Komatsu Hydraulic Excavators PC210K, PC210LCK, PC210NLCK, PC240LCK, PC240LCK, PC240NLCK Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC210-6K, PC210-7K, PC210LC-6K, PC210LC-7K, PC210NLC-7K, PC240LC-6K, PC240LC-7K, PC240NLC-6K, PC240NLC-7K, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC-6K, PC240NLC-6K, PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
EEBM001801 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC-6K, PC240NLC-6K Shop Manual.pdf
UEBM001701 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Shop Manual.pdf
PEPBK2053P00 - Hydraulic Excavator PC210-3KP, PC210LC-3KP, PC240-3KP, PC240LC-3KP, PC240NLC-3KP Parts Book.pdf
EEAM006007 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC-6K, PC240NLC-6K Operation & Maintenance Manual.pdf
EEAM006011 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC,PC240NLC-6K Operation & Maintenance Manual.pdf
EEBM000505 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240-6K, PC240LC-6K, PC240NLC-6K Operation & Maintenance Manual.pdf
UEAM001704 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC230NHD-7K, PC240LC-7K, PC240NLC-7K Operation & Maintenance Manual.pdf
UEAM003900 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC230NHD-7K, PC240LC-7K, PC240NLC-7K Operation & Maintenance Manual.pdf
Total Pages: 3,703 pages
File Format: PDF
Language: English
MAIN SECTIONS
EEAM006007 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC-6K, PC240NLC-6K Operation & Maintenance Manual...2
COVER...3
CONTENTS...13
FOREWORD...5
SAFETY INFORMATION...7
SAFETY MESSAGES...7
NOISE...8
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...17
GENERAL PRECAUTIONS...18
PRECAUTIONS DURING OPERATION...26
BEFORE STARTING ENGINE...26
OPERATING MACHINE...28
TRANSPORATION...35
BATTERY...36
TOWING...37
BUCKET WITH HOOK...38
PRECAUTIONS FOR MAINTENANCE...41
BEFORE CARRYING OUT MAINTENANCE...41
DURING MAINTENANCE...44
POSITION FOR ATTACHING SAFETY LABLES...49
POSITION FOR ATTACHING SAFETY LABELS...49
OPERATION...55
GENERAL VIEW...56
GENERAL VIEW OF MACHINE...56
GENERAL VIEW OF CONTROLS AND GAUGES...57
EXPLANATION OF COMPONENTS...59
MACHINE MONITOR...59
METERS...65
SWITCHES...70
CONTROL LEVERS, PEDALS...76
AIR CONDITIONER...87
CAB RADIO...90
FUSE...91
FUSIBLE LINK...92
CONTROLLERS...92
TOOL BOX...92
REFUELLING PUMP...93
HANDLING THE ACCUMULATOR...94
OPERATION...95
CHECK BEFORE STARTING ENGINE...95
STARTING ENGINE...107
OPERATIONS AND CHECKECKS AFTER STARTING ENGINE...108
MOVING MACHINE OFF...114
STEERING MACHINE...117
STOPPING MACHINE...119
SWINGING...120
OPERATION OF WORK EQUIPMENT...121
HANDLING ACTIVE MODE...122
WORKING MODE SELECTION...123
PROHIBITIONS FOR OPERATION...125
PRECAUTIONS FOR OPERATION...127
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS...128
HOW TO ESCAPE FROM MUD...129
WORK POSSIBLE USING HYDRAULIC EXCAVATOR...129
REPLACEMENT AND INVERSION OF BUCKET...131
PARKING THE MACHINE...133
CHECK AFTER FINISHING WORK...134
STOPPING ENGINE...134
CHECK AFTER STOPPING ENGINE...135
TRANSPORTATION...137
LOADING, UNLOADING WORK...137
COLD WEATHER OPERATION...142
PRECAUTIONS FOR LOW TEMPERATURE...142
PRECAUTIONS AFTER COMPLETION OF WORK...143
LONG-TERM STORAGE...145
BEFORE STORAGE...145
DURING STORAGE...145
AFTER STORAGE...146
STARTING MACHINE AFTER LONG-TERM STORAGE...146
TROUBLESHOOTING...147
PHENOMENA THAT ARE NOT FAILURES...147
METHOD OF TOWING MACHINE...147
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...148
PRECAUTIONS ON PARTICULAR JOBSITES...148
IF BATTERY IS DISCHARGED...149
OTHER TROUBLE...152
MAINTENANCE...157
GUIDES TO MAINTENANCE...158
OUTLINES OF SERVICE...161
OUTLINE OF OIL, FUEL COOLANT...161
EXPLANATION OF LUBRICATION CHART DECAL...164
OUTLINE OF ELECTRICAL SYSTEM...166
OUTLINE OF HYDRAULIC SYSTEM...166
WEAR PARTS LIST...168
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...169
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...173
LIST OF NECESSARY TOOLS...173
TORQUE LIST...174
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...175
MAINTENANCE SCHEDULE CHART...178
MAINTENANCE SCHEDULE CHART...178
MAINTENANCE WHEN USING HYDRAULIC BREAKER...181
SERVICE PROCEDURE...182
INITIAL 250 HOURS SERVICE...182
WHEN REQURED...182
CHECK BEFORE STARTING...194
EVERY 100 HOURS SERVICE...199
EVERY 250 HOURS SERVICE...202
EVERY 500 HOURS SERVICE...206
EVERY 1000 HOURS SERVICE...212
EVERY 2000 HOURS SERVICE...215
EVERY 4000 HOURS SERVICE...217
EVERY 5000 HOURS SERVICE...217
SPECIFICATIONS...221
SPECIFICATIONS...222
PC210-6K, PC210LC-6K...222
SPECIFICATIONS...226
PC240LC-6K, PC240NLC-6K...226
EXPLANATION OF LIFTING CAPACITY CHART...229
OPTIONS, ATTACHMENTS...239
PRECAUTIONS RELATED TO SAFETY...240
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...241
HANDLING BUCKET WITH HOOK...242
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...242
PROHIBITED OPERATIONS...242
PRECAUTIONS DURING OPERATIONS...242
MACHINES READY FOR ATTACHMENTS...243
EXPLANATION OF COMPONENTS...243
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...247
INTRODUCTION OF ATTACHMENTS...252
SPECIFICATION, USE...252
ATTACHMENT INSTALLATION COMBINATION TABLE...254
SELECTION OF TRACK SHOES...256
SELECTION OF BUCKET TEETH...258
HANDLING TRAPEZODIAL BUCKET...258
USING THE EXTENSION ARM...260
HANDLING THE CLAMSHELL BUCKET...260
EXTENDING MACHINE SERVICE LIFE...261
HYDRAULIC BREAKER...261
POWER RIPPER...265
MAIN FIELDS OF APPLICATIONS...265
FORK GRAB...266
GRAPPLE BUCKET...268
SCRAP GRAPPLE...269
CRUSHER &SMASHER...271
HYDRAULIC PILE DRIVER...272
HYDRAULIC EXCAVATOR WITH MUTIPURPOSE CRANE...274
2-PC BOOM...276
6.4 M STRAIGHT BOOM...281
EEAM006011 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC,PC240NLC-6K Operation &Maintenance Manual...287
FOREWORD...289
SAFETY INFORMATION...290
SAFETY MESSAGES...290
NOISE PC210, PC210LC-6K...291
NOISE PC240LC, PC240NLC-6K...293
VIBRATION...294
INTRODUCTION...295
INTENDED USE...295
FEATURES...295
BREAKING IN YOUR NEW MACHINE...296
LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR...297
MACHINE SERIAL NO. PLATE POSITION...297
ENGINE SERIAL NO. PLATE POSITION...297
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...297
MACHINE SERIAL PLATE...298
SAFETY...305
GENERAL PRECAUTIONS...306
PRECAUTIONS DURING OPERATION...314
BEFORE STARTING ENGINE...314
OPERATING MACHINE...316
TRANSPORTATION...323
BATTERY...324
TOWING...325
BUCKET WITH HOOK...326
GENERAL PRECAUTIONS...326
PRECAUTIONS FOR LIFTING OPERATION...327
PRECAUTIONS FOR MAINTENANCE...329
BEFORE CARRYING OUT MAINTENANCE...329
DURING MAINTENANCE...332
POSITION FOR ATTACHING SAFETY LABELS...337
POSITION FOR ATTACHING SAFETY LABELS...337
OPERATION...343
GENERAL VIEW...344
GENERAL VIEW OF MACHINE...344
GENERAL VIEW OF CONTROLS AND GAUGES...345
EXPLANATION OF COMPONENTS...347
MACHINE MONITOR...347
A: BASIC CHECK ITEMS...349
B: CAUTION ITEMS...350
C: EMERGENCY STOP ITEMS...351
D: METER DISPLAY PORTION...352
METERS...353
E: SWITCHES...355
SWITCHES...358
CONTROL LEVERS, PEDALS...364
CEILING WINDOW...369
FRONT WINDOW...370
DOOR LOCK...372
CAP, COVER WITH LOCK...372
LUGGAGE TRAY...373
ASHTRAY...374
AIR CONDITIONER...375
GENERAL LOCATIONS ON CONTROL PANEL...375
AIR CONDITIONER SWITCH...377
OFF SWITCH...377
DEFROSTER SELECTOR LEVER...377
PRECAUTIONS WHEN USING AIR CONDITIONER...377
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...378
CAB RADIO...378
FUSE...379
Fuse capacity and name of circuit...379
FUSIBLE LINK...380
CONTROLLERS...380
TOOL BOX...380
REFUELLING PUMP...381
HANDLING THE ACCUMULATOR...382
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR...382
OPERATION...383
CHECK BEFORE STARTING ENGINE...383
WALK-AROUND CHECK...383
CHECK BEFORE STARTING...384
CHECK FUEL LEVEL, ADD FUEL...386
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...387
CHECK AIR CLEANER FOR CLOGGING...388
CHECK ELECTRIC WIRINGS...388
CHECK FUNCTION OF HORN...388
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER...389
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER...389
ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT...390
USING THE SEAT BELT...391
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...392
STARTING ENGINE...394
NORMAL STARTING...394
STARTING IN COLD WEATHER...395
OPERATIONS AND CHECKS AFTER STARTING ENGINE...396
WHEN NORMAL...396
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...398
MOVING MACHINE OFF...402
MOVING MACHINE FORWARD...402
MOVING MACHINE BACKWARD...403
STEERING MACHINE...405
STEERING (changing direction)...405
STOPPING MACHINE...407
SWINGING...408
OPERATION OF WORK EQUIPMENT...409
HANDLING ACTIVE MODE...410
WORKING MODE SELECTION...411
PROHIBITIONS FOR OPERATION...413
PRECAUTIONS FOR OPERATION...415
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS...416
HOW TO ESCAPE FROM MUD...417
WHEN ONE SIDE IS STUCK...417
WHEN BOTH SIDES ARE STUCK...417
WORK POSSIBLE USING HYDRAULIC EXCAVATOR...417
BACKHOE WORK...418
SHOVEL WORK...418
DITCHING WORK...418
LOADING WORK...418
REPLACEMENT AND INVERSION OF BUCKET...419
REPLACEMENT...419
INVERSION...420
PARKING THE MACHINE...421
CHECK AFTER FINISHING WORK...422
STOPPING ENGINE...422
CHECK AFTER STOPPING ENGINE...423
LOCKING...424
OVERLOAD WARNING DEVICE...424
TRANSPORTATION...425
LOADING, UNLOADING WORK...425
PRECAUTIONS FOR LOADING...427
PRECAUTIONS FOR TRANSPORTATION...427
METHOD OF LIFTING MACHINE...428
COLD WEATHER OPERATION...430
PRECAUTIONS FOR LOW TEMPERATURE...430
FUEL AND LUBRICANTS...430
COOLANT...430
BATTERY...431
PRECAUTIONS AFTER COMPLETION OF WORK...431
AFTER COLD WEATHER...432
LONG-TERM STORAGE...433
BEFORE STORAGE...433
DURING STORAGE...433
AFTER STORAGE...434
STARTING MACHINE AFTER LONG-TERM STORAGE...434
TROUBLESHOOTING...435
PHENOMENA THAT ARE NOT FAILURES...435
METHOD OF TOWING MACHINE...435
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE...436
PRECAUTIONS ON PARTICULAR JOBSITES...436
IF BATTERY IS DISCHARGED...437
STARTING ENGINE WITH BOOSTER CABLE...438
OTHER TROUBLE...440
ELECTRICAL SYSTEM...440
CHASSIS...441
ENGINE...442
ENGINE (cont’d)...443
ELECTRONIC CONTROL SYSTEM...444
OPERATION INSTRUCTIONS FOR HIGH REACH WORK EQUIPMENT FOR PC240-6...445
PRECAUTIONS WHEN OPERATING...445
PROHIBITON OF WORK IN THE OVER SIDES DIRECTION...446
PROHIBITON OF WORK OUTSIDE THE WORKING RANGE OF THE MACHINE...446
PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER...449
