the cleaning method, follow the instruction for the deter- gent.
Page 332 MAINTENANCE SCHEDULE TABLE MAINTENANCE 26. Close engine hood (1). 4–22...
Page 333: Check And Tighten Track Shoe Bolts
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHECK AND TIGHTEN TRACK SHOE BOLTS CHECK AND TIGHTEN TRACK SHOE BOLTS:PC-DTP4-92BK00A If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. RE TIGHTENING Retightening:PC-DTP4-71AK00A Triple grouser shoe, swamp shoe, flat shoe, rubber pad shoe 1.
Page 334 It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. 1. Loosen plug (1) gradually to release the grease.
Page 335: Replace Bucket Teeth (Vertical Pin Type)
MAINTENANCE MAINTENANCE SCHEDULE TABLE REPLACE BUCKET TEETH (VERTICAL PIN TYPE) REPLACE BUCKET TEETH (VERTICAL PIN TYPE):PC-LBM1-923K00A Replace the bucket teeth before the adapter starts to wear. WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position.
Page 336 MAINTENANCE SCHEDULE TABLE MAINTENANCE Lock pin (2) is too short. Dimension (B) is 1/3 or more of dimension (A) when lock pin (2) is aligned with bottom face (C). Rubber (6) of the rubber pin lock is cut and the steel ball is about to come out.
Page 337 MAINTENANCE MAINTENANCE SCHEDULE TABLE If this happens, there is something (C) affixed preventing the tooth (1) from fitting completely in adapter (4). Locate the problem and remove the obstruction. When tooth (1) fits completely in adapter (4), knock in lock pin (2). 9.
Page 338: Replace Bucket Teeth (Horizontal Pin Type)
(2). REMARK If the bucket teeth cannot be safely removed by this method, ask your Komatsu distributor for replacement of the bucket teeth. 4. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket.
Page 339: Adjust Bucket Clearance
MAINTENANCE MAINTENANCE SCHEDULE TABLE ADJUST BUCKET CLEARANCE ADJUST BUCKET CLEARANCE:PC-LBK0-27DK00A WARNING It is dangerous if the work equipment moves by mistake when the bucket clearance is being adjusted.Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to the LOCK position (L).
Page 340: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE SCHEDULE TABLE MAINTENANCE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID:PC220-K7B0-217K00A If there is air in the window washer fluid, check the level of the fluid in window washer fluid tank (1). Add Ethyl Alcohol window washer fluid if necessary.
Page 341: Check And Maintenance Air Conditioner
(C) Colourless, transparent: No refrigerant REMARK When there are bubbles, the refrigerant gas level is low, so contact your Komatsu distributor to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 342: Wash Washable Floor
MAINTENANCE SCHEDULE TABLE MAINTENANCE WASH WASHABLE FLOOR WASH WASHABLE FLOOR:PC-K150-255K00A WARNING When setting the machine at an angle, use strong blocks to stabilize the machine and be extremely careful when carrying out the work. If the control levers are touched by mistake, the machine may suddenly move, and this may lead to a serious accident.
Page 343 MAINTENANCE MAINTENANCE SCHEDULE TABLE WASH CAB FLOOR WASH CAB FLOOR:PC220-K151-255K00A 1. Set the machine at an angle. For details, see "SET MACHINE AT ANGLE (4-35)". 2. Swing the upper structure slowly so that water drain holes (3) in the cab floor are at a low position. 3.
Page 344 MAINTENANCE SCHEDULE TABLE MAINTENANCE 4. Set lock lever (1) to LOCK position (L) and stop the engine. 5. Pull out six projections (2) on the back of the floor mat and remove the floor mat. 6. Remove the cap from water drain hole (3). 7.
Page 345 MAINTENANCE MAINTENANCE SCHEDULE TABLE SET MACHINE AT ANGLE SET MACHINE AT ANGLE:PC-K151-255K01A USE SLOPE USE SLOPE:PC-K151-255K02A WARNING Select a solid and smooth slope.Always put blocks under the track to prevent the machine from moving, and dig the work equipment into the ground. Stop the machine so that the work equipment is on the downhill side.
Page 346: Check Gas Spring
Do not make holes in it nor weld it. Do not hit it, roll it, nor give it any impact. When disposing, the gas must be released. Ask your Komatsu distributor for this work. The gas springs are located at the engine hood (right, left: two places).
Page 347 If the air is not bled from the swing motor, the motor bearings may be damaged. When replacing the travel motor safety valve, ask your Komatsu distributor for the replacement and the air bleed- ing. 5. Bleeding air from travel motor (Bleed air only when the oil inside the travel motor case is drained.)
Page 348 MAINTENANCE SCHEDULE TABLE MAINTENANCE 2) Run the engine at low idle and swing the upper structure 90° to bring the work equipment to the side of the track. 3) Push up the machine until the track is raised slightly from the ground. Rotate the track under no load for two minutes.
Page 349: Checks Before Starting
