This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu PC210-7K, PC210LC, PC210NLC-7K, PC230NHD-7K, PC240LC, PC240NLC-7K Hydraulic Excavator (SN: K40001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.
APPLICABLE MODELS :
Komatsu PC210-7K – S/N: K40001 and up
Komatsu PC210LC-7K – S/N: K40001 and up
Komatsu PC210NLC-7K – S/N: K40001 and up
Komatsu PC230NHD-7K – S/N: K40001 and up
Komatsu PC240LC-7K – S/N: K40001 and up
Komatsu PC240NLC-7K – S/N: K40001 and up
TABLE OF CONTENTS :
– FOREWORD
– SAFETY
– OPERATION
– MAINTENANCE
– SPECIFICATIONS
– ATTACHMENTS AND OPTIONS
– SUPER LONG FRONT BOOM AND ARM PC210/240-7
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM001704
Total Pages : 363
This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.
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FOREWORD
FOREWORD
SAFETY INFORMATION
NOISE (PC210,210LC,210NLC, PC230NHD)
VIBRATION
NOISE (PC240LC,240NLC)
VIBRATION
INTRODUCTION
DIRECTIONS OF MACHINE
PRODUCT INFORMATION
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
SERVICE METER LOCATION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL PLATE
SAFETY
SAFETY INFORMATION
POSITION FOR ATTACHING SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
SAFETY LABELS
SAFETY INFORMATION
SAFETY RULES
IF ABNORMALITIES ARE FOUND
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY EQUIPMENT
KEEP MACHINE CLEAN
KEEP OPERATOR’S COMPARTMENT CLEAN
LEAVING OPERATOR’S SEAT WITH LOCK
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
NO PERSONS ON ATTACHMENTS
BURN PREVENTION
FIRE PREVENTION AND EXPLOSION PREVENTION
ACTION IF FIRE OCCURS
WINDSHIELD WASHER FLUID
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
ATTACHMENT INSTALLATION
ATTACHMENT COMBINATIONS
CAB WINDOW GLASSES
UNAUTHORIZED MODIFICATIONS
SAFETY AT JOBSITE
WORKING ON LOOSE GROUND
DISTANCE TO HIGH VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREA
SIGNALMAN’S SIGNAL AND SIGNS
EMERGENCY EXIT FROM OPERATOR’S CAB
ELECTROMAGNETIC INTERFERENCE
ASBESTOS DUST HAZARD PREVENTION
SAFETY MACHINE OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
SAFETY RULES FOR STARTING ENGINE
STARTING ENGINE IN COLD WEATHER
OPERATION
CHECKS AFTER STARTING ENGINE
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS
SAFETY RULES FOR TRAVELLING
TRAVELLING ON SLOPES
OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
OPERATIONS ON SNOW
PARKING MACHINE
TRANSPORTATION
SHIPPING THE MACHINE
BATTERY
BATTERY HAZARD PREVENTION
STARTING ENGINE WITH BOOSTER CABLES
TOWING
SAFETY RULES FOR TOWING
LIFTING OBJECTS WITH BUCKET
SAFETY RULES FOR LIFTING OBJECTS
SAFETY MAINTENANCE INFORMATION
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
ACCUMULATOR
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
WHEN USING HAMMER
WELDING WORKS
REMOVING BATTERY TERMINALS
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLE RECOIL SPRINGS
SAFETY RULES FOR HIGH-PRESSURE OIL
SAFETY HANDLING HIGH-PRESSURE HOSES
WASTE MATERIALS
AIR CONDITIONER MAINTENANCE
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
MACHINE MONITOR
BASIC OPERATION OF MACHINE MONITOR
BASIC CHECK ITEMS
CAUTION ITEMS
EMERGENCY STOP ITEMS
METER DISPLAY PORTION
MONITOR SWITCHES
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)
AUTO-DECELERATION SWITCH
TRAVEL SPEED SELECTOR SWITCH
WIPER SWITCH
WINDOW WASHER SWITCH
MAINTENANCE SWITCH
SELECT SWITCH
BACK SWITCH
UP SWITCH, DOWN SWITCH
INPUT CONFIRMATION SWITCH
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH
SWITCHES
STARTING SWITCH
FUEL CONTROL DIAL
CIGARETTE LIGHTER
SWING LOCK SWITCH
LAMP SWITCH
ALARM BUZZER STOP SWITCH
HORN SWITCH
KNOB SWITCH
ROOM LAMP SWITCH
EMERGENCY PUMP DRIVE SWITCH
SWING BRAKE CANCEL SWITCH
EMERGENCY FUEL SOLENOID DRIVE SWITCH
LOWER WIPER SWITCH
REVOLVING WARNING LAMP SWITCH
HEATED OPERATOR SEAT SWITCH
CONTROL LEVERS, PEDALS
SAFETY LOCK LEVER
TRAVEL LEVERS
WORK EQUIPMENT CONTROL LEVER
CEILING WINDOW
FRONT WINDOW
EMERGENCY EXIT FROM OPERATOR’S CAB
DOOR LOCK
CAP, COVER WITH LOCK
METHOD OF OPENING AND CLOSING CAP WITH LOCK
