Komatsu PC240LC-11E0 PC240NLC-11E0 Hydraulic Excavator Operation & Maintenance Manual UENAM01572 – PDF DOWNLOAD

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Komatsu PC240LC-11E0 PC240NLC-11E0 Hydraulic Excavator Operation & Maintenance Manual UENAM01572 – PDF DOWNLOAD

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Komatsu PC240LC-11E0 PC240NLC-11E0 Hydraulic Excavator Operation & Maintenance Manual UENAM01572 – PDF DOWNLOAD

FOREWORD
WARNING:

Komatsu recommends that any service parts used for maintenance, repair or replacement of emission control systems be genuine new Komatsu or Komatsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distributor. Failure to follow these recommendations could result in ineffective service, damage to the product or safety risks (including personal injury or death).

READ THIS MANUAL

• This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
• Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
• If you perform any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform improper operation and maintenance of the machine.
• It may cause serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can read it at any time. Keep it in the magazine box on the left side of the operator’s seat.
• If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement. For details regarding the machine model name and the serial No., see the machine serial No. plate.
• In order to arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and the serial No. This manual uses the International System of Units (SI) for units of measurement. For reference, units that have been used in the past are given in
• The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual.
• If there is any question or suggestion, consult your Komatsu distributor. The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
• If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your Komatsu distributor before operating the machine

TABLE OF CONTENTS:

Komatsu PC240LC-11E0 PC240NLC-11E0 Hydraulic Excavator Operation & Maintenance Manual UENAM01572 – PDF DOWNLOAD