PROHIBITION OF WORK WITH HYDRAULIC BREAKER...449
CHECK BEFORE STARTING...451
OPERATION...452
Attachment control...452
RAISING WORK EQUIPMENT...453
WORKING RANGE AND USING RANGE OF BOOM...453
WORKING RANGE AND RANGE OF USE OF BOOM...454
TRANSPORTATION (HIGH REACH DEMOLITION)...455
MAINTENANCE...457
GUIDES TO MAINTENANCE...458
OUTLINES OF SERVICE...461
OUTLINE OF OIL, FUEL, COOLANT...461
OIL...461
FUEL...462
COOLANT...462
GREASE...463
STORING OIL AND FUEL...463
FILTERS...463
EXPLANATION OF LUBRICATION CHART DECAL...464
OUTLINE OF ELECTRICAL SYSTEM...466
OUTLINE OF HYDRAULIC SYSTEM...466
WEAR PARTS LIST...468
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...469
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...469
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...473
LIST OF NECESSARY TOOLS...473
TORQUE LIST...474
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...475
MAINTENANCE SCHEDULE CHART...478
MAINTENANCE SCHEDULE CHART...478
MAINTENANCE WHEN USING HYDRAULIC BREAKER...481
SERVICE PROCEDURE...482
INITIAL 250 HOURS SERVICE...482
WHEN REQUIRED...482
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...482
CLEAN INSIDE OF COOLING SYSTEM...484
CHECK AND TIGHTEN TRACK SHOE BOLTS...487
CHECK and adjust TRACK TENSION...488
CHECK ELECTRICAL INTAKE AIR HEATER...490
REPLACE BUCKET SIDE CUTTERS...490
REPLACE BUCKET TEETH...491
ADJUST BUCKET CLEARANCE...491
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...492
CHECK, MAINTAIN AIR CONDITIONER...493
CHECK BEFORE STARTING...494
CHECK COOLANT LEVEL, ADD COOLANT...494
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...495
CHECK FUEL LEVEL, ADD FUEL...495
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...496
CHECK AIR CLEANER FOR CLOGGING...497
CHECK ELECTRIC WIRINGS...497
CHECK FUNCTION OF HORN...498
CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR, DRAIN WATER AND SEDIMENT...498
CHECK FOR WATER IN PRIMARY FUEL FILTER, drain water...498
EVERY 100 HOURS SERVICE...499
LUBRICATING...499
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...501
DRAIN WATER AND SEDIMENT FROM FUEL TANK...501
CLEAN FRESH AIR INTAKE FILTER...502
EVERY 250 HOURS SERVICE...502
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...502
CHECK LEVEL OF BATTERY ELECTROLYTE...503
LUBRICATE SWING CIRCLE (2 POINTS)...504
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION ADJUST...504
EVERY 500 HOURS SERVICE...506
REPLACE FUEL FILTER CARTRIDGE...506
CHECK SWING PINION GREASE LEVEL, ADD GREASE...508
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...508
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W...509
REPLACE HYDRAULIC TANK BREATHER ELEMENT...510
REPLACE HYDRAULIC FILTER ELEMENT...510
EVERY 1000 HOURS SERVICE...512
CHANGE OIL IN SWING MACHINERY CASE...512
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...513
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...513
CHECK PLAY OF TURBOCHARGER ROTOR...513
CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB...514
CHECK FAN BELT TENSION...514
EVERY 2000 HOURS SERVICE...515
CHANGE OIL IN FINAL DRIVE CASE...515
CLEAN HYDRAULIC TANK STRAINER...516
CLEAN, CHECK TURBOCHARGER...516
CHECK ALTERNATOR, STARTING MOTOR...516
CHECK ENGINE VALVE CLEARANCE, ADJUST...516
CHECK VIBRATION DAMPER...516
CHANGE ANTI FREEZE...516
CHECK AND ADJUST VALVE CLEARANCE...517
EVERY 4000 HOURS SERVICE...517
CHECK WATER PUMP...517
EVERY 5000 HOURS SERVICE...517
CHANGE OIL IN HYDRAULIC TANK...517
SPECIFICATIONS...521
SPECIFICATIONS...522
PC210-6K, PC210LC-6K...522
SPECIFICATIONS...526
PC240LC-6K, PC240NLC-6K...526
explanation of LIFTING CAPACITY CHART...529
OPTIONS, ATTACHMENTS...539
PRECAUTIONS RELATED TO SAFETY...540
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...541
HANDLING BUCKET WITH HOOK...542
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...542
PROHIBITED OPERATIONS...542
PRECAUTIONS DURING OPERATIONS...542
MACHINES READY FOR ATTACHMENTS...543
EXPLANATION OF COMPONENTS...543
1. STOP VALVE...543
2. SELECTOR VALVE...544
3. CONTROL PEDAL FOR ATTACHMENT...544
4. ACCUMULATOR...544
5. HYDRAULIC CIRCUIT...545
CONNECTING HYDRAULIC CIRCUIT...546
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...547
OPERATION...548
LONG TERM STORAGE...549
SPECIFICATIONS...549
FIRST ATTACHMENT WITH CLAM-SHELL OPTION...550
FIRST AND SECOND ATTACHMENT...551
INTRODUCTION OF ATTACHMENTS...552
SPECIFICATION, USE...552
ATTACHMENT INSTALLATION COMBINATION TABLE...554
SELECTION OF TRACK SHOES...556
SELECTION OF BUCKET TEETH...558
HANDLING TRAPEZOIDAL BUCKET...558
USING THE EXTENSION ARM...560
HANDLING THE CLAMSHELL BUCKET...560
EXTENDING MACHINE SERVICE LIFE...561
HYDRAULIC BREAKER...561
POWER RIPPER...565
MAIN FIELDS OF APPLICATIONS...565
FORK GRAB...566
GRAPPLE BUCKET...568
SCRAP GRAPPLE...569
CRUSHER &SMASHER...571
HYDRAULIC PILE DRIVER...572
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE...574
2-PC BOOM...576
FEATURES OF 2-PIECE BOOM &ARM...576
OPERATION...576
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...578
TESTING AND ADJUSTING...578
PERODIC MAINTENANCE...579
TRANSPORTATION...580
6.4 M STRAIGHT BOOM...581
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...581
PREVENTION OF DAMAGE TO WORK EQUIPMENT...582
TRANSPORTATION...585
FRONT DOZER BLADE...586
BLADE OPERATIONS...586
PROHIBITED OPERATIONS...586
WEAR PARTS LIST...587
MAINTENANCE...587
EEBM000505 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240-6K, PC240LC-6K, PC240NLC-6K Operation &Maintenance Manual...588
EEBM001801 - Hydraulic Excavator PC210-6K, PC210LC-6K, PC240LC-6K, PC240NLC-6K Shop Manual...1264
10 STRUCTURE AND FUNCTION ...1287
ENGINE RELATED PARTS ...1292
RADIATOR � OIL COOLER ...1293
POWER TRAIN ...1294
FINAL DRIVE ...1295
SWING CIRCLE ...1296
SWING MACHINERY ...1297
TRACK FRAME, RECOIL SPRING ...1298
TRACK SHOE ...1299
HYDRAULIC TANK ...1301
HYDRAULIC TANK ...1302
HYDRAULIC PUMP ...1303
CONTROL VALVE ...1322
SAFETY- SUCTION VALVE FOR SERVICE VALVE ...1330
SELF- REDUCING PRESSURE VALVE ...1331
CLSS ...1336
SWING MOTOR ...1378
CENTER SWIVEL JOINT TRAVEL MOTOR ...1382
VALVE CONTROL WORK EQUIPMENT � SWING PPC VALVE ...1392
TRAVEL PPC VALVE ...1396
SERVICE PPC VALVE ...1400
SAFETY LOCK VALVE PPC ACCUMULATOR STRAIGHT- TRAVEL SYSTEM ...1405
EPC SOLENOID VALVE ...1406
OVERLOAD WARNING DEVICE ...1408
HOSE BURST PROTECTION VALVE (BOOM) ...1410
WORK EQUIPMENT ENGINE CONTROL SYSTEM ...1419
ELECTRONIC CONTROL SYSTEM ...1425
MACHINE MONITOR SYSTEM ...1450
20 TESTING AND ADJUSTING ...1464
TESTING AND ADJUSTING STANDARD VALUE TABLE ...1470
For engine - PC210- 6k ...1470
For engine - PC240- 6k For chassis ...1472
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ...1481
MEASURING ENGINE SPEED ...1490
MEASURING EXHAUST GAS COLOR ...1491
ADJUSTING VALVE CLEARANCE ...1492
MEASURING COMPRESSION PRESSURE ...1493
MEASURING BLOW- BY PRES-SURE ...1493
TESTING AND ADJUSTING FUEL INJECTION TIMING ...1494
MEASURE ENGINE OIL PRESSURE ...1495
TESTING AND ADJUSTING FAN BELT TENSION ...1496
MEASURING SPEED SENSOR ...1497
TESTING AND ADJUSTING GOV-ERNOR MOTOR LEVER STROKE ...1498
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT ...1499
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRES-SURE) ...1502
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE AND LS DIFFERENTIAL PRESSURE) ...1503
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE ...1506
TESTING SOLENOID VALVE OUT-PUT PRESSURE ...1507
MEASURING PPC VALVE OUTPUT PRESSURE ...1509
Pressure switch piping diagram ...1510
ADJUSTING WORK EQUIPMENT � SWING PPC VALVE ...1511
ADJUSTMENT OF FLOW CON-TROL SYSTEM ...1512
Graph of PPC Pressure Against HCU Circuit Oil Flow ...1514
TESTING TRAVEL DEVIATION ...1515
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ...1516
MEASURE OIL LEAKAGE ...1518
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...1520
TESTING CLEARANCE OF SWING CIRCLE BEARING ...1520
TESTING AND ADJUSTING TRACK SHOE TENSION ...1521
BLEEDING AIR ...1522
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...1524
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...1525
CHECKS BEFORE TROUBLESHOOTING ...1533
CONNECTOR TYPES AND MOUNTING LOCATIONS ...1535
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ...1540
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM ...1548
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL ...1549
METHOD OF USING JUDGEMENT TABLE ...1558
METHOD OF USING TROUBLESHOOTING CHARTS ...1560
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ...1562
SERVICE CODE TABLE ...1567
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE) ...1568
TROUBLESHOOTING OF ENGINE THROTTLE � PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) ...1570
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...1571
JUDGEMENT TABLE FOR ENGINE THROTTLE � PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS ...1575
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM ...1577
E- 1 Abnormality in engine throttle � pump controller power source (controller LED is OFF) ...1579
E- 2 [E308] Abnormality in fuel control dial input value is displayed ...1580
E- 3 [E317] Abnormality (disconnection) in motor drive system is displayed ...1581
E- 4 [E318] Abnormality (short circuit) in motor drive system is displayed ...1582
E- 5 [E306] Abnormality in feedback potentiometer system is displayed ...1583
E- 6 [E315] Abnormality (short circuit) in battery relay output system is displayed ...1584
E- 7 [E316] Abnormality (step- out) in motor is displayed ...1585
E- 8 Engine does not start ...1587
E- 8 Related electric circuit diagram E- 9 Engine speed is irregular ...1590
E- 10 Lack of output (engine high idling speed is too low) ...1594
E- 11 Engine does not stop ...1596
E- 12 Defective operation of battery relay system (engine does not stop) ...1598
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) ...1600
S- 1 Starting performance is poor (starting always takes time) ...1605
S- 2 Engine does not start ...1607
S- 3 Engine does not pick up smoothly (follow- up is poor) ...1610
S- 4 Engine stops during operations ...1611
S- 5 Engine does not rotate smoothly (hunting) ...1612
S- 6 Engine lacks output (no power) ...1613
S- 7 Exhaust smoke is black (incomplete combustion) ...1614
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ...1615
