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Komatsu PC210, PC210LC-6K PC240LC,PC240NLC-6K Hydraulic Excavator Operation & Maintenance Manual – PDF Download
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Description
Komatsu PC210, PC210LC-6K PC240LC,PC240NLC-6K Hydraulic Excavator Operation & Maintenance Manual
Description:
Komatsu PC210, PC210LC-6K PC240LC,PC240NLC-6K Hydraulic Excavator Operation & Maintenance Manual
This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners. 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 for your machine or for questions regarding information in this manual.
Table of Contents:
Komatsu PC210, PC210LC-6K PC240LC,PC240NLC-6K Hydraulic Excavator Operation & Maintenance Manual
FOREWORD............................................................................................................ 3 SAFETY INFORMATION.................................................................................................. 4 SAFETY MESSAGES................................................................................................. 4 NOISE PC210, PC210LC-6K......................................................................................... 5 NOISE PC240LC, PC240NLC-6K...................................................................................... 7 VIBRATION....................................................................................................... 8 INTRODUCTION........................................................................................................ 9 INTENDED USE.................................................................................................... 9 FEATURES........................................................................................................ 9 BREAKING IN YOUR NEW MACHINE.................................................................................... 10 LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR...................................................... 11 MACHINE SERIAL NO. PLATE POSITION............................................................................... 11 ENGINE SERIAL NO. PLATE POSITION................................................................................ 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....................................................................... 11 MACHINE SERIAL PLATE............................................................................................ 12 SAFETY.............................................................................................................. 19 GENERAL PRECAUTIONS............................................................................................. 20 PRECAUTIONS DURING OPERATION.................................................................................... 28 BEFORE STARTING ENGINE...................................................................................... 28 OPERATING MACHINE........................................................................................... 30 TRANSPORTATION.............................................................................................. 37 BATTERY..................................................................................................... 38 TOWING...................................................................................................... 39 BUCKET WITH HOOK............................................................................................ 40 GENERAL PRECAUTIONS..................................................................................... 40 PRECAUTIONS FOR LIFTING OPERATION....................................................................... 41 PRECAUTIONS FOR MAINTENANCE..................................................................................... 43 BEFORE CARRYING OUT MAINTENANCE............................................................................. 43 DURING MAINTENANCE.......................................................................................... 46 POSITION FOR ATTACHING SAFETY LABELS............................................................................ 51 POSITION FOR ATTACHING SAFETY LABELS........................................................................ 51 OPERATION........................................................................................................... 57 GENERAL VIEW.................................................................................................... 58 GENERAL VIEW OF MACHINE..................................................................................... 58 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................... 59 EXPLANATION OF COMPONENTS....................................................................................... 61 MACHINE MONITOR............................................................................................. 61 A: BASIC CHECK ITEMS.................................................................................... 63 B: CAUTION ITEMS........................................................................................ 64 C: EMERGENCY STOP ITEMS................................................................................. 65 D: METER DISPLAY PORTION................................................................................ 66 METERS...................................................................................................... 67 E: SWITCHES............................................................................................. 69 SWITCHES.................................................................................................... 72 CONTROL LEVERS, PEDALS...................................................................................... 78 CEILING WINDOW.......................................................................................... 83 FRONT WINDOW............................................................................................ 84 DOOR LOCK............................................................................................... 86 CAP, COVER WITH LOCK.................................................................................... 86 LUGGAGE TRAY............................................................................................ 87 ASHTRAY................................................................................................. 88 AIR CONDITIONER............................................................................................. 89 GENERAL LOCATIONS ON CONTROL PANEL...................................................................... 89 AIR CONDITIONER SWITCH.................................................................................. 91 OFF SWITCH.............................................................................................. 91 DEFROSTER SELECTOR LEVER................................................................................ 91 PRECAUTIONS WHEN USING AIR CONDITIONER.................................................................. 91 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER................................................... 92 CAB RADIO................................................................................................... 92 FUSE........................................................................................................ 93 Fuse capacity and name of circuit....................................................................... 93 FUSIBLE LINK................................................................................................ 94 CONTROLLERS................................................................................................. 94 TOOL BOX.................................................................................................... 94 REFUELLING PUMP............................................................................................. 95 HANDLING THE ACCUMULATOR.................................................................................... 96 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR.................. 96 OPERATION....................................................................................................... 97 CHECK BEFORE STARTING ENGINE................................................................................ 97 WALK-AROUND CHECK....................................................................................... 