CONTENTS
FOREWORD 1-1
READ THIS MANUAL 1-2
KOMATSU MACHINE OPERATOR PRIVACY POLICY 1-3
SAFETY INFORMATION 1-6
SAFETY LABELS 1-7
NOISE 1-8
VIBRATION LEVELS 1-9
VIBRATION – OPERATING CONDITION 1-9
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 1-9
INTRODUCTION 1-11
MAIN USE OF MACHINE 1-11
DEMOLITION WORK1-11
DIRECTIONS OF MACHINE1-11
VISIBILITY FROM OPERATOR’S SEAT 1-12
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 1-13
PRODUCT INFORMATION 1-14
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO PLATE 1-14
LOCATION OF ENGINE NUMBER PLATE 1-14
FLUORINATED GREENHOUSE GASES 1-15
SERVICE METER LOCATION 1-15
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1-15
SERIAL PLATE 1-16
DECLARATION OF CONFORMITY 1-17
SAFETY 2-1
SAFETY 2-2
SAFETY LABELS 2-4
LOCATION OF SAFETY LABELS 2-5
CONTENTS OF SAFETY LABELS 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-18
PRECAUTIONS BEFORE STARTING OPERATION 2-18
PREPARATIONS FOR SAFE OPERATION 2-18
PRECAUTIONS TO PREVENT FIRE 2-19
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-21
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-23
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-23
PROTECTION AGAINST FALLING, FLYING OR INTRUDING OBJECTS 2-24
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2-24
UNAUTHORIZED MODIFICATION 2-25
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-25
PRECAUTIONS RELATED TO CAB GLASS 2-25
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-25
PRECAUTIONS FOR OPERATION 2-26
PRECAUTIONS FOR JOBSITE 2-26
START ENGINE 2-28
PRECAUTIONS FOR OPERATION 2-30
PRECAUTIONS FOR TRANSPORTATION 2-35
TOWING AND BEING TOWED 2-36
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) 2-37
LIFTING OBJECTS WITH BUCKETS 2-39
PRECAUTIONS FOR MAINTENANCE 2-40
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-40
PRECAUTIONS FOR CHECK AND MAINTENANCE 2-43
PRECAUTIONS FOR DEF 2-50
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 2-50
PRECAUTIONS FOR ADDING 2-50
SAFETY RULES FOR STORAGE 2-50
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 2-50
OTHER PRECAUTIONS 2-50
OPERATION 3-1
GENERAL VIEW 3-2
MACHINE EQUIPMENT NAME 3-2
CAB EQUIPMENT NAMES 3-4
CONTROLS AND GAUGES NAMES 3-5
EXPLANATION OF COMPONENTS 3-8
EXPLANATION OF MACHINE MONITOR EQUIPMENT 3-8
SWITCHES 3-90
CONTROL LEVERS AND PEDALS 3-98
OTHER EQUIPMENT 3-102
MACHINE OPERATIONS AND CONTROLS 3-145
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 3-145
METHOD FOR STARTING ENGINE 3-177
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-180
METHOD FOR STOPPING ENGINE 3-190
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE
3-193
METHOD FOR STEERING MACHINE 3-196
METHOD FOR SWINGING MACHINE 3-198
METHOD FOR OPERATING WORK EQUIPMENT 3-199
HANDLE WORKING MODE 3-200
PROHIBITED OPERATIONS 3-202
PRECAUTIONS FOR OPERATION 3-206
PRECAUTIONS FOR WORKING ON SLOPE 3-208
METHOD FOR ESCAPING FROM MUD 3-209
RECOMMENDED APPLICATIONS 3-210
EFFECTIVE USE OF HYDRAULIC EXCAVATOR3-211
METHOD FOR REPLACING AND INVERTING BUCKET 3-212
METHOD FOR PARKING MACHINE 3-215
METHOD FOR CHECKING AFTER FINISHING WORK 3-217
LOCK 3-217
HANDLE AIR CONDITIONER 3-227
EXPLANATION OF AIR CONDITIONER EQUIPMENT 3-228
METHOD FOR OPERATING AIR CONDITIONER 3-232
HANDLE RADIO 3-241
EXPLANATION OF RADIO EQUIPMENT 3-241
METHOD FOR CONTROLLING RADIO 3-243
STOW ANTENNA 3-246
SPACE FOR RADIO CASSETTE 3-246
KomVision 3-247
PRECAUTIONS WHEN USING KomVision 3-247
MONITOR DISPLAY 3-247
TRANSPORTATION 3-249
PRECAUTIONS FOR TRANSPORTING MACHINE 3-249
SELECT TRANSPORTATION METHOD 3-249
LOADING AND UNLOADING WITH TRAILER 3-250
METHOD FOR LIFTING MACHINE 3-266
COLD WEATHER OPERATION 3-268
COLD WEATHER OPERATION INFORMATION 3-268
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 3-269
AFTER COLD WEATHER SEASON 3-270
PRECAUTIONS FOR LONG-TERM STORAGE 3-271
PREPARATION FOR LONG-TERM STORAGE 3-271
MAINTENANCE DURING LONG-TERM STORAGE 3-271
STARTING MACHINE AFTER LONG-TERM STORAGE 3-271
TROUBLES AND ACTIONS 3-273
FOREWORD CONTENTS