S- 9 Oil becomes contaminated quickly ...1616
S- 10 Fuel consumption is excessive ...1617
S- 11 Oil is in coolant, or coolant spurts black, or coolant level goes down ...1618
S- 12 Oil pressure caution lamp lights up (drop in oil pressure) ...1619
S- 13 Oil level rises (coolant, fuel in oil) ...1620
S- 14 Coolant temperature becomes too high (overheating) ...1621
S- 15 Abnormal noise is made ...1622
S- 16 Vibration is excessive ...1623
TROUBLESHOOTING OF ENGINE THROTTLE � PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C- MODE) ...1624
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM ...1624
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...1625
JUDGEMENT TABLE FOR ENGINE THROTTLE � PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS ELECTICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE ...1635
C- 1 Abnormality in controller power source system (controller LED is OFF) ...1637
C- 2 [E232] Short circuit in pump EPC solenoid system is displayed ...1638
C- 3 [E233] Disconnection in PC- EPC solenoid system is displayed ...1640
C- 4 [213] Disconnection in swing holding brake solenoid system is displayed ...1642
C- 5 [E203] Short circuit in swing holding brake solenoid system is displayed ...1644
C- 6 [E204] Short circuit in pump merge/ divider solenoid system is displayed ...1646
C- 7 [E214] Disconnection in pum merge/ divider solenoid system is displayed ...1647
C- 8 [E207] Short circuit in active mode solenoid system is displayed ...1648
C- 9 [E208] Disconnection in active mode solenoid system is displayed ...1649
C- 10 [E206] Short circuit in travel speed solenoid system is displayed ...1650
C- 13 [E215] Disconnection in 2- stage relief solenoid system is displayed ...1651
C- 14 [E217] Model selection input error is displayed ...1652
C- 15 [E222] Short circuit in LS- EPC solenoid system is displayed ...1654
C- 16 [E223] Disconnection in LS- EPC solenoid system is displayed ...1655
C- 17 [E224] Abnormality in front pump pressure sensor system is displayed ...1656
C- 18 [E225] Abnormality in rear pump pressure sensor system is displayed ...1657
C- 19 [E226] Abnormality in pressure sensor power source system is displayed ...1658
C- 20 [E227] Abnormality in engine speed sensor system is displayed ...1659
TROUBLESHOOTING OF ENGINE THROTTLE � PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) ...1660
F- 1 Bit pattern 20 - (1) Swing oil pressure switch does not light up ...1660
F- 2 Bit pattern 20-( 2) Travel oil pressure switch does not light up ...1661
F- 3 Bit pattern 20-( 3) Boom LOWER oil pressure switch does not light up ...1663
F- 4 Bit pattern 20-( 4) Boom RAISE oil pressure switch does not light up ...1664
F- 5 Bit pattern 20-( 5) Arm IN oil pressure switch does not light up ...1665
F- 6 Bit pattern 20-( 6) Arm OUT oil pressure switch does not light up ...1666
F- 7 Bit pattern 21-( 1) Bucket CURL oil pressure switch does not light up ...1667
F- 8 Bit pattern 21-( 2) Bucket DUMP oil pressure switch does not light up ...1668
F- 9 Bit pattern 21-( 3) Swing lock switch does not light up ...1669
F- 10 Bit pattern 22-( 5) Kerosene mode connection does not light up ...1670
F- 11 Bit pattern 22-( 6) L. H. knob switch does not light up ...1671
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H- MODE) ...1672
PUMP MERGE/ DIVIDER LOGIC ...1676
SOLENOID ACTUATION TABLE ...1677
H- 1 Speeds of all work equipment, swing, travel are slow ...1678
H- 3 No work equipment, travel, swing move H- 2 There is excessive drop in engine speed, or engine stalls ...1680
H- 4 Abnormal noise generated (around pump) ...1681
H- 5 Auto- deceleration does not work (when PPC shuttle valve) ...1681
H- 6 Fine control ability is poor or response is poor ...1682
H- 7 Boom is slow or lacks power ...1684
H- 8 Arm is slow or lacks power ...1686
H- 9 Bucket is slow or lacks power ...1688
H- 10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) ...1689
H- 11 Excessive hydraulic drift (boom, arm, bucket) ...1689
H- 12 Excessive time lag (engine at low idling) ...1690
H- 13 Other equipment moves when single circuit is relieved ...1690
M- 30 Related electric circuit diagram H- 14 Lack of power when pressure rises ...1693
H- 16 In compound operations, work equipment with larger load is slow ...1694
H- 15 In L/ O, F/ O modes, work equipment speed is faster than specified speed ...1694
H- 17 In swing + boom RAISE, boom RAISE is slow ...1695
H- 18 In swing + travel, travel speed drops excessively ...1695
H- 19 Travel deviation ...1695
H- 20 Travel speed is slow ...1696
H- 21 Steering does not turn easily or lacks power ...1698
H- 23 Travel does not move (one side only) ...1700
H- 22 Travel speed does not switch or is faster than specified speed ...1700
H- 24 Does not swing ...1701
H- 25 Swing acceleration is poor or swing speed is slow ...1702
H- 26 Excessive overrun when stopping swing ...1704
H- 27 Excessive shock when stopping wing (one direction only) H- 28 Excessive abnormal noise when stopping swing ...1705
H- 29 Excessive hydraulic drift of swing ...1705
H- 30 Swing speed is faster than specified speed in L/ O and F/ O modes ...1706
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M CODE ) ...1707
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...1707
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM M- 1 [E101] Abnormality in error data is displayed [E102] Error in clock data is displayed ...1711
M- 2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed ...1712
M- 3 [E104] Air clogging detected is displayed ...1713
M- 4 [E108] Engine coolant temperature 105° C detected is displayed ...1713
M- 5 When starting switch is turned ON, none of the lamps on the monitor panel light up for 3 seconds ...1714
M- 6 When starting switch is turned ON, monitor panel lamps all stay lit up and do not go out M- 7 When starting switch is turned ON, items lit up on monitor panel are different from actual machine (model) ...1716
M- 8 When starting switch is turned ON (engine stopped), basic check items flashes ...1717
M- 9 Preheating is not being used but (preheating monitor) lights up ...1720
M- 10 When starting switch is turned ON and engine is started, basic check items flash ...1721
M- 11 When starting switch is turned ON (engine stopped), caution items, emergency items flash (battery, engine oil pressure lamps do not light up) ...1723
M- 12 When starting switch is turned ON and engine is started, caution items, emergency items flash (then there is no abnormality in engine or items to check before troubleshooting) ...1725
M- 13 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second Caution item flashes but buzzer does not sound ...1728
M- 14 No abnormality is displayed on monitor but buzzer sounds ...1728
M- 15 Night lighting on monitor panel does not light up (liquid crystal display is normal) ...1729
M- 16 Coolant temperature gauge does not rise ...1730
M- 17 Coolant temperature gauge does not give any display (none of the gauge lamps light up during operation) ...1731
M- 18 Fuel level gauge always displays FULL ...1732
M- 19 Fuel level gauge does not give display ...1732
M- 20 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up ...1733
M- 21 Swing prolix switch is turned ON (prolix), but (swing lock monitor) does not flash ...1734
M- 22 Service meter does not advance while engine is running M- 23 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed ...1735
M- 24 Defective fuel level sensor system ...1736
M- 25 Defective coolant temperature sensor system ...1737
M- 26 Defective engine oil sensor system ...1738
M- 27 Defective coolant level sensor system ...1739
M- 28 Defective hydraulic oil level sensor system ...1740
M- 29 Wiper does not work or switch is not being used but wiper is actuated ...1741
M- 30 Washer motor does not work, or switch is not being used but washer motor is actuated ...1746
30 DISASSEMBLY AND ASSEMBLY ...1748
METHOD OF USING MANUAL ...1753
SPECIAL TOOL LIST ...1756
SKETCHES OF SPECIAL TOOLS ...1760
STARTING MOTOR ...1761
ALTERNATOR ...1762
FUEL INJECTION PUMP ...1763
WATER PUMP ...1766
NOZZLE HOLDER ...1768
TURBOCHARGER ...1769
THERMOSTAT ...1770
GOVERNOR MOTOR ...1772
CYLINDER HEAD ASSEMBLY ...1773
RADIATOR � HYDRAULIC OIL COOLER ...1781
ENGINE, MAIN PUMP ...1783
DAMPER ...1787
FUEL TANK ...1788
CENTER SWIVEL JOINT ...1789
FINAL DRIVE ...1792
SPROCKET ...1801
SWING MOTOR ...1802
SWING MACHINERY ...1803
SWING MACHINERY ...1804
REVOLVING FRAME ...1811
REMOVAL OF SWING CIRCLE ASSEMBLY ...1813
INSTALLATION OF SWING CIRCLE ASSEMBLY ...1814
REMOVAL OF IDLER � RECOIL SPRING ASSEMBLY ...1815
INSTALLATION OF IDLER � RECOIL SPRING ASSEMBLY ...1815
DISASSEMBLY OF RECOIL SPRING ASSEMBLY ...1816
ASSEMBLY OF RECOIL SPRING ASSEMBLY ...1817
DISASSEMBLY OF IDLER ASSEMBLY ...1818
ASSEMBLY OF IDLER ASSEMBLY ...1819
REMOVAL OF TRACK ROLLER ASSEMBLY ...1821
INSTALLATION OF TRACK ROLLER ASSEMBLY ...1821
DISASSEMBLY OF TRACK ROLLER ASSEMBLY ...1822
ASSEMBLY OF TRACK ROLLER ASSEMBLY ...1823
REMOVAL OF CARRIER ROLLER ASSEMBLY ...1825
INSTALLATION OF CARRIER ROLLER ASSEMBLY ...1825
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY ...1826
ASSEMBLY OF CARRIER ROLLER ASSEMBLY ...1827
REMOVAL OF TRACK SHOE ASSEMBLY ...1829
INSTALLATION OF TRACK SHOE ASSEMBLY ...1829
HYDRAULIC TANK ...1830
MAIN PUMP ...1832
MAIN PUMP INPUT SHAFT OIL SEAL ...1835
CONTROL VALVE ...1836
PUMP MERGE- DIVIDER VALVE ...1845
MAIN RELIEF VALVE ...1846
PC VALVE ...1847
LS VALVE ...1848
PC, LS- EPC VALVE ...1849
SOLENOID VALVE ...1850
REMOVAL OF WORK EQUIPMENT � SWING PPC VALVE ASSEMBLY ...1851
INSTALLATION OF WORK EQUIPMENT � SWING PPC VALVE ASSEMBLY ...1851
TRAVEL PPC VALVE ...1854
REMOVAL OF BOOM CYLINDER ASSEMBLY ...1856
INSTALLATION OF BOOM CYLINDER ASSEMBLY ...1857
REMOVAL OF ARM CYLINDER ASSEMBLY ...1858
INSTALLATION OF ARM CYLINDER ASSEMBLY ...1859
REMOVAL OF BUCKET CYLINDER ASSEMBLY ...1860
INSTALLATION OF BUCKET CYLINDER ASSEMBLY ...1861
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ...1862
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ...1864
WORK EQUIPMENT ...1867
BUCKET ...1869
ARM ...1871
BUCKET - ARM ...1873
BOOM ...1875
REMOVAL OF OPERATOR™S CAB ASSEMBLY ...1877
INSTALLATION OF OPERATOR™S CAB ASSEMBLY ...1879
COUNTERWEIGHT ...1880
REMOVAL OF ENGINE THROTTLE CONTROLLER ASSEMBLY ...1881