97 CHECK BEFORE STARTING................................................................................... 98 CHECK FUEL LEVEL, ADD FUEL..............................................................................100 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................................................101 CHECK AIR CLEANER FOR CLOGGING..........................................................................102 CHECK ELECTRIC WIRINGS..................................................................................102 CHECK FUNCTION OF HORN..................................................................................102 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER............................................103 CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER.....................................................103 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT.............................................................104 USING THE SEAT BELT.....................................................................................105 OPERATIONS AND CHECKS BEFORE STARTING ENGINE............................................................106 STARTING ENGINE.............................................................................................108 NORMAL STARTING.........................................................................................108 STARTING IN COLD WEATHER................................................................................109 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................110 WHEN NORMAL.............................................................................................110 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)..........................................................112 MOVING MACHINE OFF..........................................................................................116 MOVING MACHINE FORWARD..................................................................................116 MOVING MACHINE BACKWARD.................................................................................117 STEERING MACHINE............................................................................................119 STEERING (changing direction)...........................................................................119 STOPPING MACHINE............................................................................................121 SWINGING....................................................................................................122 OPERATION OF WORK EQUIPMENT.................................................................................123 HANDLING ACTIVE MODE........................................................................................124 WORKING MODE SELECTION......................................................................................125 PROHIBITIONS FOR OPERATION..................................................................................127 PRECAUTIONS FOR OPERATION...................................................................................129 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS................................................................130 HOW TO ESCAPE FROM MUD......................................................................................131 WHEN ONE SIDE IS STUCK..................................................................................131 WHEN BOTH SIDES ARE STUCK...............................................................................131 WORK POSSIBLE USING HYDRAULIC EXCAVATOR.....................................................................131 BACKHOE WORK............................................................................................132 SHOVEL WORK.............................................................................................132 DITCHING WORK...........................................................................................132 LOADING WORK............................................................................................132 REPLACEMENT AND INVERSION OF BUCKET.........................................................................133 REPLACEMENT.............................................................................................133 INVERSION...............................................................................................134 PARKING THE MACHINE.........................................................................................135 CHECK AFTER FINISHING WORK..................................................................................136 STOPPING ENGINE.............................................................................................136 CHECK AFTER STOPPING ENGINE.................................................................................137 LOCKING.................................................................................................138 OVERLOAD WARNING DEVICE.................................................................................138 TRANSPORTATION..................................................................................................139 LOADING, UNLOADING WORK.....................................................................................139 PRECAUTIONS FOR LOADING.................................................................................141 PRECAUTIONS FOR TRANSPORTATION..........................................................................141 METHOD OF LIFTING MACHINE...............................................................................142 COLD WEATHER OPERATION..........................................................................................144 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................144 FUEL AND LUBRICANTS.....................................................................................144 COOLANT.................................................................................................144 BATTERY.................................................................................................145 PRECAUTIONS AFTER COMPLETION OF WORK........................................................................145 AFTER COLD WEATHER......................................................................................146 LONG-TERM STORAGE...............................................................................................147 BEFORE STORAGE..............................................................................................147 DURING STORAGE..............................................................................................147 AFTER STORAGE...............................................................................................148 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................148 TROUBLESHOOTING.................................................................................................149 PHENOMENA THAT ARE NOT FAILURES.............................................................................149 METHOD OF TOWING MACHINE....................................................................................149 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...................................................................150 PRECAUTIONS ON PARTICULAR JOBSITES..........................................................................150 IF BATTERY IS DISCHARGED....................................................................................151 STARTING ENGINE WITH BOOSTER CABLE......................................................................152 OTHER TROUBLE...............................................................................................154 ELECTRICAL SYSTEM.......................................................................................154 CHASSIS.................................................................................................155 ENGINE..................................................................................................156 ENGINE (cont’d).........................................................................................157 ELECTRONIC CONTROL SYSTEM...............................................................................158 OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6................................................159 PRECAUTIONS WHEN OPERATING..................................................................................159 PROHIBITON OF WORK IN THE OVER SIDES DIRECTION..........................................................160 PROHIBITON OF WORK OUTSIDE THE WORKING RANGE OF THE MACHINE.............................................160 PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER.....................................................163 PROHIBITION OF WORK WITH HYDRAULIC BREAKER..............................................................163 CHECK BEFORE STARTING.......................................................................................165 OPERATION...................................................................................................166 Attachment control......................................................................................166 RAISING WORK EQUIPMENT......................................................................................167 WORKING RANGE AND USING RANGE OF BOOM.......................................................................167 WORKING RANGE AND RANGE OF USE OF BOOM......................................................................168 TRANSPORTATION (HIGH REACH DEMOLITION)......................................................................169 MAINTENANCE.........................................................................................................171 GUIDES TO MAINTENANCE...........................................................................................172 OUTLINES OF SERVICE.............................................................................................175 OUTLINE OF OIL, FUEL, COOLANT...............................................................................175 OIL.....................................................................................................175 FUEL....................................................................................................176 COOLANT.................................................................................................176 GREASE..................................................................................................177 STORING OIL AND FUEL....................................................................................177 FILTERS.................................................................................................177 EXPLANATION OF LUBRICATION CHART DECAL......................................................................178 OUTLINE OF ELECTRICAL SYSTEM................................................................................180 OUTLINE OF HYDRAULIC SYSTEM.................................................................................180 WEAR PARTS LIST.................................................................................................182 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................183 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................................183 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................187 LIST OF NECESSARY TOOLS.....................................................................................187 TORQUE LIST.................................................................................................188 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................189 MAINTENANCE SCHEDULE CHART......................................................................................192 MAINTENANCE SCHEDULE CHART..................................................................................192 MAINTENANCE WHEN USING HYDRAULIC BREAKER....................................................................195 SERVICE PROCEDURE...............................................................................................196 INITIAL 250 HOURS SERVICE...................................................................................196 WHEN REQUIRED...............................................................................................196 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................196 CLEAN INSIDE OF COOLING SYSTEM..........................................................................198 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................201 CHECK and adjust TRACK TENSION..........................................................................202 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................204 REPLACE BUCKET SIDE CUTTERS.............................................................................204 REPLACE BUCKET TEETH....................................................................................205 ADJUST BUCKET CLEARANCE.................................................................................205 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................206 CHECK, MAINTAIN AIR CONDITIONER.........................................................................207 CHECK BEFORE STARTING.......................................................................................208 CHECK COOLANT LEVEL, ADD COOLANT........................................................................208 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL..............................................................209 CHECK FUEL LEVEL, ADD FUEL..............................................................................209 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................................................210 CHECK AIR CLEANER FOR CLOGGING..........................................................................211 CHECK ELECTRIC WIRINGS..................................................................................211 CHECK FUNCTION OF HORN..................................................................................212 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR, DRAIN WATER AND SEDIMENT....................................212 CHECK FOR WATER IN PRIMARY FUEL FILTER, drain water.....................................................212 EVERY 100 HOURS SERVICE.....................................................................................213 LUBRICATING.............................................................................................213 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL........................................................215 DRAIN WATER AND SEDIMENT FROM FUEL TANK.................................................................215 CLEAN FRESH AIR INTAKE FILTER...........................................................................216 EVERY 250 HOURS SERVICE.....................................................................................216 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................216 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................217 LUBRICATE SWING CIRCLE (2 POINTS).......................................................................218 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION ADJUST....................................................218 EVERY 500 HOURS SERVICE.....................................................................................220 REPLACE FUEL FILTER CARTRIDGE...........................................................................220 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................................................222 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................222 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W.......223 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................224 REPLACE HYDRAULIC FILTER ELEMENT........................................................................224 EVERY 1000 HOURS SERVICE....................................................................................226 CHANGE OIL IN SWING MACHINERY CASE......................................................................226 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................227 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................................................227 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................227 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.......................................................228 CHECK FAN BELT