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHECKS BEFORE STARTING CHECKS BEFORE STARTING:ALL-3340-208A00A For details of the following items, see "Checks Before Starting (3-143)"in the OPERATION section. Drain of water and sediment from fuel tank Check of water separator, drain of water and sediment Check of oil level in hydraulic tank, addition of oil Check of coolant level, addition of coolant Check of oil level in engine oil pan, addition of oil...
Page 350: Every 100 Hours Maintenance
MAINTENANCE SCHEDULE TABLE MAINTENANCE EVERY 100 HOURS MAINTENANCE EVERY 100 HOURS MAINTENANCE:ALL-33A0-001A00A LUBRICATING LUBRICATING:PC220_KU-L410-242K01A (When greasing is carried out by using grease pump instead of using automatic greasing system.) NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval.
Page 351: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE SCHEDULE TABLE EVERY 250 HOURS MAINTENANCE EVERY 250 HOURS MAINTENANCE:ALL-33B0-001A00A Maintenance for every 100 hours should be carried out at the same time. CHECK LEVEL OF BATTERY ELECTROLYTE CHECK LEVEL OF BATTERY ELECTROLYTE:PC220-AW10-217K00A Carry out this procedure before operating the machine. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line.
Page 352 Neutralize the removed electro- lyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your Komatsu distributor or your battery maker. WHEN THE ELECTROLYTE LEVEL CAN BE CHECKED WITH AN INDICATOR, ETC.
Page 353: Check Air Conditioner Compressor Belt Tension, Adjust
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST:ALL-K5A0-92CK00A CHECK CHECK:ALL-K5A0-285K00A Press the belt with a finger force of approx. 60 N (6.2 kg) at a point midway between drive pulley (1) and compressor pulley (2).
Page 354 In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones. The fan belt has elongated, leaving little allowance for adjustment. A cut or crack is found on the belt.
Page 355: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE SCHEDULE TABLE EVERY 500 HOURS MAINTENANCE EVERY 500 HOURS MAINTENANCE:ALL-33C0-015A00A Maintenance for every 100 and 250 hours should be carried out at the same time. LUBRICATING LUBRICATING:PC220_KU-L410-242K00A (When greasing is carried out by using grease pump instead of using automatic greasing system.) NOTICE If any abnormal noise is generated from any greasing point, carry out greasing regardless of the greasing interval.
Page 356: Lubricate Swing Circle
MAINTENANCE SCHEDULE TABLE MAINTENANCE (2) Boom foot pin (2 places) (3) Boom cylinder rod end pin (2 places) (4) Arm cylinder foot pin (1 place) (5) Boom - Arm coupling pin (1 place) (6) Arm cylinder rod end (1 place) (7) Bucket cylinder foot pin (1 place) LUBRICATE SWING CIRCLE LUBRICATE SWING CIRCLE:PC-J110-242K00A...
Page 357: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE:PC-AB02-923K00A WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause burns.Wait for the temperature to go down before starting the work.
Page 358 MAINTENANCE SCHEDULE TABLE MAINTENANCE REMARK When the ambient temperature is low, water or emulsified mat- ter may stick to the oil level gauge oil filler cap, etc. or the drained oil may be milky white because of water vapour in the blow-by gas.
Page 359: Replace Fuel Pre-Filter Cartridge
Do not bring any fire or flame close. NOTICE Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering perfor- mance. When replacing the filter cartridge, Komatsu recommends using a genuine Komatsu part. The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzles.
Page 360 MAINTENANCE SCHEDULE TABLE MAINTENANCE 9. When installing, apply oil lightly to the packing surface and bring the packing surface into contact with the seal surface of filter cartridge (4) and then tighten it further by 1/4 to 1/2 turns. If the transparent cap is tightened too much, the O-ring will be damaged and this will cause leakage of fuel;...
Page 361: Check Swing Pinion Grease Level, Add Grease
9 mm. Add grease if the level is low. 3. Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Contact your Komatsu distributor. The total amount of grease: 14.6 litres.
Page 362: Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Air Conditioner Condenser Fins
5. Visually check the rubber hose connected to the heat exchanger. If it is cracked or become fragile, ask your Komatsu distributor for replacement. Also, check the hose clamp for looseness. 6. Remove undercover (9) and blow the mud, dirt, and leaves out to the outside.
Page 363 MAINTENANCE MAINTENANCE SCHEDULE TABLE OPENING AND CLOSING CONDENSER 1. Open the rear door on the left side of the machine and remove bolts (A) (at 2 places) on the right end of the con- denser. 2. Pull the condenser forward to open it. 3.
Page 364: Clean Air Conditioner Fresh / Recirc Filters