1-19
ACTIONS WHEN RUNNING OUT OF FUEL 3-273
PHENOMENA THAT ARE NOT FAILURES 3-273
PRECAUTIONS FOR TOWING MACHINE 3-274
PRECAUTIONS FOR SEVERE JOB CONDITION 3-275
PRECAUTIONS FOR DISCHARGED BATTERY 3-276
OTHER TROUBLE 3-279
MAINTENANCE 4-1
PRECAUTIONS FOR MAINTENANCE 4-2
CHECK 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
PRECAUTIONS FOR REFILLING OIL OR FUEL 4-2
PRECAUTIONS FOR ADDING DEF 4-2
WELDING INSTRUCTIONS 4-2
DO NOT DROP THINGS INSIDE MACHINE 4-2
PRECAUTIONS FOR KDPF 4-3
PRECAUTIONS FOR SCR ASSEMBLY 4-3
DUSTY JOBSITES 4-3
AVOID MIXING OIL 4-3
LOCK INSPECTION COVERS 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT 4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES 4-3
CHECKS AFTER INSPECTION AND MAINTENANCE 4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE 4-4
CLOSE ENGINE HOOD SECURELY 4-4
PRECAUTIONS WHEN YOU CLEAN WORK EQUIPMENT CONTROL LEVER 4-4
OUTLINE OF MAINTENANCE 4-5
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-5
HANDLE ELECTRICAL COMPONENTS 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS4-11
MAINTENANCE SCHEDULE 4-13
MAINTENANCE SCHEDULE TABLE 4-13
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4-14
MAINTENANCE PROCEDURE 4-16
WHEN REQUIRED 4-16
CHECK AUTOMATIC GREASE SYSTEM 4-39
CHECKS BEFORE STARTING 4-41
EVERY 100 HOURS MAINTENANCE 4-42
EVERY 250 HOURS MAINTENANCE 4-43
EVERY 500 HOURS MAINTENANCE 4-46
EVERY 1000 HOURS MAINTENANCE 4-57
EVERY 2000 HOURS MAINTENANCE 4-64
EVERY 4000 HOURS MAINTENANCE 4-75
EVERY 4500 HOURS MAINTENANCE 4-78
EVERY 5000 HOURS MAINTENANCE 4-78
EVERY 8000 HOURS MAINTENANCE 4-80
EVERY 9000 HOURS MAINTENANCE 4-80
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
EXPLANATION OF LIFT CAPACITY CHART (1-PIECE BOOM) 5-3
ATTACHMENTS AND OPTIONS 6-1
PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS 6-2
PRECAUTIONS WHEN SELECTING 6-2
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY 6-2
PRECAUTIONS WHEN REMOVING AND INSTALLING 6-2
CONTENTS FOREWORD
1-20
PRECAUTIONS WHEN USING 6-2
QUICK COUPLER SYSTEM 6-4
HANDLING QUICK COUPLER 6-4
AUTOMATIC GREASE SYSTEM 6-8
HANDLING AUTOMATIC GREASE SYSTEM 6-8
DIAGRAM OF AUTOMATIC GREASING POINTS 6-9
SYSTEM OPERATION 6-9
CHANGING THE GREASE INTERVAL WITH THE IN-CAB DISPLAY 6-10
INDICATION ON THE IN-CAB DISPLAY 6-10
CHECK AUTOMATIC GREASE SYSTEM6-11
2-PIECE BOOM 6-14
GENERAL VIEW OF MACHINE FOR 2-PIECE BOOM 6-14
OPERATION 6-14
STORAGE POSTURE WHEN LEAVING MACHINE 6-16
INSPECTION AND MAINTENANCE 6-16
PERIODIC MAINTENANCE 6-17
MAINTENANCE SCHEDULE 6-18
SPECIFICATIONS – 2-PIECE BOOM 6-19
EXPLANATION OF LIFT CAPACITY CHART (2-PIECE BOOM) 6-20
SUPER LONG FRONT BOOM AND ARM 6-23
GENERAL VIEW OF MACHINE FOR SUPER LONG FRONT BOOM AND ARM 6-23
CHECKS BEFORE STARTING 6-23
WORKING MODES 6-24
METHOD OF WORK 6-25
WHEN TRAVELLING 6-26
TRANSPORT AND STORAGE OF SUPER LONG FRONT MACHINE 6-27
MAINTENANCE 6-27
SPECIFICATIONS – SUPER LONG FRONT 6-31
HANDLE BUCKET WITH HOOK 6-34
PRECAUTIONS FOR OPERATION 6-34
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT 6-35
EXPLANATION OF COMPONENTS ON MACHINE EQUIPPED WITH ATTACHMENT 6-35
METHOD FOR CHANGE-OVER AND CONNECT HYDRAULIC CIRCUIT FOR MACHINE READY
FOR INSTALLATION OF ATTACHMENT 6-40
METHOD FOR REMOVING AND INSTALLING ATTACHMENT 6-43
METHOD FOR OPERATING ATTACHMENT 6-47
LONG-TERM STORAGE 6-53
MAINTENANCE OF ADDITIONAL FILTER FOR BREAKER 6-53
ARM/PIN INFORMATION 6-57
ATTACHMENTS AND OPTIONS 6-58
INSTALL ATTACHMENT 6-58
TRACK SHOES SELECTION 6-59
BUCKET TEETH SELECTION 6-60
HANDLE TRAPEZOIDAL BUCKET 6-60
HANDLE EXTENSION ARM 6-62
RECOMMENDED ATTACHMENT OPERATIONS 6-63
HYDRAULIC BREAKER 6-63
REPLACEMENT PARTS 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 7-2
DEFINED LIFE PARTS LIST 7-2
CONSUMABLE PARTS 7-3
CONSUMABLE PARTS 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 7-5
LUBRICATION CHART 7-5
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 7-7
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS 7-8
INDEX 8-1
FOREWORD CONTENTS
1-21

