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Operation &
Maintenance Manual
PC210-8, PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-8
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC210, PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-8
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
- K51095 and up
- K51095 and up
- K50114 and up
- K50304 and up
- K50304 and up
ORIGINAL INSTRUCTIONS
UEAM004912
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Summary of Contents for Komatsu PC210-8
- Page 1 Operation & UEAM004912 Maintenance Manual PC210-8, PC210LC-8 PC210NLC-8 PC230NHD-8 PC240LC-8 PC240NLC-8 HYDRAULIC EXCAVATOR SERIAL NUMBER PC210, PC210LC-8 - K51095 and up PC210NLC-8 - K51095 and up PC230NHD-8 - K50114 and up PC240LC-8 - K50304 and up PC240NLC-8 - K50304 and up...
- Page 2 Find manuals at https://best-manuals.com...
- Page 3 FOREWORD Find manuals at https://best-manuals.com...
- Page 4 Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically. In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
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Page 5: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa- tions. - Page 6 Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
- Page 7 FOREWORD SAFETY INFORMATION NOISE (PC210,210LC,210NLC, PC230NHD) Two labels indicating the machine noise level are affixed on the machine. q Sound pressure level at the operator’s station, measured according to ISO6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
- Page 8 FOREWORD SAFETY INFORMATION NOISE (PC240LC,240NLC) Two labels indicating the machine noise level are affixed on the machine. q Sound pressure level at the operator’s station, measured according to ISO6396 (Dynamic test method,simulated working cycle). The maximum value of the standard deviation of the mea- sured time-averaged A-weighted emission sound pressure level at the operator's position is 2.5 dB, in accordance with ISO 11201.
- Page 9 FOREWORD SAFETY INFORMATION Vibration levels When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera- tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
- Page 10 FOREWORD SAFETY INFORMATION 6. Adjust the machine speed and travel path to minimize the vibration level Q When pushing with bucket or blade, avoid sudden loading; load gradually Q Drive around obstacles and rough terrain conditions Q Slow down when it is necessary to go over rough terrain Q Make the curve radius of travelling path as large as possible Q Travel at low speed when travelling around sharp curves 7.
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Page 11: Directions Of Machine
FOREWORD INTRODUCTION INTRODUCTION This Komatsu machine is designed to be used mainly for the following work: q Digging work q Levelling work q Ditching work q Loading work q Demolition work See the section “RECOMMENDED APPLICATIONS (3-172)“ for further details. -
Page 12: Breaking-In The New Machine
BREAKING-IN THE NEW MACHINE NOTICE Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How- ever, operating the machine under full load before breaking the machine in can adversely affect the per- formance and shorten the machine life. -
Page 13: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE On the bottom right of the operator's cab The design of the nameplate differs according to the territory. -
Page 14: Service Meter Location
On top of the machine monitor TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU UK Ltd. Address: Durham Road Birtley Chester-Le-Street County Durham DH3 2QX United Kingdom Distributor name:... -
Page 15: Machine Serial Plates
PRODUCT INFORMATION MACHINE SERIAL PLATES SERIAL PLATE (WHERE FITTED) MODEL SERIAL No. MANUFACT. YEAR MASS ENGINE POWER Product Identification Number Manufactured by Komatsu UK Ltd. MANUFACTURER for Komatsu Ltd.,Tokyo,Japan 205-00-K1291 MODEL ENGINE POWER SERIAL PRODUCT IDENTIFICATION NUMBER MANUFACTURING YEAR MANUFACTURER... - Page 16 FOREWORD PRODUCT INFORMATION DECLARATION OF CONFORMITY The manufacturer: KOMATSU UK Ltd Durham Road Birtley Chester-Le-Street County Durham DH3 2QX United Kingdom Declares that this machine: PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 PC240LC-8 PC240NLC-8 Fulfils all the relevant provisions of following EC Directives:...
- Page 17 CONTENTS CONTENTS FOREWORD FOREWORD................................. 1-4 SAFETY INFORMATION............................1-5 NOISE (PC210,210LC,210NLC, PC230NHD).................... 1-7 NOISE (PC240LC,240NLC)........................1-8 VIBRATION LEVELS ..........................1-9 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE .............. 1-9 INTRODUCTION..............................1-11 DIRECTIONS OF MACHINE ........................1-11 OPERATOR PROTECTIVE STRUCTURE....................1-11 VISIBILITY FOR OPERATOR ........................1-11 BREAKING-IN THE NEW MACHINE .......................