As a guideline, the filters should be cleaned every 500 hours, but on dusty jobsites, clean the filters more frequently. Always use genuine Komatsu filters to ensure safe working conditions are maintained for the operator. Contact your Komatsu distributor for the correct filter information.
Page 365: Clean Fresh Air Filter
MAINTENANCE MAINTENANCE SCHEDULE TABLE CLEAN FRESH AIR FILTER CLEAN FRESH AIR FILTER:PC220-K522-250K00A 1. Use the starting switch key to open cover (4) at the rear left of the operator's cab, then open cover (4) by hand and remove filter (5) inside the cover while holding the cover. 2.
Page 366: Replace Breather Element In Hydraulic Tank
MAINTENANCE SCHEDULE TABLE MAINTENANCE REPLACE BREATHER ELEMENT IN HYDRAULIC TANK REPLACE BREATHER ELEMENT IN HYDRAULIC TANK:PC220_KU-PM39-923K00A WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns. Wait for the temperature to go down before cleaning the engine breather. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 367: Check Oil Level In Swing Machinery Case, Add Oil
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL:PC220-J135-212K00A WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns.
Page 368: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SCHEDULE TABLE MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL:PC-DF30-212K00A WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns.
Page 369: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE SCHEDULE TABLE EVERY 1000 HOURS MAINTENANCE EVERY 1000 HOURS MAINTENANCE:ALL-33D0-015A00A Carry out the periodic maintenance work of every 100, 250 and 500 hours of operation at the same time. REPLACE HYDRAULIC OIL FILTER ELEMENT REPLACE HYDRAULIC OIL FILTER ELEMENT:PC220_KU-PM35-923K00A WARNING The parts and oil are at high temperature after the engine is stopped, and may cause serious burns.
Page 370: Change Oil In Swing Machinery Case
MAINTENANCE SCHEDULE TABLE MAINTENANCE CHANGE OIL IN SWING MACHINERY CASE CHANGE OIL IN SWING MACHINERY CASE:PC220-J135-292K00A WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work. Refill capacity: 6.5 litres 1.
Page 371: Check Oil Level In Damper Case, Add Oil
MAINTENANCE MAINTENANCE SCHEDULE TABLE CHECK OIL LEVEL IN DAMPER CASE, ADD OIL CHECK OIL LEVEL IN DAMPER CASE, ADD OIL:PC220-CB10-212K00A WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the temperature to go down before starting the work. NOTICE Park the machine on flat ground and stop the engine.
Page 372: Replace Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzles. If any part other than the genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using sub- stitute parts.
Page 373 MAINTENANCE MAINTENANCE SCHEDULE TABLE NOTICE Do not fill the new filter cartridge with fuel. Remove cap (B) and install the filter cartridge. 6. When installing, tighten it until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn.
Page 374: Check All Tightening Points Of Engine Exhaust Pipe Clamps
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS:ALL-A980-286K00A Ask your Komatsu distributor to check the tightening of the clamps between the air cleaner and turbocharger and aftercooler and engine. CHECK FAN BELT TENSION AND REPLACE FAN BELT CHECK FAN BELT TENSION AND REPLACE FAN BELT:ALL-B430-92EK00A Special tools are required for inspection and replacement of the fan belt.
Page 375: Every 2000 Hours Maintenance
MAINTENANCE MAINTENANCE SCHEDULE TABLE EVERY 2000 HOURS MAINTENANCE EVERY 2000 HOURS MAINTENANCE:ALL-33E0-015A00A Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN FINAL DRIVE CASE:PC220-DF30-292K00A WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns.
Page 376: Clean Hydraulic Tank Strainer
MAINTENANCE SCHEDULE TABLE MAINTENANCE CLEAN HYDRAULIC TANK STRAINER CLEAN HYDRAULIC TANK STRAINER:PC-PM3E-255K00A WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, the oil may spurt out.
Page 377: Check Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)
Do not bring it near flame or dispose of it in fire. Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor for the work. NOTICE...
Page 378 MAINTENANCE SCHEDULE TABLE MAINTENANCE CHECK FUNCTION OF ACCUMULATOR Check function of accumulator:PC-PL40-360K00A CAUTION When carrying out the inspection, check first that there is no person or obstacle in the surrounding area. Check the nitrogen gas charge pressure as follows. 1. Stop the machine on firm and level ground. 2.
Page 379 Ask your Komatsu distributor for inspection. 7. This completes the inspection. After completion of the inspection, set the lock lever to the LOCK position and turn the starting switch to the OFF position.
Page 380: Check Alternator
Contact your Komatsu distributor to have the alternator checked. If the engine is started frequently, have this inspection carried out every 1000 hours. CHECK ENGINE VALVE CLEARANCE, ADJUST CHECK ENGINE VALVE CLEARANCE, ADJUST:ALL-A700-27DK00A Special tools are needed for inspection and maintenance. Contact your Komatsu distributor. 4–70...