SAFETY
Please read and make sure that you fully understand the precautions described
in this manual and the safety labels on the machine When operating or
servicing the machine, always follow these precautions strictly
2-1
SAFETY
SAFETY LABELS 2-4
LOCATION OF SAFETY LABELS 2-5
CONTENTS OF SAFETY LABELS 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2-18
PRECAUTIONS BEFORE STARTING OPERATION 2-18
ENSURE SAFE OPERATION 2-18
UNDERSTAND THE MACHINE 2-18
PREPARATIONS FOR SAFE OPERATION 2-18
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT 2-18
INSPECT MACHINE 2-18
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-18
KEEP MACHINE CLEAN 2-19
PRECAUTIONS FOR INSIDE OPERATOR’S COMPARTMENT 2-19
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-19
IF ANY PROBLEM IS FOUND 2-19
PRECAUTIONS TO PREVENT FIRE 2-19
ACTIONS IF FIRE OCCURS 2-19
PREVENT FIRE 2-20
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2-21
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2-21
NO JUMPING ON OR OFF MACHINE 2-22
LIFTING OF PERSONNEL PROHIBITED 2-22
NO PEOPLE ON ATTACHMENTS 2-22
PRECAUTIONS WHEN STANDING UP FROM OPERATOR’S SEAT 2-22
PRECAUTIONS WHEN LEAVING MACHINE 2-22
EMERGENCY EXIT FROM OPERATOR’S CAB 2-23
ELECTROMAGNETIC INTERFERENCE 2-23
DO NOT GET CAUGHT IN WORK EQUIPMENT 2-23
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-23
PROTECTION AGAINST FALLING, FLYING OR INTRUDING OBJECTS 2-24
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES 2-24
UNAUTHORIZED MODIFICATION 2-25
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-25
PRECAUTIONS RELATED TO CAB GLASS 2-25
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2-25
PRECAUTIONS FOR OPERATION 2-26
PRECAUTIONS FOR JOBSITE 2-26
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2-26
PRECAUTIONS WHEN WORKING ON LOOSE GROUND 2-26
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2-26
ENSURE GOOD VISIBILITY 2-27
CHECK SIGNS AND SIGNALMAN’S SIGNALS 2-27
BEWARE OF ASBESTOS DUST 2-28
START ENGINE 2-28
USE WARNING TAGS 2-28
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 2-28
PRECAUTIONS WHEN STARTING ENGINE 2-29
IN COLD WEATHER 2-29
START ENGINE WITH JUMPER CABLES 2-29
PRECAUTIONS FOR OPERATION 2-30
CHECKS BEFORE OPERATION 2-30
WHEN TRAVELLING IN FORWARD OR REVERSE AND SWINGING 2-30
PRECAUTIONS WHEN TRAVELLING 2-31
PRECAUTIONS WHEN TRAVELLING ON SLOPES 2-32
PRECAUTIONS WHEN OPERATING ON SLOPES 2-33
PROHIBITED OPERATIONS 2-33
SAFETY SAFETY
2-2
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES 2-34
PRECAUTIONS WHEN PARKING MACHINE 2-35
PRECAUTIONS FOR TRANSPORTATION 2-35
PRECAUTIONS WHEN LOADING AND UNLOADING 2-36
TOWING AND BEING TOWED 2-36
PRECAUTIONS FOR TOWING AND BEING TOWED 2-36
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT) 2-37
SAFETY RULES FOR LIFTING OBJECTS 2-37
LIFTING OBJECTS WITH BUCKETS 2-39
SAFETY RULES FOR LIFTING OBJECTS 2-39
PRECAUTIONS FOR MAINTENANCE 2-40
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2-40
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2-40
KEEP WORK PLACE CLEAN AND TIDY 2-40
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2-40
ONLY AUTHORIZED PERSONNEL 2-40
APPOINT LEADER WHEN WORKING WITH OTHERS 2-40
STABILITY 2-41
GUARDS 2-41
END OF SERVICE LIFE 2-41
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2-41
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2-41
PRECAUTIONS WHEN INSTALLING, REMOVING, OR STORING ATTACHMENTS 2-42
PRECAUTIONS FOR WORKING AT HIGH PLACES 2-42
PRECAUTIONS WHEN WORKING ON MACHINE 2-42
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2-43
USE PROPER TOOLS 2-43
PRECAUTIONS FOR CHECK AND MAINTENANCE 2-43
TURN BATTERY DISCONNECT SWITCH TO OFF POSITION 2-43
PRECAUTIONS FOR WELDING 2-44
HANDLE BATTERY 2-44
PRECAUTIONS WHEN USING HAMMER 2-45
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT 2-45
PRECAUTIONS FOR HIGH-TEMPERATURE OIL 2-45
PRECAUTIONS FOR HIGH-TEMPERATURE PARTS 2-45
PRECAUTIONS FOR HIGH-PRESSURE OIL 2-45
PRECAUTIONS FOR HIGH-PRESSURE FUEL 2-46
HANDLE HIGH-PRESSURE HOSES AND PIPING 2-46
PRECAUTIONS FOR HIGH VOLTAGE 2-46
PRECAUTIONS FOR NOISE 2-46
PRECAUTIONS FOR HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION 2-47
DO NOT DISASSEMBLE RECOIL SPRING 2-47
HANDLE ACCUMULATOR AND GAS SPRING 2-47
PRECAUTIONS FOR COMPRESSED AIR 2-48
MAINTENANCE OF AIR CONDITIONER 2-48
CHEMICAL HAZARD 2-48
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 2-48
METHOD FOR SELECTING WINDOW WASHER FLUID 2-48
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 2-48
PRECAUTIONS FOR DEF 2-50
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 2-50
PRECAUTIONS FOR ADDING 2-50
SAFETY RULES FOR STORAGE 2-50
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 2-50
OTHER PRECAUTIONS 2-50

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