MONITOR ...1882
40 MAINTENANCE STANDARD ...1885
SWING MACHINERY ...1888
SWING CIRCLE FINAL DRIVE ...1891
TRACK FRAME, RECOIL SPRING ...1893
IDLER ...1894
CARRIER ROLLER ...1896
TRACK ROLLER ...1897
TRACK SHOE ...1898
HYDRAULIC PUMP ...1900
CONTROL VALVE ...1901
VARIABLE PRESSURE COMPENSATION VALVE ...1907
SAFETY- SUCTION VALVE FOR SERVICE VALVE ...1908
SELF- REDUCING PRESSURE VALVE ...1909
SWING MOTOR ...1910
TRAVEL MOTOR ...1911
TRAVEL PPC VALVE WORK EQUIPMENT � SWING PPC VALVE EPC SOLENOID VALVE ...1914
CENTER SWIVEL JOINT HYDRAULIC CYLINDER ...1916
WORK EQUIPMENT DIMENSIONS OF WORK EQUIPMENT ...1924
PEPBK2053P00 - Hydraulic Excavator PC210-3KP, PC210LC-3KP, PC240-3KP, PC240LC-3KP, PC240NLC-3KP Parts Book...1929
UEAM001704 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC230NHD-7K, PC240LC-7K, PC240NLC-7K Operation &Maintenance Manual...2317
FOREWORD...2319
FOREWORD...2320
SAFETY INFORMATION...2321
NOISE (PC210,210LC,210NLC, PC230NHD)...2323
VIBRATION...2323
NOISE (PC240LC,240NLC)...2324
VIBRATION...2324
INTRODUCTION...2325
DIRECTIONS OF MACHINE...2325
PRODUCT INFORMATION...2326
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...2326
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...2326
SERVICE METER LOCATION...2327
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...2327
MACHINE SERIAL PLATE...2328
SAFETY...2335
SAFETY INFORMATION...2336
POSITION FOR ATTACHING SAFETY LABELS...2338
POSITION FOR ATTACHING SAFETY LABELS...2338
SAFETY LABELS...2339
SAFETY INFORMATION...2346
SAFETY RULES...2346
IF ABNORMALITIES ARE FOUND...2346
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...2346
FIRE EXTINGUISHER AND FIRST AID KIT...2346
SAFETY EQUIPMENT...2347
KEEP MACHINE CLEAN...2347
KEEP OPERATOR'S COMPARTMENT CLEAN...2347
LEAVING OPERATOR'S SEAT WITH LOCK...2347
HANDRAILS AND STEPS...2348
MOUNTING AND DISMOUNTING...2349
NO PERSONS ON ATTACHMENTS...2349
BURN PREVENTION...2349
FIRE PREVENTION AND EXPLOSION PREVENTION...2350
ACTION IF FIRE OCCURS...2351
WINDSHIELD WASHER FLUID...2351
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...2351
ATTACHMENT INSTALLATION...2351
ATTACHMENT COMBINATIONS...2352
CAB WINDOW GLASSES...2352
UNAUTHORIZED MODIFICATIONS...2352
SAFETY AT JOBSITE...2352
WORKING ON LOOSE GROUND...2352
DISTANCE TO HIGH VOLTAGE CABLES...2353
ENSURE GOOD VISIBILITY...2353
VENTILATION FOR ENCLOSED AREA...2354
SIGNALMAN'S SIGNAL AND SIGNS...2354
EMERGENCY EXIT FROM OPERATOR'S CAB...2354
ELECTROMAGNETIC INTERFERENCE...2354
ASBESTOS DUST HAZARD PREVENTION...2355
SAFETY MACHINE OPERATION...2356
STARTING ENGINE...2356
CHECKS BEFORE STARTING ENGINE...2356
SAFETY RULES FOR STARTING ENGINE...2357
STARTING ENGINE IN COLD WEATHER...2357
OPERATION...2358
CHECKS AFTER STARTING ENGINE...2358
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...2358
SAFETY RULES FOR TRAVELLING...2359
TRAVELLING ON SLOPES...2360
OPERATIONS ON SLOPES...2361
PROHIBITED OPERATIONS...2361
OPERATIONS ON SNOW...2363
PARKING MACHINE...2363
TRANSPORTATION...2364
SHIPPING THE MACHINE...2364
BATTERY...2365
BATTERY HAZARD PREVENTION...2365
STARTING ENGINE WITH BOOSTER CABLES...2366
TOWING...2367
SAFETY RULES FOR TOWING...2367
LIFTING OBJECTS WITH BUCKET...2368
SAFETY RULES FOR LIFTING OBJECTS...2368
SAFETY MAINTENANCE INFORMATION...2369
WARNING TAG...2369
KEEP WORK PLACE CLEAN AND TIDY...2369
APPOINT LEADER WHEN WORKING WITH OTHERS...2369
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...2370
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...2371
PROPER TOOLS...2371
ACCUMULATOR...2372
PERSONNEL...2372
ATTACHMENTS...2372
WORK UNDER THE MACHINE...2372
NOISE...2373
WHEN USING HAMMER...2373
WELDING WORKS...2373
REMOVING BATTERY TERMINALS...2373
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...2374
DO NOT DISASSEMBLE RECOIL SPRINGS...2374
SAFETY RULES FOR HIGH-PRESSURE OIL...2374
SAFETY HANDLING HIGH-PRESSURE HOSES...2375
WASTE MATERIALS...2375
AIR CONDITIONER MAINTENANCE...2375
COMPRESSED AIR...2375
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2376
OPERATION...2377
GENERAL VIEW...2378
GENERAL VIEW OF MACHINE...2378
GENERAL VIEW CONTROLS AND GAUGES...2379
EXPLANATION OF COMPONENTS...2380
MACHINE MONITOR...2380
BASIC OPERATION OF MACHINE MONITOR...2381
BASIC CHECK ITEMS...2383
CAUTION ITEMS...2385
EMERGENCY STOP ITEMS...2388
METER DISPLAY PORTION...2390
MONITOR SWITCHES...2394
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)...2395
AUTO-DECELERATION SWITCH...2396
TRAVEL SPEED SELECTOR SWITCH...2397
WIPER SWITCH...2398
WINDOW WASHER SWITCH...2398
MAINTENANCE SWITCH...2399
SELECT SWITCH...2401
BACK SWITCH...2402
UP SWITCH, DOWN SWITCH...2402
INPUT CONFIRMATION SWITCH...2402
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH...2403
SWITCHES...2405
STARTING SWITCH...2405
FUEL CONTROL DIAL...2406
CIGARETTE LIGHTER...2406
SWING LOCK SWITCH...2407
LAMP SWITCH...2407
ALARM BUZZER STOP SWITCH...2407
HORN SWITCH...2408
KNOB SWITCH...2408
ROOM LAMP SWITCH...2408
EMERGENCY PUMP DRIVE SWITCH...2409
SWING BRAKE CANCEL SWITCH...2409
EMERGENCY FUEL SOLENOID DRIVE SWITCH...2409
LOWER WIPER SWITCH...2410
REVOLVING WARNING LAMP SWITCH...2410
HEATED OPERATOR SEAT SWITCH...2410
CONTROL LEVERS, PEDALS...2411
SAFETY LOCK LEVER...2411
TRAVEL LEVERS...2412
WORK EQUIPMENT CONTROL LEVER...2413
CEILING WINDOW...2414
FRONT WINDOW...2415
EMERGENCY EXIT FROM OPERATOR'S CAB...2420
DOOR LOCK...2420
CAP, COVER WITH LOCK...2421
METHOD OF OPENING AND CLOSING CAP WITH LOCK...2421
METHOD OF OPENING AND CLOSING COVER WITH LOCK...2421
HOT AND COOL BOX...2422
CAB RADIO...2422
MAGAZINE BOX...2422
ASHTRAY...2423
HANDLING AIR CONDITIONER...2424
GENERAL LOCATIONS OF CONTROL PANEL...2424
METHOD OF OPERATION...2428
PRECAUTIONS WHEN USING AIR CONDITIONER...2435
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...2435
OTHER FUNCTIONS...2436
CAR RADIO...2437
FUSE...2438
FUSE CAPACITIES AND CIRCUIT NAMES...2439
FUSIBLE LINK...2439
CONTROLLER (COMPUTER)...2440
TOOLBOX...2440
GREASE GUN HOLDER...2440
REFUELLING PUMP...2441
HANDLING THE ACCUMULATOR...2441
RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR...2442
MACHINE OPERATIONS AND CONTROLS...2443
BEFORE STARTING ENGINE...2443
WALK-AROUND CHECKS...2443
CHECKS BEFORE STARTING...2444
ADJUST BEFORE OPERATION...2449
SEAT BELT...2452
OPERATIONS BEFORE STARTING ENGINE...2453
STARTING ENGINE...2456
NORMAL STARTING...2456
STARTING ENGINE IN COLD WEATHER...2457
AFTER STARTING ENGINE...2460
BREAKING-IN THE NEW MACHINE...2460
WARMING-UP OPERATION...2461
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...2464
STOPPING THE ENGINE...2468
CHECK AFTER SHUTTING OFF ENGINE...2468
MACHINE OPERATION...2469
PREPARATIONS FOR MOVING THE MACHINE OFF...2469
MOVING MACHINE FORWARD...2470
MOVING MACHINE BACKWARD...2471
STOPPING MACHINE...2472
STEERING THE MACHINE...2473
Steering...2473
SWINGING...2475
WORK EQUIPMENT CONTROLS AND OPERATIONS...2476
OPERATING WORKING MODE...2477
PROHIBITED OPERATIONS...2478
OPERATIONS USING SWING FORCE...2478
OPERATIONS USING TRAVEL FORCE...2478
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS...2478
OPERATIONS USING BUCKET DROPPING FORCE...2479
OPERATIONS USING MACHINE DROPPING FORCE...2479
DIGGING HARD ROCKY GROUND...2479
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...2479
GENERAL OPERATION INFORMATION...2480
TRAVELING...2480
HIGH SPEED TRAVEL...2480
PERMISSIBLE WATER DEPTH...2480
TRAVELING ON SLOPES...2481
TRAVELING DOWNHILL...2482
ENGINE STOPPED ON SLOPE...2482
PRECAUTIONS ON SLOPES...2482
ESCAPE FROM MUD...2483
STUCK ONE SIDE OF TRACK...2483
STUCK BOTH SIDES OF TRACKS...2483
RECOMMENDED APPLICATIONS...2484
BACKHOE WORK...2484
SHOVEL WORK...2484
DITCHING WORK...2484
LOADING WORK...2485
REPLACEMENT AND INVERSION OF BUCKET...2486
REPLACEMENT...2486
INVERSION...2488
PARKING MACHINE...2489
CHECK AFTER FINISHING WORK...2490
LOCKING...2491
TRANSPORTATION...2492
TRANSPORTATION PROCEDURE...2492
SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-7 AND PC230NHD-7...2492
LOADING AND UNLOADING WITH TRAILER...2493
LOADING...2494
SECURING MACHINE...2496
UNLOADING...2498
LIFTING MACHINE...2500
STANDARD SPECIFICATION MACHINE...2500
COLD WEATHER OPERATION...2502
COLD WEATHER OPERATION INFORMATION...2502
FUEL AND LUBRICANTS...2502
COOLING SYSTEM COOLANT...2502
BATTERY...2503
AFTER DAILY WORK COMPLETION...2504
AFTER COLD WEATHER SEASON...2505
LONG TERM STORAGE...2506
BEFORE STORAGE...2506
DURING STORAGE...2506
AFTER STORAGE...2507
STARTING MACHINE AFTER LONG-TERM STORAGE...2507
TROUBLESHOOTING...2508
AFTER RUNNING OUT OF FUEL...2508
PHENOMENA THAT ARE NOT FAILURES...2508
TOWING THE MACHINE...2509
LIGHTWEIGHT TOWING HOOK...2509
PRECAUTIONS ON PARTICULAR JOBSITES...2510
DISCHARGED BATTERY...2511
REMOVAL AND INSTALLATION OF BATTERY...2512
BATTERY CHARGES...2512
STARTING ENGINE WITH BOOSTER CABLES...2513
OTHER TROUBLE...2515
ELECTRICAL SYSTEM...2515
CHASSIS...2516
ENGINE...2517
ELECTRONIC CONTROL SYSTEM...2519
MAINTENANCE...2521
MAINTENANCE INFORMATION...2522
SERVICE METER READING...2522
KOMATSU GENUINE REPLACEMENT PARTS...2522
KOMATSU GENUINE LUBRICANTS...2522
WINDSHIELD WASHER FLUID...2522
FRESH AND CLEAN LUBRICANTS...2522
CHECK DRAINED OIL AND USED FILTER...2522
FUEL STRAINER...2522
WELDING INSTRUCTIONS...2522
DO NOT DROP THINGS INSIDE MACHINE...2523
DUSTY JOBSITE...2523
AVOID MIXING LUBRICANTS...2523
LOCKING THE INSPECTION COVERS...2523
HYDRAULIC SYSTEM - AIR BLEEDING...2523
HYDRAULIC HOSE INSTALLATION...2523
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...2524
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...2524
LUBRICANTS, COOLANT AND FILTERS...2525
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...2525
OIL...2525
FUEL...2525
COOLING SYSTEM COOLANT...2526
GREASE...2526
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...2526
OIL AND FUEL STORAGE...2527
FILTERS...2528
EXPLANATION OF LUBRICATION CHART DECAL...2529
ELECTRIC SYSTEM MAINTENANCE...2531
HANDLING HYDRAULIC SYSTEM...2531
WEAR PARTS LIST...2532
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2533
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...2533
TIGHTENING TORQUE SPECIFICATIONS...2536
TIGHTENING TORQUE LIST...2536
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2537
SAFETY CRITICAL PARTS...2537
MAINTENANCE SCHEDULE...2538