- Page 18 CONTENTS NO PERSONS ON ATTACHMENTS ....................2-19 DO NOT GET CAUGHT IN ARTICULATED PORTION ..............2-19 BURN PREVENTION ........................2-19 ACTION IF FIRE OCCURS ......................2-21 WINDSHIELD WASHER FLUID ...................... 2-21 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............2-21 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ....2-22 ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES ..........
- Page 19 CONTENTS SAFETY MAINTENANCE INFORMATION ......................2-44 WARNING TAG ..........................2-44 KEEP WORK PLACE CLEAN AND TIDY ..................2-44 STABILITY............................2-44 GUARDS ............................2-44 END OF SERVICE LIFE........................2-44 APPOINT LEADER WHEN WORKING WITH OTHERS..............2-45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............2-45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ........
- Page 20 CONTENTS DOOR LOCK ............................3-91 CAP WITH LOCK............................3-92 DRINK BOX .............................. 3-94 MAGAZINE BOX............................3-94 ASHTRAY ..............................3-94 AIR CONDITIONER CONTROLS ......................3-95 AIR CONDITIONER CONTROL PANEL ..................3-95 METHOD OF OPERATION ......................3-100 USE AIR CONDITIONER WITH CARE ..................3-107 AIR CONDITIONER MAINTENANCE ...................
- Page 21 CONTENTS WORKING MODE........................... 3-163 PROHIBITED OPERATIONS ......................... 3-165 GENERAL OPERATION INFORMATION ....................3-167 TRAVELLING ON SLOPES........................3-169 ESCAPE FROM MUD..........................3-171 TRACK ON ONE SIDE STUCK..................... 3-171 TRACKS ON BOTH SIDES STUCK....................3-171 RECOMMENDED APPLICATIONS......................3-172 BACKHOE WORK ......................... 3-172 SHOVEL WORK ..........................
- Page 22 OIL ..............................4-5 FUEL..............................4-6 COOLANT AND WATER FOR DILUTION..................4-6 GREASE ............................4-7 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) ............4-8 STORING OIL AND FUEL ......................... 4-9 FILTERS ............................4-9 EXPLANATION OF LUBRICATION CHART DECAL ................4-10 ELECTRIC SYSTEM MAINTENANCE ..................... 4-12 WEAR PARTS ..............................
- Page 23 CONTENTS CLEAN INSIDE OF COOLING SYSTEM ..................4-28 COOLANT DENSITY TABLE ......................4-29 CHECK AND TIGHTEN TRACK SHOE BOLTS................4-31 CHECK AND ADJUST TRACK TENSION ..................4-32 REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ..............4-34 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..............4-37 ADJUST BUCKET CLEARANCE ....................
- Page 24 REPLACE HIGH-PRESSURE PIPING CLAMP ................4-89 AUTOMATIC GREASE SYSTEM........................4-90 FILLING THE GREASE RESERVOIR ...................... 4-91 METHOD OF FILLING GREASE RESERVOIR..................4-92 RECOMMENDED KOMATSU PUMPS FOR FILLING GREASE RESERVOIR ........4-92 INDICATION ON THE IN-CAB DISPLAY ....................4-93 TESTS ..............................4-94 MAINTENANCE............................4-94 END OF SERVICE LIFE .............................
- Page 25 CONTENTS EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-8 2 PIECE BOOM) ......5-21 PC240LC-8, PC240NLC-8 2 PIECE BOOM ..................... 5-22 ATTACHMENTS AND OPTIONS GENERAL PRECAUTIONS FOR SAFETY......................6-2 PRECAUTIONS WHEN SELECTING......................6-2 READ THE INSTRUCTION MANUAL THOROUGHLY................6-2 PRECAUTIONS WHEN REMOVING OR INSTALLING ................6-2 PRECAUTIONS WHEN USING........................