Page 381: Replace Kccv Filter Element
MAINTENANCE MAINTENANCE SCHEDULE TABLE REPLACE KCCV FILTER ELEMENT CLEAN HYDRAULIC TANK STRAINER:PC-PM3E-255K00A WARNING After the engine is operated, all parts are at high temperature, so do not replace the filter element immedi- ately. Wait for all parts to cool down before starting the work. NOTICE If the engine is operated without the filter element, the turbocharger and aftercooler will become dirty and their performance will lower and that can cause engine problems such as overrun caused by suc-...
Page 382 MAINTENANCE SCHEDULE TABLE MAINTENANCE 2. After ring (3) comes off, remove case (4) from body (2) and remove element (5). Oil may be accumulated or sticking in the case and element. When replacing the element, take care that the oil will not spill out.
Page 383 MAINTENANCE MAINTENANCE SCHEDULE TABLE 6. Fit ring (3) to the threaded part of the body and tighten it with the hand firmly until it stops. 7. Using the special wrench, further tighten the ring 1/15 to 2/ 15 turns (1 to 2 ridges of the ring). If the engine is operated with the ring tightened insufficiently, oil and blow-by gas may leak.
Page 384: Every 4000 Hours Maintenance
CHECK WATER PUMP CHECK WATER PUMP:ALL-BA10-360K00A Check for leakage of water and oil around the water pump. If any problem is found, ask your Komatsu distributor to carry out disassembly, repair, or replacement. CHECK VIBRATION DAMPER CHECK VIBRATION DAMPER:ALL-A5E0-360K00A For the check and replacement of the vibration damper, special tools are required.
Page 385: Replace Accumulator (For Control Circuit)
Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor for the work. If operations are continued after the performance of the accu-...
Page 386: Check For Looseness Of High-Pressure Piping Clamp, Hardening Of Rubber
(2 places) for the high-pressure piping between the supply pump and the common rail. If there are any problems, the parts must be replaced. In this case, ask your Komatsu distributor for replacement. Replacement of the high-pressure piping must be made as an assembly.
Page 387: Check Operating Condition Of Compressor
1. When the air conditioner switch is turned ON-OFF, do the compressor and magnet clutch also turn ON-OFF? 2. Is any abnormal noise generated by the clutch or compressor unit? If any problem is found, contact your Komatsu distributor to have the parts disassembled, repaired, or replaced. 4–77...
Page 388: Every 4500 Hours Maintenance
Carry out the periodic maintenance work of every 100, 250 and 500 hours of operation at the same time. CLEAN KDPF CLEAN KDPF:PC-A9H0-923K00A Komatsu recommends contacting your Komatsu distributor for cleaning of the KDPF. REPLACE KCCV HOSE REPLACE KCCV HOSE:PC-A18D-923K00A Have your Komatsu distributor replace the KCCV hose.
Page 389: Every 5000 Hours Maintenance
MAINTENANCE MAINTENANCE SCHEDULE TABLE EVERY 5000 HOURS MAINTENANCE EVERY 5000 HOURS MAINTENANCE:ALL-33G0-015A00A Carry out the periodic maintenance work of every 100, 250, 500 and 1000 hours of operation at the same time. CHANGE OIL IN HYDRAULIC TANK CHANGE OIL IN HYDRAULIC TANK:PC220-PM30-292K00A WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause seri- ous burns.
Page 390: Every 8000 Hours Maintenance
REPLACE FUEL SPRAY PREVENTION CAP REPLACE FUEL SPRAY PREVENTION CAP:ALL-AEFU-923K00A Contact your Komatsu distributor to have the fuel spray prevention cap replaced. REPLACE HIGH-PRESSURE PIPING CLAMP When replacing the engine high-pressure piping clamps, always ask your Komatsu distributor to carry out the replacement. 4–80...
Page 391: End Of Service Life
MAINTENANCE END OF SERVICE LIFE END OF SERVICE LIFE For safe dismantling of the machine at end of service life, please contact your local Komatsu Distributor. 4–81...
Page 392 END OF SERVICE LIFE MAINTENANCE 4–82...
Page 393: Specifications
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS:ALL-0000-001K04A SPECIFICATIONS 5–1...
Page 394 SPECIFICATIONS SPECIFICATIONS:PC220-2110-930A01A Item Unit PC210-10 PC210LC-10 Operating weight 21,440 22,310 Bucket capacity Name of engine KOMATSU SAA6D107E-2 diesel engine 118/2,000 (ISO 9249) Engine Power kW /rpm 123/2,000 (ISO14396) A Overall length 9,625 B Overall height 2,970 C Overall width 2,800...
Page 395 SPECIFICATIONS SPECIFICATIONS Working ranges Unit PC210-10, PC210LC-10 A Max. digging reach 9,875 B Max. digging depth 6,620 C Max. digging height 10,000 D Max. vertical wall depth 5,980 E Max. dumping height 7,110 F Min. dumping height 2,645 G Max. digging reach at ground level...
Page 396: Explanation Of Lifting Capacity Chart Pc210, Pc210Lc-10 1-Piece Boom