MAINTENANCE SCHEDULE CHART...2538
Initial 250 Hours Maintenance (Only after the first 250 hours)...2538
When Required...2538
Checks Before Starting...2538
Every 100 Hours Maintenance...2538
Every 250 Hours Maintenance...2538
Every 500 Hours Maintenance...2539
Every 1000 Hours Maintenance...2539
Every 2000 Hours Maintenance...2539
Every 4000 Hours Maintenance...2539
Every 5000 Hours Maintenance...2539
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...2540
MAINTENANCE PROCEDURE...2541
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...2541
WHEN REQUIRED...2542
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...2542
CLEAN INSIDE OF COOLING SYSTEM...2547
CHECK AND TIGHTEN TRACK SHOE BOLTS...2550
CHECK AND ADJUST TRACK TENSION...2551
CHECK ELECTRICAL INTAKE AIR HEATER...2553
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...2554
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...2557
ADJUST BUCKET CLEARANCE...2558
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...2559
CHECK AND ADJUST AIR CONDITIONER (IF EQUIPPED)...2560
WASHING WASHABLE FLOOR...2561
BLEEDING AIR FROM HYDRAULIC SYSTEM...2563
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...2565
CHECK BEFORE STARTING...2566
EVERY 100 HOURS MAINTENANCE...2566
LUBRICATING...2566
EVERY 250 HOURS MAINTENANCE...2568
LUBRICATING...2568
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...2569
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...2570
CHECK LEVEL OF BATTERY ELECTROLYTE...2571
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...2574
EVERY 500 HOURS MAINTENANCE...2575
LUBRICATING...2575
LUBRICATE SWING CIRCLE (2 POINTS)...2576
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...2577
REPLACE FUEL FILTER CARTRIDGE...2578
CHECK SWING PINION GREASE LEVEL, ADD GREASE...2579
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...2579
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...2580
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...2581
EVERY 1000 HOURS MAINTENANCE...2583
REPLACE HYDRAULIC FILTER ELEMENT...2583
CHANGE OIL IN SWING MACHINERY CASE...2584
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...2585
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...2585
CHECK PLAY OF TURBOCHARGER ROTOR...2585
CHECK FAN BELT TENSION AND REPLACE FAN BELT...2585
EVERY 2000 HOURS MAINTENANCE...2586
CHANGE OIL IN FINAL DRIVE CASE...2586
CLEAN HYDRAULIC TANK STRAINER...2587
CLEAN, CHECK TURBOCHARGER...2587
CHECK ALTERNATOR, STARTING MOTOR...2587
CHECK ENGINE VALVE CLEARANCE, ADJUST...2587
CHECK VIBRATION DAMPER...2587
EVERY 4000 HOURS MAINTENENCE...2588
CHECK WATER PUMP...2588
EVERY 5000 HOURS MAINTENANCE...2589
CHANGE OIL IN HYDRAULIC TANK...2589
SPECIFICATIONS...2591
SPECIFICATIONS...2592
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC210NLC-7K)...2595
PC210NLC-7K...2596
PC210-7K...2597
PC210LC-7K...2598
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC230NHD - 2 PIECE BOOM)...2599
PC210-7K, PC210LC-7K 2 PIECE BOOM...2600
PC210NLC-7K, PC230NHD-7K 2 PIECE BOOM...2601
EXPLANATION OF LIFTING CAPACITY CHART (PC230NHD-7K)...2602
PC230NHD-7K...2603
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC, PC240NLC-7K)...2604
PC240LC-7K...2605
PC240NLC-7K...2606
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-7K 2 PIECE BOOM)...2607
ATTACHMENTS AND OPTIONS...2611
GENERAL PRECAUTIONS...2612
PRECAUTIONS RELATED TO SAFETY...2612
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...2614
HANDLING BUCKET WITH HOOK...2615
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2615
PROHIBITED OPERATIONS...2615
PRECAUTIONS DURING OPERATIONS...2615
MACHINES READY FOR ATTACHMENTS...2616
EXPLANATION OF COMPONENTS...2616
STOP VALVE...2616
SELECTOR VALVE...2617
ATTACHMENT CONTROL PEDAL...2617
LOCK PIN...2617
ADDITIONAL FILTER FOR BREAKER...2618
ACCUMULATOR...2618
HYDRAULIC CIRCUIT...2619
SWITCHING HYDRAULIC CIRCUIT...2619
ADJUSTING OIL FLOW...2619
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT...2619
HYDRAULIC CIRCUIT CONNECTION...2620
PATH OF OIL...2620
REPLACE ADDITIONAL BREAKER FILTER ELEMENT...2621
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...2622
OPERATION...2624
LONG-TERM STORAGE...2626
SPECIFICATIONS...2626
ATTACHMENT GUIDE...2627
COMBINATIONS OF WORK EQUIPMENT...2627
SELECTION OF TRACK SHOES...2630
METHOD OF SELECTING SHOES...2630
SELECTION OF BUCKET TEETH...2631
METHOD OF SELECTING TEETH...2631
Use of vertical pin teeth...2631
Use of horizontal pin teeth...2631
Use of long-life teeth...2631
Self-sharpening teeth (both vertical pin type and horizontal pin type)...2631
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH...2631
HANDLING OF RUBBER PAD SHOE AND ROAD LINER...2632
WORKING ENVIRONMENT...2632
WORKING CONDITIONS...2632
STORAGE AND MAINTENANCE...2633
EXTENT OF DAMAGE TO RUBBER...2633
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)...2633
HANDLING TRAPEZOIDAL BUCKET...2634
HOW TO PERFORM EXCAVATION...2634
HANDLING EXTENSION ARM...2635
HANDLING CLAMSHELL BUCKET...2636
PRECAUTIONS WHEN USING...2636
LUBRICATING...2636
RECOMMENDED ATTACHMENT OPERATIONS...2637
HYDRAULIC BREAKER...2637
MAIN APPLICATIONS...2637
PROHIBITED WORKS...2639
GREASING POSITION FOR HYDRAULIC BREAKER...2641
2-PC BOOM...2642
FEATURES OF 2-PIECE BOOM &ARM...2642
OPERATION...2643
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...2644
TESTING AND ADJUSTING...2645
PERODIC MAINTENANCE...2645
TRANSPORTATION...2646
STRAIGHT BOOM PC210/240-7K...2649
OPERATION...2649
GENERAL VIEW OF MACHINE...2649
CAUTION ITEMS...2650
CONTROL PEDALS (AUXILIARY HYDRAULIC CIRCUITS)...2650
CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING...2651
CRUSHER CONTROL PEDAL FOR ROTATION...2652
WORKING RANGE (PC 210 STRAIGHT BOOM)...2653
TRANSPORTATION (PC 210 Straight Boom equipment)...2654
WORKING RANGE (PC 240 STRAIGHT BOOM)...2655
TRANSPORTATION (PC 240 Straight Boom equipment)...2656
SUPER LONG FRONT BOOM AND ARM PC210/240-7...2657
OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM...2658
WORKING MODES...2659
CHECKS BEFORE STARTING...2660
USING SUPER LONG FRONT...2661
METHOD OF WORK...2662
WHEN TRAVELLING...2662
CONTROL LEVERS, PEDALS...2663
TRANSPORT &STORAGE OF SUPER LONG FRONT MACHINE...2666
INSTALLATION OF SUPPORTING LINK...2666
TRANSPORTATION OF SUPER LONG FRONT MACHINE...2667
WORKING RANGE OF SUPER LONG FRONT...2668
LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT...2669
LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT...2670
LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT...2671
LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT...2672
MAINTENANCE...2673
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT...2673
EVERY 50 HOURS SERVICE...2674
LUBRICATING...2674
EVERY 100 HOURS SERVICE...2675
LUBRICATING...2675
UEAM003900 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC230NHD-7K, PC240LC-7K, PC240NLC-7K Operation &Maintenance Manual...2680
FOREWORD...2682
FOREWORD...2683
SAFETY INFORMATION...2684
NOISE (PC210,210LC,210NLC, PC230NHD)...2686
VIBRATION...2686
NOISE (PC240LC,240NLC)...2687
VIBRATION...2687
INTRODUCTION...2688
DIRECTIONS OF MACHINE...2688
BREAKING-IN THE NEW MACHINE...2688
PRODUCT INFORMATION...2689
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...2689
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...2689
SERVICE METER LOCATION...2690
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...2690
MACHINE SERIAL PLATE...2691
SAFETY...2698
SAFETY INFORMATION...2699
POSITION FOR ATTACHING SAFETY LABELS...2701
POSITION FOR ATTACHING SAFETY LABELS...2701
SAFETY LABELS...2702
SAFETY INFORMATION...2709
SAFETY RULES...2709
IF ABNORMALITIES ARE FOUND...2709
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...2709
FIRE EXTINGUISHER AND FIRST AID KIT...2709
SAFETY EQUIPMENT...2710
KEEP MACHINE CLEAN...2710
KEEP OPERATOR'S COMPARTMENT CLEAN...2710
LEAVING OPERATOR'S SEAT WITH LOCK...2710
HANDRAILS AND STEPS...2711
MOUNTING AND DISMOUNTING...2712
NO PERSONS ON ATTACHMENTS...2712
BURN PREVENTION...2712
FIRE PREVENTION AND EXPLOSION PREVENTION...2713
ACTION IF FIRE OCCURS...2714
WINDSHIELD WASHER FLUID...2714
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...2714
ATTACHMENT INSTALLATION...2714
ATTACHMENT COMBINATIONS...2715
CAB WINDOW GLASSES...2715
UNAUTHORIZED MODIFICATIONS...2715
SAFETY AT JOBSITE...2715
WORKING ON LOOSE GROUND...2715
DISTANCE TO HIGH VOLTAGE CABLES...2716
ENSURE GOOD VISIBILITY...2716
VENTILATION FOR ENCLOSED AREA...2717
SIGNALMAN'S SIGNAL AND SIGNS...2717
EMERGENCY EXIT FROM OPERATOR'S CAB...2717
ELECTROMAGNETIC INTERFERENCE...2717
ASBESTOS DUST HAZARD PREVENTION...2718
SAFETY MACHINE OPERATION...2719
STARTING ENGINE...2719
CHECKS BEFORE STARTING ENGINE...2719
SAFETY RULES FOR STARTING ENGINE...2720
STARTING ENGINE IN COLD WEATHER...2720
OPERATION...2721
CHECKS AFTER STARTING ENGINE...2721
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...2721
SAFETY RULES FOR TRAVELLING...2722
TRAVELLING ON SLOPES...2723
OPERATIONS ON SLOPES...2724
PROHIBITED OPERATIONS...2724
OPERATIONS ON SNOW...2726
PARKING MACHINE...2726
TRANSPORTATION...2727
SHIPPING THE MACHINE...2727
BATTERY...2728
BATTERY HAZARD PREVENTION...2728
STARTING ENGINE WITH BOOSTER CABLES...2729
TOWING...2730
SAFETY RULES FOR TOWING...2730
LIFTING OBJECTS WITH BUCKET...2731
SAFETY RULES FOR LIFTING OBJECTS...2731
SAFETY MAINTENANCE INFORMATION...2732
WARNING TAG...2732
KEEP WORK PLACE CLEAN AND TIDY...2732
APPOINT LEADER WHEN WORKING WITH OTHERS...2732
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...2733
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...2734
PROPER TOOLS...2734
ACCUMULATOR...2735
PERSONNEL...2735
ATTACHMENTS...2735
WORK UNDER THE MACHINE...2735
NOISE...2736
WHEN USING HAMMER...2736
WELDING WORKS...2736
REMOVING BATTERY TERMINALS...2736
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...2737
DO NOT DISASSEMBLE RECOIL SPRINGS...2737
SAFETY RULES FOR HIGH-PRESSURE OIL...2737
SAFETY HANDLING HIGH-PRESSURE HOSES...2738
WASTE MATERIALS...2738
AIR CONDITIONER MAINTENANCE...2738
COMPRESSED AIR...2738
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2739
OPERATION...2740
GENERAL VIEW...2741
GENERAL VIEW OF MACHINE...2741
GENERAL VIEW CONTROLS AND GAUGES...2742
EXPLANATION OF COMPONENTS...2743
MACHINE MONITOR...2743