METHOD OF OPENING AND CLOSING COVER WITH LOCK
HOT AND COOL BOX
CAB RADIO
MAGAZINE BOX
ASHTRAY
HANDLING AIR CONDITIONER
GENERAL LOCATIONS OF CONTROL PANEL
METHOD OF OPERATION
PRECAUTIONS WHEN USING AIR CONDITIONER
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER
OTHER FUNCTIONS
CAR RADIO
FUSE
FUSE CAPACITIES AND CIRCUIT NAMES
FUSIBLE LINK
CONTROLLER (COMPUTER)
TOOLBOX
GREASE GUN HOLDER
REFUELLING PUMP
HANDLING THE ACCUMULATOR
RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR
MACHINE OPERATIONS AND CONTROLS
BEFORE STARTING ENGINE
WALK-AROUND CHECKS
CHECKS BEFORE STARTING
ADJUST BEFORE OPERATION
SEAT BELT
OPERATIONS BEFORE STARTING ENGINE
STARTING ENGINE
NORMAL STARTING
STARTING ENGINE IN COLD WEATHER
AFTER STARTING ENGINE
BREAKING-IN THE NEW MACHINE
WARMING-UP OPERATION
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)
STOPPING THE ENGINE
CHECK AFTER SHUTTING OFF ENGINE
MACHINE OPERATION
PREPARATIONS FOR MOVING THE MACHINE OFF
MOVING MACHINE FORWARD
MOVING MACHINE BACKWARD
STOPPING MACHINE
STEERING THE MACHINE
Steering
SWINGING
WORK EQUIPMENT CONTROLS AND OPERATIONS
OPERATING WORKING MODE
PROHIBITED OPERATIONS
OPERATIONS USING SWING FORCE
OPERATIONS USING TRAVEL FORCE
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS
OPERATIONS USING BUCKET DROPPING FORCE
OPERATIONS USING MACHINE DROPPING FORCE
DIGGING HARD ROCKY GROUND
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL
GENERAL OPERATION INFORMATION
TRAVELING
HIGH SPEED TRAVEL
PERMISSIBLE WATER DEPTH
TRAVELING ON SLOPES
TRAVELING DOWNHILL
ENGINE STOPPED ON SLOPE
PRECAUTIONS ON SLOPES
ESCAPE FROM MUD
STUCK ONE SIDE OF TRACK
STUCK BOTH SIDES OF TRACKS
RECOMMENDED APPLICATIONS
BACKHOE WORK
SHOVEL WORK
DITCHING WORK
LOADING WORK
REPLACEMENT AND INVERSION OF BUCKET
REPLACEMENT
INVERSION
PARKING MACHINE
CHECK AFTER FINISHING WORK
LOCKING
TRANSPORTATION
TRANSPORTATION PROCEDURE
SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-7 AND PC230NHD-7
LOADING AND UNLOADING WITH TRAILER
LOADING
SECURING MACHINE
UNLOADING
LIFTING MACHINE
STANDARD SPECIFICATION MACHINE
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
FUEL AND LUBRICANTS
COOLING SYSTEM COOLANT
BATTERY
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
TOWING THE MACHINE
LIGHTWEIGHT TOWING HOOK
PRECAUTIONS ON PARTICULAR JOBSITES
DISCHARGED BATTERY
REMOVAL AND INSTALLATION OF BATTERY
BATTERY CHARGES
STARTING ENGINE WITH BOOSTER CABLES
OTHER TROUBLE
ELECTRICAL SYSTEM
CHASSIS
ENGINE
ELECTRONIC CONTROL SYSTEM
MAINTENANCE
MAINTENANCE INFORMATION
SERVICE METER READING
KOMATSU GENUINE REPLACEMENT PARTS
KOMATSU GENUINE LUBRICANTS
WINDSHIELD WASHER FLUID
FRESH AND CLEAN LUBRICANTS
CHECK DRAINED OIL AND USED FILTER
FUEL STRAINER
WELDING INSTRUCTIONS
DO NOT DROP THINGS INSIDE MACHINE
DUSTY JOBSITE
AVOID MIXING LUBRICANTS
LOCKING THE INSPECTION COVERS
HYDRAULIC SYSTEM – AIR BLEEDING
HYDRAULIC HOSE INSTALLATION
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE
LUBRICANTS, COOLANT AND FILTERS
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
FUEL
COOLING SYSTEM COOLANT
GREASE
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)
OIL AND FUEL STORAGE
FILTERS
EXPLANATION OF LUBRICATION CHART DECAL
ELECTRIC SYSTEM MAINTENANCE
HANDLING HYDRAULIC SYSTEM
WEAR PARTS LIST
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
Initial 250 Hours Maintenance (Only after the first 250 hours)
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 5000 Hours Maintenance
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN INSIDE OF COOLING SYSTEM
CHECK AND TIGHTEN TRACK SHOE BOLTS
CHECK AND ADJUST TRACK TENSION
CHECK ELECTRICAL INTAKE AIR HEATER
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND ADJUST AIR CONDITIONER (IF EQUIPPED)
WASHING WASHABLE FLOOR
BLEEDING AIR FROM HYDRAULIC SYSTEM
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT
CHECK BEFORE STARTING
EVERY 100 HOURS MAINTENANCE
LUBRICATING
EVERY 250 HOURS MAINTENANCE
LUBRICATING
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT
EVERY 500 HOURS MAINTENANCE
LUBRICATING
LUBRICATE SWING CIRCLE (2 POINTS)
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
REPLACE FUEL FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK
EVERY 1000 HOURS MAINTENANCE
REPLACE HYDRAULIC FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER
CHECK PLAY OF TURBOCHARGER ROTOR
CHECK FAN BELT TENSION AND REPLACE FAN BELT
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CLEAN HYDRAULIC TANK STRAINER
CLEAN, CHECK TURBOCHARGER
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
CHECK VIBRATION DAMPER
EVERY 4000 HOURS MAINTENENCE
CHECK WATER PUMP
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK
SPECIFICATIONS
SPECIFICATIONS
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC210NLC-7K)
PC210NLC-7K
PC210-7K
PC210LC-7K
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC230NHD – 2 PIECE BOOM)
PC210-7K, PC210LC-7K 2 PIECE BOOM
PC210NLC-7K, PC230NHD-7K 2 PIECE BOOM
EXPLANATION OF LIFTING CAPACITY CHART (PC230NHD-7K)
PC230NHD-7K
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC, PC240NLC-7K)
PC240LC-7K
PC240NLC-7K
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-7K 2 PIECE BOOM)
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
PRECAUTIONS WHEN INSTALLING ATTACHMENTS
HANDLING BUCKET WITH HOOK
CHECKING FOR DAMAGE TO BUCKET WITH HOOK
PROHIBITED OPERATIONS
PRECAUTIONS DURING OPERATIONS
MACHINES READY FOR ATTACHMENTS
EXPLANATION OF COMPONENTS
STOP VALVE
SELECTOR VALVE
ATTACHMENT CONTROL PEDAL
LOCK PIN
ADDITIONAL FILTER FOR BREAKER
ACCUMULATOR
HYDRAULIC CIRCUIT
SWITCHING HYDRAULIC CIRCUIT
ADJUSTING OIL FLOW
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT
HYDRAULIC CIRCUIT CONNECTION
PATH OF OIL
REPLACE ADDITIONAL BREAKER FILTER ELEMENT
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE
OPERATION
LONG-TERM STORAGE
SPECIFICATIONS
ATTACHMENT GUIDE
COMBINATIONS OF WORK EQUIPMENT
SELECTION OF TRACK SHOES
METHOD OF SELECTING SHOES
SELECTION OF BUCKET TEETH
METHOD OF SELECTING TEETH
Use of vertical pin teeth
Use of horizontal pin teeth
Use of long-life teeth
Self-sharpening teeth (both vertical pin type and horizontal pin type)
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH
HANDLING OF RUBBER PAD SHOE AND ROAD LINER
WORKING ENVIRONMENT
WORKING CONDITIONS
STORAGE AND MAINTENANCE
EXTENT OF DAMAGE TO RUBBER
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)
HANDLING TRAPEZOIDAL BUCKET
HOW TO PERFORM EXCAVATION
HANDLING EXTENSION ARM
HANDLING CLAMSHELL BUCKET
PRECAUTIONS WHEN USING
LUBRICATING
RECOMMENDED ATTACHMENT OPERATIONS
HYDRAULIC BREAKER
MAIN APPLICATIONS
PROHIBITED WORKS
GREASING POSITION FOR HYDRAULIC BREAKER
2-PC BOOM
FEATURES OF 2-PIECE BOOM & ARM
OPERATION
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE
TESTING AND ADJUSTING
PERODIC MAINTENANCE
TRANSPORTATION
STRAIGHT BOOM PC210/240-7K
OPERATION
GENERAL VIEW OF MACHINE
CAUTION ITEMS
CONTROL PEDALS (AUXILIARY HYDRAULIC CIRCUITS)
CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING
CRUSHER CONTROL PEDAL FOR ROTATION
WORKING RANGE (PC 210 STRAIGHT BOOM)
TRANSPORTATION (PC 210 Straight Boom equipment)
WORKING RANGE (PC 240 STRAIGHT BOOM)
TRANSPORTATION (PC 240 Straight Boom equipment)
SUPER LONG FRONT BOOM AND ARM PC210/240-7
OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM
WORKING MODES
CHECKS BEFORE STARTING
USING SUPER LONG FRONT
METHOD OF WORK
WHEN TRAVELLING
CONTROL LEVERS, PEDALS
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE
INSTALLATION OF SUPPORTING LINK
TRANSPORTATION OF SUPER LONG FRONT MACHINE
WORKING RANGE OF SUPER LONG FRONT
LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT
LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT
LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT
LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT
MAINTENANCE
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT
EVERY 50 HOURS SERVICE
LUBRICATING
EVERY 100 HOURS SERVICE
LUBRICATING
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Source : Sitelux.com