WITH FULLY EXTENDED BUCKET CYLINDER. ON A COMPACT HORIZONTAL LEVEL GROUND. PC210-10 with 600 width shoe PC210LC-10 with 600mm width shoe Loads do not exceed 87% of hydraulic capacity or 75% of tipping capacity (* load limited by hydraulic capacity rather than tipping).
Page 397 SPECIFICATIONS SPECIFICATIONS PC210-10 5–5...
Page 398 SPECIFICATIONS SPECIFICATIONS PC210LC-10 5–6...
Page 399: Attachments And Options
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS:ALL-RA17-001K00A ATTACHMENTS AND OPTIONS WARNING Please read and make sure that you understand the SAFETY section before reading this section. 6–1...
Page 400: General Precautions For Safety
Install only attachments or options authorized by Komatsu. Komatsu cannot accept any responsibility for any accident, damage, or failure caused by the use of attachments or options not authorized by Komatsu. When installing attachments or options to the machine, it is necessary to pay attention to safety. Please observe the following precautions strictly when selecting, installing, or using attachments or options.
Page 401 ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY PRECAUTIONS WHEN USING:ALL-RA17-170K00A WARNING NOTE: When calculating the allowable mass of attachments, the mass of the bucket, see the following: explanation of lifting capacity chart PC210, PC210LC-10 1-PIECE BOOM (5-4) should be taken into consid- eration.
Page 402: Handling Quick Coupler
Maximum circuit pressure 34.3 MPa (350 kgf/cm 5. Ensure that the quick coupler is installed by a suitably qualified technician. If in doubt contact your Komatsu distributor. NAME OF EACH PART...
Page 403 This machine has a system installed to give a warning if there is a failure to maintain pressure in the quick coupler system. If the buzzer sounds in the cab make sure that the cause is clarified before con- tinuing work. In particular check for leaks in the system. If in doubt call your Komatsu distributor. 6–5...
Page 404 HANDLING QUICK COUPLER ATTACHMENTS AND OPTIONS 1. Position the quick coupler over the new bucket or attach- ment. 2. Operate switch (1). REMARK The switch has a safety lock mechanism to prevent acci- dental operation. Slide the lock towards you then rock the switch.
Page 405: Automatic Grease System
RECOMMENDED GREASE Komatsu genuine grease is provided to maintain reliability and durability of Komatsu construction equipment and components. In order to keep you machine in the best condition for long periods of time, it is essential to follow the instruc- tions in this Operation and Maintenance Manual.
Page 406: Diagram Of Greasing Points
AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS DIAGRAM OF GREASING POINTS part Swing circle Boom cylinder foot pin Boom foot pin Boom cylinder rod end Arm cylinder foot pin Boom arm coupling Arm cylinder rod end Bucket cylinder foot pin Bucket cylinder rod end (may not be available with some specifications) Bucket—link coupling pin (may not be available with some specifications)
Page 407: Indication On The In-Cab Display
ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM INDICATION ON THE IN-CAB DISPLAY Indication Meaning The red lamp (6) flashes as soon 1. The pump is not powered. Check fuses and connections to earth. Immedi- as the ignition has been switched ate action required. 2.
Page 408: Check Auto-Greasing System
AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS CHECK AUTO-GREASING SYSTEM CHECK AUTO-GREASING SYSTEM:PC220_KU-Q850-280K00A Periodic Checks Check the grease level in the reservoir, but do not refill the reservoir before minimum level is reached. Check the in-cab display is functioning. Check if the selected interval time is correct for the working conditions of the machine. Check the pump for damage and leakage.
Page 409: Refilling Grease
ATTACHMENTS AND OPTIONS AUTOMATIC GREASE SYSTEM REFILLING GREASE If the yellow lamp (5) on the in-cab display (2) illuminates, the minimum grease level in the reservoir has been reached. The grease reservoir must be refilled as soon as possible. GREASING PROCEDURE 1.
Page 410 AUTOMATIC GREASE SYSTEM ATTACHMENTS AND OPTIONS A test cycle can only be started when the system is not in the pump phase of a current greasing cycle. If the sys- tem is busy with a pump cycle, it will not react to the test push button. NOTICE Only use grease tests cycles if necessary.
Page 411: Bucket With Hook
BUCKET WITH HOOK Bucket with hook:PC-LBKN-001K00A HOOK CONDITION HOOK CONDITION:PC-LBKN-280K00A Check that there is no damage to the hook, stopper, or hook mount. If there is any problem, contact your Komatsu distributor. PROHIBITED OPERATIONS Prohibited operations:PC-LBKN-001K01A SAFETY RULES FOR LIFTING OPERATIONS...
Page 412: Machine Ready For Installation Of Attachment
MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT Machine ready for installation of attachment :PC-L411-001K00A EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS:PC220_KU-LGC0-04DK00A Stop valve Accumulator (for low pressure) Selector valve 1st-line attachment proportional switch Attachment control pedal 2nd-line attachment proportional switch Lock pin...
Page 413 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT SELECTOR VALVE SELECTOR VALVE:PC220-PQH0-043K00A This valve (2) switches the flow of hydraulic oil. It is automatically switched according to the selected working mode. It is necessary to switch the working mode to match the attachment that is installed.
Page 414 Do not make holes in it or weld it. Do not hit it, roll it, or subject it to any impact. When disposing of the accumulator, the gas must be released. Ask your Komatsu distributor to have this work carried out.
Page 415 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT 1ST-LINE ATTACHMENT PROPORTIONAL SWITCH 1st-line attachment proportional switch:PC220_KU-PT0R-043K01A WARNING When operating attachment using rolling switch, lock the pedal with the lock pin to avoid accidental oper- ation. Switch (7) operates the 1st attachment circuit (e.g. crusher). The switch (7) is a roller proportional control switch.
Page 416: Hydraulic Circuit
} when ATT/P or ATT/E mode is selected. Depending on the attachment, it may be necessary to adjust the pressure. Ask your Komatsu distributor for the adjustment. SWITCHING THE HYDRAULIC CIRCUIT Depending on the type of attachment, set the working mode on the monitor as follows.
Page 417 Be careful not to lose or damage the removed parts. 3. After removing plug, connect the attachment piping (5) which is provided by the attachment manufacturer. For the fitting size and accumulator add-on, the action to take differs according to the attachment manufacturer, so consult your Komatsu distributor. 6–19...
Page 418 MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS OIL FLOW PATH OIL FLOW PATH:PC220-RA18-044K00A The direction of operation of the pedal and the path of the oil flow is as shown in the figure below. When the front of the pedal is depressed, oil flows to the piping on the left side of the work equipment; when the rear of the pedal is depressed, oil flows to the piping on the right side of the work equipment.
Page 419 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT REPLACE ELEMENT FOR ADDITIONAL FILTER FOR BREAKER REPLACE ELEMENT FOR ADDITIONAL FILTER FOR BREAKER:PC220-LGC5-923K00A WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the work.
Page 420 MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 4. Set the lock lever to LOCK position (L). 5. Loosen slowly oil filler cap (F) on the top of the hydraulic tank to release the internal pressure in the hydraulic circuit. 6.
Page 421 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT REPLACE ELEMENT FOR ADDITIONAL PILOT FILTER FOR BREAKER REPLACE ELEMENT FOR ADDITIONAL PILOT FILTER FOR BREAKER:PC220-LGC6-923K00A WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the work.
Page 422 MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 4. Set the lock lever to LOCK position (L). 5. Loosen slowly oil filler cap (F) on the top of the hydraulic tank to release the internal pressure in the hydraulic circuit. 6.
Page 423: Removal And Installation Of Attachment
ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT REMOVAL AND INSTALLATION OF ATTACHMENT REMOVAL AND INSTALLATION OF ATTACHMENT:PC-L411-922K00A REMOVAL Removal:PC220-L411-520K00A 1. Lower the attachment to the ground and stop the engine. 2. Turn the starting switch to ON position (B), then set the lock lever to FREE position (F).
Page 424 MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS 6. After checking that the oil temperature is low, set the rotor of the stop valve installed to the inlet port on the side face of the arm and the outlet port piping to LOCK position (b). (a) FREE: Hydraulic oil flows (direction of arrow is parallel to longish direction of arm) (b) LOCK: Hydraulic oil does not flow (direction of arrow is at...
Page 425 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT 5. Set the lock lever to LOCK position (L). 6. Loosen slowly oil filler cap (F) on the top of the hydraulic tank to release the internal pressure in the hydraulic circuit. 7.
Page 426: Attachment Operations
MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS ATTACHMENT OPERATIONS ATTACHMENT OPERATIONS:PC220_KU-L411-130K00A WARNING If the pedal is operated when the auto-deceleration is being actuated and the engine speed is dropped, the engine speed will suddenly increase, so be careful when operating. If you leave your foot resting on the pedal and depress the pedal by mistake, there is a danger that the attachment may suddenly move and cause serious personal injury.