BASIC OPERATION OF MACHINE MONITOR...2744
BASIC CHECK ITEMS...2746
CAUTION ITEMS...2748
EMERGENCY STOP ITEMS...2751
METER DISPLAY PORTION...2753
MONITOR SWITCHES...2757
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)...2758
AUTO-DECELERATION SWITCH...2759
TRAVEL SPEED SELECTOR SWITCH...2760
WIPER SWITCH...2761
WINDOW WASHER SWITCH...2761
MAINTENANCE SWITCH...2762
SELECT SWITCH...2764
BACK SWITCH...2765
UP SWITCH, DOWN SWITCH...2765
INPUT CONFIRMATION SWITCH...2765
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH...2766
SWITCHES...2768
STARTING SWITCH...2768
FUEL CONTROL DIAL...2769
CIGARETTE LIGHTER...2769
SWING LOCK SWITCH...2770
LAMP SWITCH...2770
ALARM BUZZER STOP SWITCH...2770
HORN SWITCH...2771
KNOB SWITCH...2771
ROOM LAMP SWITCH...2771
EMERGENCY PUMP DRIVE SWITCH...2772
SWING BRAKE CANCEL SWITCH...2772
EMERGENCY FUEL SOLENOID DRIVE SWITCH...2772
LOWER WIPER SWITCH...2773
REVOLVING WARNING LAMP SWITCH...2773
HEATED OPERATOR SEAT SWITCH...2773
CONTROL LEVERS, PEDALS...2774
SAFETY LOCK LEVER...2774
TRAVEL LEVERS...2775
WORK EQUIPMENT CONTROL LEVER...2776
CEILING WINDOW...2777
FRONT WINDOW...2778
EMERGENCY EXIT FROM OPERATOR'S CAB...2783
DOOR LOCK...2783
CAP, COVER WITH LOCK...2784
METHOD OF OPENING AND CLOSING CAP WITH LOCK...2784
METHOD OF OPENING AND CLOSING COVER WITH LOCK...2784
HOT AND COOL BOX...2785
CAB RADIO...2785
MAGAZINE BOX...2785
ASHTRAY...2786
HANDLING AIR CONDITIONER...2787
GENERAL LOCATIONS OF CONTROL PANEL...2787
METHOD OF OPERATION...2792
PRECAUTIONS WHEN USING AIR CONDITIONER...2799
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...2799
OTHER FUNCTIONS...2800
CAR RADIO...2801
FUSE...2802
FUSE CAPACITIES AND CIRCUIT NAMES...2803
FUSIBLE LINK...2803
CONTROLLER (COMPUTER)...2804
TOOLBOX...2804
GREASE GUN HOLDER...2804
REFUELLING PUMP...2805
HANDLING THE ACCUMULATOR...2805
RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR...2806
MACHINE OPERATIONS AND CONTROLS...2807
BEFORE STARTING ENGINE...2807
WALK-AROUND CHECKS...2807
CHECKS BEFORE STARTING...2808
ADJUST BEFORE OPERATION...2813
SEAT BELT...2816
OPERATIONS BEFORE STARTING ENGINE...2817
STARTING ENGINE...2820
NORMAL STARTING...2820
STARTING ENGINE IN COLD WEATHER...2821
AFTER STARTING ENGINE...2824
BREAKING-IN THE NEW MACHINE...2824
WARMING-UP OPERATION...2825
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)...2828
STOPPING THE ENGINE...2832
CHECK AFTER SHUTTING OFF ENGINE...2832
MACHINE OPERATION...2833
PREPARATIONS FOR MOVING THE MACHINE OFF...2833
MOVING MACHINE FORWARD...2834
MOVING MACHINE BACKWARD...2835
STOPPING MACHINE...2836
STEERING THE MACHINE...2837
Steering...2837
SWINGING...2839
WORK EQUIPMENT CONTROLS AND OPERATIONS...2840
OPERATING WORKING MODE...2841
PROHIBITED OPERATIONS...2842
OPERATIONS USING SWING FORCE...2842
OPERATIONS USING TRAVEL FORCE...2842
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS...2842
OPERATIONS USING BUCKET DROPPING FORCE...2843
OPERATIONS USING MACHINE DROPPING FORCE...2843
DIGGING HARD ROCKY GROUND...2843
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...2843
GENERAL OPERATION INFORMATION...2844
TRAVELING...2844
HIGH SPEED TRAVEL...2844
PERMISSIBLE WATER DEPTH...2844
TRAVELING ON SLOPES...2845
TRAVELING DOWNHILL...2846
ENGINE STOPPED ON SLOPE...2846
PRECAUTIONS ON SLOPES...2846
ESCAPE FROM MUD...2847
STUCK ONE SIDE OF TRACK...2847
STUCK BOTH SIDES OF TRACKS...2847
RECOMMENDED APPLICATIONS...2848
BACKHOE WORK...2848
SHOVEL WORK...2848
DITCHING WORK...2848
LOADING WORK...2849
REPLACEMENT AND INVERSION OF BUCKET...2850
REPLACEMENT...2850
INVERSION...2852
PARKING MACHINE...2853
CHECK AFTER FINISHING WORK...2854
LOCKING...2855
TRANSPORTATION...2856
TRANSPORTATION PROCEDURE...2856
SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-7 AND PC230NHD-7...2856
LOADING AND UNLOADING WITH TRAILER...2857
LOADING...2858
SECURING MACHINE...2860
UNLOADING...2862
LIFTING MACHINE...2864
STANDARD SPECIFICATION MACHINE...2864
COLD WEATHER OPERATION...2866
COLD WEATHER OPERATION INFORMATION...2866
FUEL AND LUBRICANTS...2866
COOLING SYSTEM COOLANT...2866
BATTERY...2867
AFTER DAILY WORK COMPLETION...2868
AFTER COLD WEATHER SEASON...2869
LONG TERM STORAGE...2870
BEFORE STORAGE...2870
DURING STORAGE...2870
AFTER STORAGE...2871
STARTING MACHINE AFTER LONG-TERM STORAGE...2871
TROUBLESHOOTING...2872
AFTER RUNNING OUT OF FUEL...2872
PHENOMENA THAT ARE NOT FAILURES...2872
TOWING THE MACHINE...2873
LIGHTWEIGHT TOWING HOOK...2873
PRECAUTIONS ON PARTICULAR JOBSITES...2874
DISCHARGED BATTERY...2875
REMOVAL AND INSTALLATION OF BATTERY...2876
BATTERY CHARGES...2876
STARTING ENGINE WITH BOOSTER CABLES...2877
OTHER TROUBLE...2879
ELECTRICAL SYSTEM...2879
CHASSIS...2880
ENGINE...2881
ELECTRONIC CONTROL SYSTEM...2883
MAINTENANCE...2886
MAINTENANCE INFORMATION...2887
SERVICE METER READING...2887
KOMATSU GENUINE REPLACEMENT PARTS...2887
KOMATSU GENUINE LUBRICANTS...2887
WINDSHIELD WASHER FLUID...2887
FRESH AND CLEAN LUBRICANTS...2887
CHECK DRAINED OIL AND USED FILTER...2887
FUEL STRAINER...2887
WELDING INSTRUCTIONS...2887
DO NOT DROP THINGS INSIDE MACHINE...2888
DUSTY JOBSITE...2888
AVOID MIXING LUBRICANTS...2888
LOCKING THE INSPECTION COVERS...2888
HYDRAULIC SYSTEM - AIR BLEEDING...2888
HYDRAULIC HOSE INSTALLATION...2888
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...2889
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...2889
LUBRICANTS, COOLANT AND FILTERS...2890
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...2890
OIL...2890
FUEL...2890
COOLING SYSTEM COOLANT...2891
GREASE...2891
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...2891
OIL AND FUEL STORAGE...2892
FILTERS...2893
EXPLANATION OF LUBRICATION CHART DECAL...2894
ELECTRIC SYSTEM MAINTENANCE...2896
HANDLING HYDRAULIC SYSTEM...2896
WEAR PARTS LIST...2897
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2898
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...2898
TIGHTENING TORQUE SPECIFICATIONS...2901
TIGHTENING TORQUE LIST...2901
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2902
SAFETY CRITICAL PARTS...2902
MAINTENANCE SCHEDULE...2903
MAINTENANCE SCHEDULE CHART...2903
Initial 250 Hours Maintenance (Only after the first 250 hours)...2903
When Required...2903
Checks Before Starting...2903
Every 100 Hours Maintenance...2903
Every 250 Hours Maintenance...2903
Every 500 Hours Maintenance...2904
Every 1000 Hours Maintenance...2904
Every 2000 Hours Maintenance...2904
Every 4000 Hours Maintenance...2904
Every 5000 Hours Maintenance...2904
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...2905
MAINTENANCE PROCEDURE...2906
EVERY 10 HOURS MAINTENANCE (FOR THE FIRST 50 HOURS)...2906
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...2906
WHEN REQUIRED...2907
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...2907
CLEAN INSIDE OF COOLING SYSTEM...2912
CHECK AND TIGHTEN TRACK SHOE BOLTS...2915
CHECK AND ADJUST TRACK TENSION...2916
CHECK ELECTRICAL INTAKE AIR HEATER...2918
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...2919
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...2922
ADJUST BUCKET CLEARANCE...2923
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...2924
CHECK AND ADJUST AIR CONDITIONER (IF EQUIPPED)...2925
WASHING WASHABLE FLOOR...2926
BLEEDING AIR FROM HYDRAULIC SYSTEM...2928
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...2930
CHECK BEFORE STARTING...2931
EVERY 100 HOURS MAINTENANCE...2931
LUBRICATING...2931
EVERY 250 HOURS MAINTENANCE...2933
LUBRICATING...2933
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...2934
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...2935
CHECK LEVEL OF BATTERY ELECTROLYTE...2936
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...2939
EVERY 500 HOURS MAINTENANCE...2940
LUBRICATING...2940
LUBRICATE SWING CIRCLE (2 POINTS)...2941
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...2942
REPLACE FUEL FILTER CARTRIDGE...2943
CHECK SWING PINION GREASE LEVEL, ADD GREASE...2944
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...2944
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...2945
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...2946
EVERY 1000 HOURS MAINTENANCE...2948
REPLACE HYDRAULIC FILTER ELEMENT...2948
CHANGE OIL IN SWING MACHINERY CASE...2949
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...2950
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...2950
CHECK PLAY OF TURBOCHARGER ROTOR...2950
CHECK FAN BELT TENSION AND REPLACE FAN BELT...2950
EVERY 2000 HOURS MAINTENANCE...2951
CHANGE OIL IN FINAL DRIVE CASE...2951
CLEAN HYDRAULIC TANK STRAINER...2952
CLEAN, CHECK TURBOCHARGER...2952
CHECK ALTERNATOR, STARTING MOTOR...2952
CHECK ENGINE VALVE CLEARANCE, ADJUST...2952
CHECK VIBRATION DAMPER...2952
EVERY 4000 HOURS MAINTENENCE...2953
CHECK WATER PUMP...2953
EVERY 5000 HOURS MAINTENANCE...2954
CHANGE OIL IN HYDRAULIC TANK...2954
SPECIFICATIONS...2956
SPECIFICATIONS...2957
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC210NLC-7K)...2960
PC210NLC-7K...2961
PC210-7K...2962
PC210LC-7K...2963
EXPLANATION OF LIFTING CAPACITY CHART (PC210, PC210LC, PC230NHD - 2 PIECE BOOM)...2964
PC210-7K, PC210LC-7K 2 PIECE BOOM...2965
PC210NLC-7K, PC230NHD-7K 2 PIECE BOOM...2966
EXPLANATION OF LIFTING CAPACITY CHART (PC230NHD-7K)...2967
PC230NHD-7K...2968
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC, PC240NLC-7K)...2969
PC240LC-7K...2970
PC240NLC-7K...2971
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-7K 2 PIECE BOOM)...2972
ATTACHMENTS AND OPTIONS...2976
GENERAL PRECAUTIONS...2977
PRECAUTIONS RELATED TO SAFETY...2977
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...2979
HANDLING BUCKET WITH HOOK...2980
CHECKING FOR DAMAGE TO BUCKET WITH HOOK...2980
PROHIBITED OPERATIONS...2980
PRECAUTIONS DURING OPERATIONS...2980
MACHINES READY FOR ATTACHMENTS...2981
EXPLANATION OF COMPONENTS...2981
STOP VALVE...2981
SELECTOR VALVE...2982
ATTACHMENT CONTROL PEDAL...2982
LOCK PIN...2982
ADDITIONAL FILTER FOR BREAKER...2983
ACCUMULATOR...2983
HYDRAULIC CIRCUIT...2984
SWITCHING HYDRAULIC CIRCUIT...2984
ADJUSTING OIL FLOW...2984
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT...2984
HYDRAULIC CIRCUIT CONNECTION...2985
PATH OF OIL...2985
REPLACE ADDITIONAL BREAKER FILTER ELEMENT...2986
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE...2987
OPERATION...2989