TENSION..................................................................................228 EVERY 2000 HOURS SERVICE....................................................................................229 CHANGE OIL IN FINAL DRIVE CASE..........................................................................229 CLEAN HYDRAULIC TANK STRAINER...........................................................................230 CLEAN, CHECK TURBOCHARGER...............................................................................230 CHECK ALTERNATOR, STARTING MOTOR........................................................................230 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................230 CHECK VIBRATION DAMPER..................................................................................230 CHANGE ANTI FREEZE......................................................................................230 CHECK AND ADJUST VALVE CLEARANCE........................................................................231 EVERY 4000 HOURS SERVICE....................................................................................231 CHECK WATER PUMP........................................................................................231 EVERY 5000 HOURS SERVICE....................................................................................231 CHANGE OIL IN HYDRAULIC TANK............................................................................231 SPECIFICATIONS......................................................................................................235 SPECIFICATIONS..................................................................................................236 PC210-6K, PC210LC-6K........................................................................................236 SPECIFICATIONS..................................................................................................240 PC240LC-6K, PC240NLC-6K.....................................................................................240 explanation of LIFTING CAPACITY CHART.......................................................................243 OPTIONS, ATTACHMENTS................................................................................................253 PRECAUTIONS RELATED TO SAFETY...................................................................................254 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.....................................................................255 HANDLING BUCKET WITH HOOK.......................................................................................256 CHECKING FOR DAMAGE TO BUCKET WITH HOOK.....................................................................256 PROHIBITED OPERATIONS.......................................................................................256 PRECAUTIONS DURING OPERATIONS...............................................................................256 MACHINES READY FOR ATTACHMENTS..................................................................................257 EXPLANATION OF COMPONENTS...................................................................................257 1. STOP VALVE...........................................................................................257 2. SELECTOR VALVE.......................................................................................258 3. CONTROL PEDAL FOR ATTACHMENT.........................................................................258 4. ACCUMULATOR..........................................................................................258 5. HYDRAULIC CIRCUIT....................................................................................259 CONNECTING HYDRAULIC CIRCUIT............................................................................260 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...................................................................261 OPERATION...............................................................................................262 LONG TERM STORAGE.......................................................................................263 SPECIFICATIONS..........................................................................................263 FIRST ATTACHMENT WITH CLAM-SHELL OPTION.................................................................264 FIRST AND SECOND ATTACHMENT.............................................................................265 INTRODUCTION OF ATTACHMENTS.....................................................................................266 SPECIFICATION, USE..........................................................................................266 ATTACHMENT INSTALLATION COMBINATION TABLE...................................................................268 SELECTION OF TRACK SHOES....................................................................................270 SELECTION OF BUCKET TEETH...................................................................................272 HANDLING TRAPEZOIDAL BUCKET.................................................................................272 USING THE EXTENSION ARM.....................................................................................274 HANDLING THE CLAMSHELL BUCKET...............................................................................274 EXTENDING MACHINE SERVICE LIFE..................................................................................275 HYDRAULIC BREAKER...........................................................................................275 POWER RIPPER................................................................................................279 MAIN FIELDS OF APPLICATIONS.................................................................................279 FORK GRAB...................................................................................................280 GRAPPLE BUCKET..............................................................................................282 SCRAP GRAPPLE...............................................................................................283 CRUSHER & SMASHER...........................................................................................285 HYDRAULIC PILE DRIVER.......................................................................................286 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE.................................................................288 2-PC BOOM...................................................................................................290 FEATURES OF 2-PIECE BOOM & ARM..........................................................................290 OPERATION...............................................................................................290 BEFORE STORAGE POSTURE WHEN LEAVING MACHINE.............................................................292 TESTING AND ADJUSTING...................................................................................292 PERODIC MAINTENANCE.....................................................................................293 TRANSPORTATION..........................................................................................294 6.4 M STRAIGHT BOOM.........................................................................................295 BEFORE STORAGE POSTURE WHEN LEAVING MACHINE.............................................................295 PREVENTION OF DAMAGE TO WORK EQUIPMENT..................................................................296 TRANSPORTATION..........................................................................................299 FRONT DOZER BLADE...........................................................................................300 BLADE OPERATIONS........................................................................................300 PROHIBITED OPERATIONS...................................................................................300 WEAR PARTS LIST.........................................................................................301 MAINTENANCE.............................................................................................301
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KOMATSU PC210, PC210LC-6K PC240LC,PC240NLC-6K HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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