Page 427 ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT If the pilot monitor in the working mode does not display B for the breaker mode, press working mode selector switch (1) and set to the breaker mode as follows. When working mode selector switch (1) is pressed, the screen switches to the working mode selection screen.
Page 428 MACHINE READY FOR INSTALLATION OF ATTACHMENT ATTACHMENTS AND OPTIONS WHEN USING GENERAL ATTACHMENTS SUCH AS CRUSHER: If the pilot monitor in the working mode does not display ATT for the attachment mode, press working mode selector switch (1) and set to the attachment mode as follows. Even if P, E, or L mode are selected, the attachment is not operated.
Page 429: Long-Term Storage
ATTACHMENTS AND OPTIONS MACHINE READY FOR INSTALLATION OF ATTACHMENT OPERATION WHEN USING GENERAL ATTACHMENT 1 (E.G. CRUSHER) WARNING When operating the attachment using rolling switch, lock the pedal with the lock pin to avoid accidental operation. General attachment 1 can be operated using either the rolling switch on the right lever or right attachment control pedal.
Page 430: Specifications
} (B mode) In addition, valves with safety valve relief set pressure of 24.5 MPa {250 kg/cm } and relief valve cracking pres- sure of 20.1 MPa {205 kg/cm } are also available. Contact your Komatsu distributor. ARM/PIN INFORMATION KS000339 +0.5...
Page 431: Attachments And Options
When installing any attachment or optional equipment, there may be problems with safety, so please contact your Komatsu distributor before installing. Installing attachments or optional equipment without consulting your Komatsu distributor may not only cause problems with safety, but may also have an adverse effect on the operation of the machine and the life of the equipment.
Page 432: Track Shoes Selection
Take note of low gradeability due to the flat shoes and exercise due care. Be sure to follow the instructions set forth in the “Handling of Road Liner” section Paved road for the protection of the rubber pad shoes. PC210-10 PC210LC-10 Specifications Category...
Page 433: Bucket Teeth Selection
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS BUCKET TEETH SELECTION BUCKET TEETH SELECTION:PC-LBM0-05AK00A Depending on the working conditions, there is a danger that an adapter and tooth may be lost. Select either one from the vertical pin type of tooth or horizontal pin type of tooth that is suitable for the purpose. While the standard teeth of both vertical and horizontal pin types may be used widely, the following kinds of teeth are recommended depending on the working conditions.
Page 434: Handling Of Rubber Pad Shoe And Road Liner
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING OF RUBBER PAD SHOE AND ROAD LINER HANDLING OF RUBBER PAD SHOE AND ROAD LINER:PC-DTLJ-170K00A Be sure to observe the following instructions, when using a machine equipped with rubber pad shoes or Road Liner.
Page 435 Replace Road Liner:PC-DTLK-923K00A When all the road liners of the machine need to be replaced, ask your Komatsu distributor to replace them. When replacing only part of the road liner, use the special road liner removal tool. Order the tool from your Komatsu distributor.
Page 436: Handling Trapezoidal Bucket
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING TRAPEZOIDAL BUCKET HANDLING TRAPEZOIDAL BUCKET:PC-LBR2-130K00A Use the trapezoidal bucket when digging trapezoidal ditches in fields. By installing the angle plate with different angle, it is pos- sible to excavate three angles of ditch slope face (45°, 40°, 38°).
Page 437 ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS DITCH SLOPE FACE 40 DEGREES, 38 DEGREES Install the angle plate using the respective ditch slope angle holes, and use the method above for digging. Even when the angle plate is fitted, keep the line on the bucket side plate perpendicular to the ground face during the digging operation.
Page 438: Handling Extension Arm
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING EXTENSION ARM HANDLING EXTENSION ARM:PC-L850-170K00A When an extension arm is installed, the bucket will hit the boom cylinder foot and revolving frame when the arm is pulled in, so be extremely careful during operations and when trans- porting the machine.
Page 439: Handling Clamshell Bucket
ATTACHMENTS AND OPTIONS ATTACHMENTS AND OPTIONS HANDLING CLAMSHELL BUCKET HANDLING CLAMSHELL BUCKET:PC-LC60-130K00A Use a clamshell bucket for digging or loading soil for side ditching and in limited areas. DIGGING WORK Digging is carried out with the clamshell pushed by the boom, but when operating the bucket, raise the boom slightly and carry out digging.
Page 440: Recommended Attachment Operations