LONG-TERM STORAGE...2991
SPECIFICATIONS...2991
ATTACHMENT GUIDE...2992
COMBINATIONS OF WORK EQUIPMENT...2992
SELECTION OF TRACK SHOES...2995
METHOD OF SELECTING SHOES...2995
SELECTION OF BUCKET TEETH...2996
METHOD OF SELECTING TEETH...2996
Use of vertical pin teeth...2996
Use of horizontal pin teeth...2996
Use of long-life teeth...2996
Self-sharpening teeth (both vertical pin type and horizontal pin type)...2996
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH...2996
HANDLING OF RUBBER PAD SHOE AND ROAD LINER...2997
WORKING ENVIRONMENT...2997
WORKING CONDITIONS...2997
STORAGE AND MAINTENANCE...2998
EXTENT OF DAMAGE TO RUBBER...2998
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)...2998
HANDLING TRAPEZOIDAL BUCKET...2999
HOW TO PERFORM EXCAVATION...2999
HANDLING EXTENSION ARM...3000
HANDLING CLAMSHELL BUCKET...3001
PRECAUTIONS WHEN USING...3001
LUBRICATING...3001
RECOMMENDED ATTACHMENT OPERATIONS...3002
HYDRAULIC BREAKER...3002
MAIN APPLICATIONS...3002
PROHIBITED WORKS...3004
GREASING POSITION FOR HYDRAULIC BREAKER...3006
2-PC BOOM...3007
FEATURES OF 2-PIECE BOOM &ARM...3007
OPERATION...3008
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...3009
TESTING AND ADJUSTING...3010
PERODIC MAINTENANCE...3010
TRANSPORTATION...3011
STRAIGHT BOOM PC210/240-7K...3014
OPERATION...3014
GENERAL VIEW OF MACHINE...3014
CAUTION ITEMS...3015
CONTROL PEDALS (AUXILIARY HYDRAULIC CIRCUITS)...3015
CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING...3016
CRUSHER CONTROL PEDAL FOR ROTATION...3017
WORKING RANGE (PC 210 STRAIGHT BOOM)...3018
TRANSPORTATION (PC 210 Straight Boom equipment)...3019
WORKING RANGE (PC 240 STRAIGHT BOOM)...3020
TRANSPORTATION (PC 240 Straight Boom equipment)...3021
SUPER LONG FRONT BOOM AND ARM PC210/240-7...3022
OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM...3023
WORKING MODES...3024
CHECKS BEFORE STARTING...3025
USING SUPER LONG FRONT...3026
METHOD OF WORK...3027
WHEN TRAVELLING...3027
CONTROL LEVERS, PEDALS...3028
TRANSPORT &STORAGE OF SUPER LONG FRONT MACHINE...3031
INSTALLATION OF SUPPORTING LINK...3031
TRANSPORTATION OF SUPER LONG FRONT MACHINE...3032
WORKING RANGE OF SUPER LONG FRONT...3033
LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT...3034
LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT...3035
LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT...3036
LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT...3037
MAINTENANCE...3038
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT...3038
EVERY 50 HOURS SERVICE...3039
LUBRICATING...3039
EVERY 100 HOURS SERVICE...3040
LUBRICATING...3040
UEBM001701 - Hydraulic Excavator PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Shop Manual...3046
PC200-7_Sec01.pdf...0
PC240LC-7K, PC240NLC-7K...3055
DIMENSIONS...3055
WORKING RANGES...3055
DIMENSIONS...3056
Working ranges...3056
PC240LC-7K, PC240NLC-7K...3059
SPECIFICATION DIMENSION DRAWINGS...3053
PC210-7K, PC210LC-7K, PC210NLC-7K...3053
DIMENSIONS...3053
WORKING RANGES...3053
DIMENSIONS...3054
Working ranges...3054
SPECIFICATIONS...3057
PC210-7K, PC210LC-7K, PC210NLC-7K...3057
WEIGHT TABLE...3061
pc210-7K, pc210lc-7K, PC210NLC-7K...3061
pc240LC-7K, pc240Nlc-7K...3063
FUEL, COOLANT, AND LUBRICANTs...3065
PC200-7_Sec10.pdf...0
ENGINE RELATED PARTS...3067
RADIATOR • OIL COOLER • AFTERCOOLER...3068
POWER TRAIN...3069
This page left intentionally blank...3070
FINAL DRIVE...3071
SWING MACHINERY...3073
PC210-7K, PC210LC-7K, PC210NLC-7K...3073
SWING CIRCLE...3077
PC210-7K, PC210LC-7K, PC210NLC-7K...3077
PC240LC-7K, PC240NLC-7K...3078
TRACK FRAME • RECOIL SPRING...3079
IDLER...3081
CARRIER ROLLER...3083
TRACK ROLLER...3084
TRACK SHOE...3085
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE...3085
TRIPLE GROUSER SHOE...3088
SWAMP SHOE...3088
hydraulic equipment layout drawing...3089
HYDRAULIC TANK...3091
This page left intentionally blank...3092
HYDRAULIC PUMP...3093
HPV95 + 95(PC210/LC/NLC-7K)...3093
HPV95 + 95(PC240LC/NLC-7K)...3095
LS VALVE...3100
PC VALVE...3100
LS(pc)-EPC VALVE...3113
This page left intentionally blank...3116
CONTROL VALVE...3117
pc210-7K, pc210lc-7K, PC210NLC-7K...3118
This page left intentionally blank...3127
CONTROL VALVE...3133
pc240LC-7K, pc240Nlc-7K...3133
This page left intentionally blank...3142
MAIN RELIEF VALVE (PC210/LC/NLC-7K)...3152
Function...3152
MAIN RELIEF VALVE (PC240LC/NLC-7K)...3153
Variable pressure compensation valve...3154
CLSS...3156
OUTLINE OF CLSS...3156
SWING MOTOR...3157
REVERSE PREVENTION VALVE...3162
CENTER SWIVEL JOINT...3164
TRAVEL MOTOR...3165
TRAVEL JUNCTION VALVE...3175
TRAVEL PPC SHUTTLE VALVE...3177
VALVE CONTROL...3179
WORK EQUIPMENT • SWING PPC VALVE...3181
TRAVEL PPC VALVE...3185
SERVICE PPC VALVE...3194
SOLENOID VALVE...3197
PPC ACCUMULATOR...3199
return oil filter...3200
For Breaker...3200
BOOM HYDRAULIC DRIFT PREVENTION VALVE...3201
LIFT CHECK VALVE...3206
attachment circuit selector valve...3207
HYDRAULIC CYLINDER...3209
pc210-7K, pc210lc-7K, PC210NLC-7K...3209
BOOM CYLINDER...3209
ARM CYLINDER...3209
BUCKET CYLINDER...3209
pc240LC-7K, pc240Nlc-7K...3211
BOOM CYLINDER...3211
ARM CYLINDER...3211
BUCKET CYLINDER...3211
work equipment...3213
Pc210-7K, pc210lc-7K, PC210NLC-7K...3214
Pc240LC-7K, pc240Nlc-7K...3215
This page left intentionally blank...3216
1. DIMENSION OF ARM...3217
2. Dimension of bucket...3221
air conditioner...3223
air conditioner piping...3223
ENGINE CONTROL...3224
Governor motor...3228
This page left intentionally blank...3229
Engine throttle and pump controller...3230
This page left intentionally blank...3232
ELECTRONIC CONTROL SYSTEM...3233
This page left intentionally blank...3234
machine control system diagram...3235
This page left intentionally blank...3258
mULTI MONITOR SYSTEM...3259
SENSOR...3282
PC240LC-7K, PC240NLC-7K...3075
SELF PRESSURE REDUCING VALVE...3148
20-001.pdf...0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...3287
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...3288
Flow control characteristic of PC valve (STD)...3301
20_101.pdf...0
INSPECTION AND ADJUSTMENT OF ENGINE RPM...3303
MEASUREMENT OF EXHAUST GAS COLOR...3305
ADJUSTMENT OF VALVE CLEARANCE...3306
MEASUREMENT OF COMPRESSION PRESSURE...3308
MEASUREMENT OF BLOW-BY PRESSURE...3309
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...3310
MEASUREMENT OF ENGINE OIL PRESSURE...3312
ADJUSTMENT OF ENGINE SPEED SENSOR...3313
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION...3313
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM...3314
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...3315
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...3316
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWIN...3317
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE...3321
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC240LC/NLC)...3322
iNSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC210/LC/NLC)...3325
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc240lc/nlc)...3328
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc210/lc/nlc)...3332
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE...3336
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE...3339
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE...3340
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT...3341
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT...3342
MEASUREMENT OF OIL LEAKAGE AMOUNT...3343
AIR BLEEDING OF VARIOUS PARTS...3345
INSPECTION PROCEDURES FOR DIODE...3347
SPECIAL FUNCTION OF MULTI-MONITOR PANEL...3348
Operation of Operator's Menu and Display (Outline)...3350
Table for Service and Failure Code Nos...3355
Operation and Display of Service Menu...3357
Table for Monitoring Items...3360
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM...3372
20_201.pdf...0
POINTS TO REMEMBER WHEN TROUBLESHOOTING...3385
SEQUENCE OF EVENTS IN TROUBLESHOOTING...3386
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...3387
CHECKS BEFORE TROUBLESHOOTING...3395
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...3396
Classification of troubleshooting...3396
Steps for troubleshooting...3396
Failure-looking Phenomenon and Troubleshooting No...3397
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...3401
Connector table...3401
CONNECTOR LOCATION STEREOGRAM...3407
Monitor Panel System Circuit Diagram (M Circuit)...3413
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller...3415
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller...3417
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...3419
20_301.pdf...0
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...3440
Service Code in Electrical System (Abnormal data in Error History)...3436
Service Code in Electrical System (Short-circuiting in normal rotation system of windshield wiper...3449
Service Code in Electrical System (Short-circuiting in reverse rotation system of windshield wipe...3451
Service Code in Electrical System (Short-circuiting in window washer drive system)...3453
Service Code in Electrical System (Abnormal Windshield Wiper Motion)...3455
Service Code in Electrical System (Abnormality in retracting windshield wiper)...3457
Service Code in Electrical System (Short-circuiting in travel interlocking solenoid)...3355
Service Code in Electrical System (Short-circuiting in swing and parking brake solenoid - in gove...3461
Service Code in Electrical System (Short-circuiting in merge/divide solenoid)...3463
Service Code in Electrical System (Short-circuiting in 2-stage relief solenoid)...3465
Service Code in Electrical System (Short-circuiting in travel speed shifting solenoid)...3467
Service Code in Electrical System (Disconnection in travel interlocking solenoid)...3469
Service Code in Electrical System (Disconnection in Swing Parking Brake Solenoid)...3471
Service Code in Electrical System (Disconnection of merge/divide solenoid)...3473
Service Code in Electrical System (Disconnection in 2-stage relief solenoid)...3475
Service Code in Electrical System (Disconnection in travel speed shifting solenoid)...3477
Service Code in Electrical System (Abnormality in inputting model code)...3433
Service Code in Electrical System Disconnection of S-NET signal)...3370
Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)...3485