- Page 26 CONTENTS WORKING ENVIRONMENT......................6-33 WORKING CONDITIONS........................ 6-33 STORAGE AND MAINTENANCE ....................6-34 EXTENT OF DAMAGE TO RUBBER ....................6-34 CHECK ROAD LINER ........................6-34 REPLACE ROAD LINER ......................... 6-34 TRAPEZOIDAL BUCKET ......................... 6-35 HANDLING EXTENSION ARM......................... 6-36 HANDLING CLAMSHELL BUCKET ......................6-37 RECOMMENDED ATTACHMENT OPERATIONS.....................
- Page 27 CONTENTS SUPER LONG FRONT BOOM AND ARM PC210/240-8 OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM ..........7-2 WORKING MODES ............................ 7-3 CHECKS BEFORE STARTING......................7-4 USING SUPER LONG FRONT ......................7-5 METHOD OF WORK PC210LC-8 (15M), PC210NLC-8 (15M)............7-6 WHEN TRAVELLING ........................
- Page 28 CONTENTS SPECIFICATIONS .............................. 8-14 GROUND PRESSURE TABLE......................8-14 WORKING RANGE ......................... 8-14 TRANSPORT DIMENSIONS ......................8-15 INDEX COLOPHON 1-28...
- Page 29 SAFETY WARNING 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.
- Page 30 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS..............................2-42 LOCATION OF SAFETY LABELS ....................... 2-42 SAFETY LABELS............................2-52 SAFETY INFORMATION Safety rules ..............................2-162 If problems are found ..........................2-162 Working wear and personal protective items ..................... 2-162 Fire extinguisher and first aid kit ........................ 2-162 Safety equipment ............................
- Page 31 SAFETY SAFETY INFORMATION TURN OFF BATTERY DISCONNECT SWITCH ..................2-382 BATTERY ..............................2-382 Battery hazard prevention........................2-382 Starting engine with booster cables ....................2-392 TOWING ..............................2-402 Safety rules for towing ........................2-402 LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT)......2-412 LIFTING OBJECTS WITH BUCKET......................
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Page 32: Location Of Safety Labels
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the labels, see this manual or the actual label, and place an order with your Komatsu distributor. - Page 33 SAFETY SAFETY LABELS SAFETY LABELS 1. (20Y-00-K2021) q Warnings for operation, inspection and maintenance q Improper operation and maintenance can cause serious injury or death. q Read the manual and labels before operation and mainte- nance. Follow instructions and warnings in manual and in labels on machine.
- Page 34 SAFETY SAFETY LABELS q c. WARNING - No passengers No passengers allowed to ride on machine while it is mov- q d. WARNING - DANGER OF FALLING OBJECTS Do not operate where a danger of falling objects exists. Consult your dealer for fitting of FOPS protection q e.
- Page 35 SAFETY SAFETY LABELS q f. Control levers operational function diagram. WARNING In order to prevent an accident resulting in injury or death caused by error-operation, confirm the machine motion a n d i n d i c a t e d o p e r a t i n g pa t t e r n , w h e n o p e r a t i n g machines.
- Page 36 SAFETY SAFETY LABELS q h. Caution when reversing To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments: q Sound horn to alert people nearby. q Be sure no one is on or near machine or in swing area. q Rotate cab for full view of travel path if it can be done safely.
- Page 37 SAFETY SAFETY LABELS 3. Caution for high-temperature coolant and hydraulic oil (09653-A0481) q Never remove the cap when the engine is at operating (high) temperature. Steam or high temperature oil blowing up from the radiator or hydraulic tank, will cause personal injury and/or burns.
- Page 38 SAFETY SAFETY LABELS 7. Stopping rotation for inspection and maintenance (09667-A0481) q Sign indicates a hazard of rotating parts, such as belt. q Turn off before inspection and maintenance. Emergency escape (09844-00050) 9. Caution against falling (09805-A0881) q There is the hazard of falling down. q Do not go close to the edge of the machine by mistake.
- Page 39 SAFETY SAFETY LABELS 10. Caution against falling (09805-C0481) q Sign indicates a hazard of falling. q Do not stand on this place here. 11. Prohibited to enter swing radius (20E-00-K1150) q There is danger of getting caught when upper structure swings.
- Page 40 SAFETY SAFETY LABELS 13. Prohibition of jump start (09842-A0481) q Start the engine only after sitting down in the operator’s seat. q Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire.
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