Select the optimum model of attachment for a hydraulic excavator on which it is to be mounted. Depending on machine models of hydraulic excavator, the kind of attachments or the model of spe- cific attachments that can be mounted will vary. Hence, consult your Komatsu distributor for the selec- tion of optimum attachments.
Page 441 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within one minute, change the point of impact and carry out breaking operations closer to the edge. The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other, always adjust the bucket cylinder to keep them aligned.
Page 442 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it penetrates the rock Pecking operations 6–44...
Page 443 ATTACHMENTS AND OPTIONS RECOMMENDED ATTACHMENT OPERATIONS Extending the bucket cylinder rod fully and thrusting to raise the machine off the ground POSTURE OF HYDRAULIC BREAKER TO BE GREASED Be sure to grease the breaker, holding it in the right posture. NOTICE If the breaker is greased in an improper posture, it is filled with more grease than necessary.
Page 444 RECOMMENDED ATTACHMENT OPERATIONS ATTACHMENTS AND OPTIONS 6–46...
Page 445: Replacement Parts
REPLACEMENT PARTS REPLACEMENT PARTS Replacement parts:ALL-0000-001K16A REPLACEMENT PARTS 7–1...
Page 446: Safety Critical Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the critical parts. SAFETY CRITICAL PARTS LIST Safety critical parts listPC220-0000-20MK00A...
Page 447: Consumable Parts
When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check the latest part number when ordering parts. CONSUMABLE PARTS LIST CONSUMABLE PARTS LIST:PC220-0000-20NK00A The parts in parentheses are to be replaced at the same time.
Page 448: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the engine, power train, cooling system, and/or other components. Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive.
Page 449: Lubrication Chart
REPLACEMENT PARTS RECOMMENDED FUEL, COOLANT, AND LUBRICANT LUBRICATION CHART LUBRICATION CHART:PC220_KU-2131-930A00A The lubrication standard chart uses symbols to show the lubrication points and types of lubricant by each lubrication interval. Keep this standard chart in the magazine box inside the cab so that the people concerned can reference it any time needed during lubrication.
Page 450 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Symbols used in the lubrication standard chart Symbol Meaning of symbol Symbol Meaning of symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check engine oil level Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level Replace engine oil filter...
Page 451: Fuel, Coolant, And Lubricants To Match The Ambient Temperature
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500 hours), so replace oil and filter cartridge every 250 hours. For changing maintenance interval of machine monitor, ask Komatsu distributor to carry out. Note 2: Powertrain oil has different properties from engine oil.
Page 452: Recommended Brands And Quality For Products Other Than Komatsu Genuine Oil
We strongly recommend HO56-HE for hydraulic oil. RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL:PC-RA1B-05AK01A When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor. 7–8...
Page 453: Index
INDEX 8–1...
Page 454 INDEX INDEX ACTIONS IN THE EVENT OF DAMAGE TO SAFETY EMERGENCY ESCAPE HAMMER 3-93 STRUCTURES 2-23 END OF SERVICE LIFE 2-43 4-81 AFTER COLD WEATHER SEASON 3-226 EPA REGULATIONS, ENGINE NUMBER PLATE 1-8 AFTER DAILY WORK COMPLETION 3-226 ESCAPE FROM MUD 3-197 AFTER DAILY WORK COMPLETION 3-206 EVERY 100 HOURS MAINTENANCE 4-40 AFTER STORAGE 3-228...
Page 455 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-24 PRECAUTIONS RELATED TO CAB GLASS 2-24 KOMATSU GENUINE LUBRICANTS 4-2 PRECAUTIONS RELATED TO PROTECTIVE KOMATSU GENUINE REPLACEMENT PARTS 4-2 STRUCTURES 2-22 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-20 LIFTING MACHINE 3-223 PRECAUTIONS WHEN INSTALLING HYDRAULIC...
Page 456 INDEX SAFETY MACHINE OPERATION 2-28 SAFETY RULES FOR LIFTING OBJECTS 2-42 SERVICE METER LOCATION 1-9 SERVICE METER READING 4-2 SEVERE JOB CONDITION 3-231 SPACE FOR RADIO CASSETTE 3-120 SPECIFICATIONS 5-2 6-32 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-8 STARTING ENGINE 3-163 STARTING ENGINE 2-28 STARTING MACHINE AFTER LONG-TERM STORAGE 3-228...
Page 457 COLOPHON...

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Pc210lc-10 demolition base spec.Pc210lc-10

Komatsu PC210-10 Operation & Maintenance Manual

Table of Contents

Maintenance Schedule

When Required

Checks before Starting

Every 100 Hours Maintenance

Every 250 Hours Maintenance

Every 500 Hours Maintenance

Every 1000 Hours Maintenance

Every 2000 Hours Maintenance

Every 4000 Hours Maintenance

Every 4500 Hours Maintenance

Every 5000 Hours Maintenance

Every 8000 Hours Maintenance

Automatic Grease System

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Summary of Contents for Komatsu PC210-10