Service Code in Electrical System (Disconnection in LS-EPC solenoid system)...3307
Service Code in Electrical System (Abnormality in F pump pressure sensor)...3487
Service Code in Electrical System (Abnormality in R pump pressure sensor)...3489
Service Code in Electrical System (Abnormality in Pressure sensor power source)...3491
Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump contr...3493
Service Code in Electrical System (Short-circuiting in attachment return switching relay)...3494
Service Code in Electrical System (Short-circuiting in PC-EPC Solenoid...3495
Service Code in Electrical System (Disconnection in PC-EPC solenoid system)...3497
Service Code in Electrical System (Disconnection in attachment return switching relay)...3499
Service Code in Electrical Equipment (Short-circuiting in attachment oil flow rate adjusting EPC)...3501
Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC) (Mult...3502
Service Code in Electrical System (Incorrect nonvolatile memory data)...3503
Service Code in Electrical System (Abnormality in governor potentiometer)...3505
Service Code in Electrical System (Abnormality in fuel dial)...3507
Service Code in Electrical System (Short-circuiting in battery relay)...3509
Service Code in Electrical System (Step-out in governor motor)...3511
Service Code in Electrical System (Disconnection in governor motor Phase A and B)...3513
Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B)...3406
Service Code in Electrical System ("Model Selection" function not provided yet)...3517
Service Mode in Electrical System (Model selecting signal fault)...3518
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling)...3402
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)...3403
Failure Code in Mechanical System (Air cleaner clogging)...3520
Failure Code in Mechanical System (Abnormally lowered charging voltage)...3521
Failure Code in Mechanical System (Abnormally lowered engine oil pressure)...3523
Failure Code in Mechanical System (Abnormally lowered engine oil level)...3524
Failure Code in Mechanical System (Engine cooling water overheating)...3525
Failure Code in Mechanical System (Abnormally lowered radiator water level)...3526
Failure Code in Mechanical System (Hydraulic oil overheating)...3527
20_501.pdf...0
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...3453
Relative Electrical Circuit Diagram...3529
E-1 Engine does not start (Engine does not rotate)...3530
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging...3532
E-2 Engine stops while in operation...3355
Electrical Circuit Diagram for Fuel Dial...3533
E-3 Engine speed is irregular, or there is hunting...3534
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging...3357
E-4 Engine does not stop...3536
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging...3537
E-5 Auto-decelerator does not work...3538
E-6 Auto engine warm-up device does not work...3539
E-7 Preheater does not work...3540
Electrical Circuit Diagram for Engine Preheater...3541
E-8 All work equipment, swing and travel do not move...3542
Electrical Circuit Diagram for PPC Lock Solenoid...3543
E-9 One-touch Power Max Switch does not work...3544
Electric Circuit Diagram for One-Touch Power Max. Switch...3544
E-10 No display in monitor panel at all...3545
Electrical Circuit Diagram for Power Source in Monitor Panel...3545
E-11 Part of display on monitor panel is missing...3546
E-12 Monitor panel displays contents irrelevant to the model...3485
E-13 Fuel level monitor red lamp lights up while engine is running...3547
Electrical Circuit Diagram for Fuel Level Sensor...3547
E-14 Engine cooling water temperature gauge does not indicate correctly...3548
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor...3548
E-15 Hydraulic oil temperature gauge does not display correctly...3549
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor...3549
E-16 Fuel gauge does not display correctly...3550
Electrical Circuit Diagram for Fuel Level Sensor...3550
E-17 Swing lock monitor does not display correctly...3551
Electrical Circuit Diagram for Swing Lock Switch...3317
E-18 When the monitor switch is operated, no display appears...3553
E-19 Windshield wiper does not work...3554
Electrical Circuit Diagram for Windshield Wiper Motor...3555
E-20 Alarming buzzer cannot be cancelled...3556
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch...3556
E-21 "Boom RAISE" is not correctly displayed in monitor function...3557
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch...3351
E-22 "Boom LOWER" is not correctly displayed in monitor function...3558
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch...3558
E-23 "Arm DIGGING" is not correctly displayed in monitor function...3559
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch...3559
E-24 "Arm DUMPING" is not correctly displayed in monitor function...3560
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch...3560
E-25 "Bucket DIGGING" is not correctly displayed in monitor function...3561
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch...3561
E-26 "Bucket DUMPING" is not correctly displayed in monitor function...3562
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch...3398
E-27 "SWING" is not correctly displayed in monitor function...3563
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches...3564
E-28 "TRAVEL" is not correctly displayed in monitor function...3565
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm...3566
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function...3567
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch...3568
E-30 "Service" is not correctly displayed in monitor function...3569
Electrical Circuit Diagram for Service PPC hydraulic Switch...3570
E-31 Air Conditioner does not work...3571
Electrical Circuit Diagram for Air Conditioner...3571
E-32 Travel alarm does not sound...3572
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm...3573
20_601.pdf...0
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...3575
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...3577
H-1 All work equipment lack power, or travel and swing speeds are slow...3578
H-2 Engine speed sharply drops or engine stalls...3579
H-3 No work equipment, travel or swing move...3580
H-4 Abnormal noise is heard from around hydraulic pump...3580
H-5 Auto-decelerator does not work...3581
H-6 Fine control mode does not function...3581
H-7 Boom moves slowly or lacks power...3582
H-8 Arm moves slowly or lacks power...3583
H-9 Bucket moves slowly or lacks power...3584
H-10 Work equipment does not move in its single operation...3584
H-11 Work equipment has a bit too fast hydraulic drift...3585
H-12 Work equipment has big time lag...3586
H-13 Other work equipment moves when relieving single circuit...3586
H-14 One-touch power max. switch does not operate...3530
H-15 In compound operation, work equipment with larger load moves slowly...3587
H-16 In swing + boom RAISE operation, boom moves slowly...3587
H-17 In swing + travel, travel speed drops sharply...3587
H-18 Machine swerves in travel...3588
H-19 Machine travels slowly...3589
H-20 Machine cannot be easily steered or lacks power...3355
H-21 Travel speed does not shift, or it is too slow or fast...3534
H-22 Track shoe does not turn (on one side only)...3592
H-23 Machine does not swing...3593
H-24 Swing acceleration is poor, or swing speed is slow...3594
H-25 Excessive overrun when stopping swing...3595
H-26 There is big shock when stopping swing...3596
H-27 There is big abnormal noise caused when stopping swing...3596
H-28 Swing natural drift is too big...3360
Sec 30.pdf...0
HOW TO READ THIS MANUAL...3600
REMOVAL AND INSTALLATION OF ASSEMBLIES...3600
DisassemblY and assemblY OF assemblIES...3601
PRECAUTIONS WHEN PERFORMING OPERATION...3602
STARTING MOTOR ASSEMBLY...3604
REMOVAL...3604
INSTALLATION...3604
FUEL INJECTION PUMP ASSEMBLY...3605
ENGINE FRONT SEAL...3609
ENGINE REAR SEAL...3611
CYLINDER HEAD ASSEMBLY...3613
RADIATOR ASSEMBLY...3619
HYDRAULIC OIL COOLER ASSEMBLY...3621
ENGINE AND HYDRAULIC PUMP ASSEMBLIES...3623
FINAL DRIVE ASSEMBLY...3629
FINAL DRIVE ASSEMBLY...3630
SKETCHES OF SPECIAL TOOLS...3637
SWING MOTOR AND SWING MACHINERY ASSEMBLY...3638
SWING MOTOR AND SWING MACHINERY ASSEMBLY...3639
CARRIER ROLLER ASSEMBLY...3646
TRACK ROLLER ASSEMBLY...3647
IDLER ASSEMBLY...3648
RECOIL SPRING ASSEMBLY...3651
SPROCKET...3653
TRACK SHOE ASSEMBLY...3654
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON)...3654
REMOVal AND EXPANsion OF ROAD LINERS...3656
INSTALLation OF ROAD LINERS...3657
SWING CIRCLE...3658
ASSEMBLY...3658
REVOLVING FRAME ASSEMBLY...3659
CENTER SWIVEL JOINT ASSEMBLY...3661
CENTER SWIVEL JOINT ASSEMBLY...3663
HYDRAULIC TANK ASSEMBLY...3664
CONTROL VALVE ASSEMBLY...3666
CONTROL VALVE ASSEMBLY...3669
HYDRAULIC PUMP ASSEMBLY...3672
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...3675
WORK EQUIPMENT PPC VALVE ASSEMBLY...3676
TRAVEL PPC VALVE ASSEMBLY...3677
HYDRAULIC CYLINDER ASSEMBLY...3678
WORK EQUIPMENT ASSEMBLY...3684
AIR CONDITIONER UNIT ASSEMBLY...3687
COUNTERWEIGHT ASSEMBLY...3690
OPERATOR’S CAB ASSEMBLY...3691
MONITOR ASSEMBLY...3693
GOVERNOR PUMP CONTROLLER ASSEMBLY...3694
PC200-7_Sec90.pdf...0
This page left intentionally blank...3697
PC200-7_Sec90_Body.pdf...0
hydraulic circuit diagram (1/2)...3698
PC210-7K, PC210LC-7K, pc210nlc-7K...3698
This page left intentionally blank...3699
hydraulic circuit diagram (2/2)...3700
PC210-7K, PC210lc-7K, PC210nLC-7K...3700
This page left intentionally blank...3701
HYDRAULIC diagram (1/1)...3702
pc240lc-7K, pc240nlc-7K...3702
This page left intentionally blank...3703
electrical circuit diagram (1/4)...3704
for multi monitor...3704
pc210-7K, pc210lc-7K, pc210nlc-7K...3704
pc240lc-7K, pc240nlc-7K...3704
This page left intentionally blank...3705
electrical circuit diagram (2/4)...3706
for multi monitor...3706
This page left intentionally blank...3707
electrical circuit diagram (3/4)...3708
for multi monitor...3708
This page left intentionally blank...3709
electrical circuit diagram (4/4)...3710
for multi monitor...3710
This page left intentionally blank...3711
electrical circuit diagram for air conditioner...3712
This page left intentionally blank...3713
Komatsu Hydraulic Excavators PC210K, PC210LCK, PC210NLCK, PC240LCK, PC240LCK, PC240NLCK Repair Service Manuals
