Komatsu PC210,210LC,210NLC,PC230NHD,240LC,240NLC-8 Galeo Hydraulic Excavator OM Manual - UEAM004904

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Galeo Komatsu Hydraulic Excavator. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PC210-8 - S/N: K50001 and up
Komatsu PC210LC-8 - S/N: K50001 and up
Komatsu PC210NLC-8 - S/N: K50001 and up
Komatsu PC230NHD-8 - S/N: K50001 and up
Komatsu PC240LC-8 - S/N: K50001 and up
Komatsu PC240NLC-8 - S/N: K50001 and up
Komatsu PC240LC-8 - S/N: 10001 and up
Komatsu PC240NLC-8 - S/N: 10001 and up


TABLE OF CONTENTS :

- FOREWORD
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- ATTACHMENTS AND OPTIONS
- SUPER LONG FRONT BOOM AND ARM PC210/240-8
- INDEX
- COLOPHON


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM004904
Total Pages : 464


This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

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FOREWORD
FOREWORD
SAFETY INFORMATION
NOISE (PC210,210LC,210NLC, PC230NHD)
NOISE (PC240LC,240NLC)
Vibration levels
Guide to Reduce Vibration Levels on Machine
INTRODUCTION
DIRECTIONS OF MACHINE
BREAKING-IN THE NEW MACHINE
PRODUCT INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
SERVICE METER LOCATION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL PLATES
STANDARD SERIAL PLATE
FOREWORD
SAFETY
OPERATION
MAINTENANCE
SPECIFICATIONS
ATTACHMENTS AND OPTIONS
SUPER LONG FRONT BOOM AND ARM PC210/240-8
INDEX
COLOPHON

SAFETY
SAFETY INFORMATION
SAFETY LABELS
LOCATION OF SAFETY LABELS
SAFETY LABELS
SAFETY INFORMATION
SAFETY RULES
IF PROBLEMS ARE FOUND
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY EQUIPMENT
KEEP MACHINE CLEAN
KEEP OPERATOR'S COMPARTMENT CLEAN
LEAVING OPERATOR'S SEAT WITH LOCK
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
NO PERSONS ON ATTACHMENTS
DO NOT GET CAUGHT IN ARTICULATED PORTION
BURN PREVENTION
ACTION IF FIRE OCCURS
WINDSHIELD WASHER FLUID
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
ATTACHMENT INSTALLATION
ATTACHMENT COMBINATIONS
CAB WINDOW GLASSES
UNAUTHORIZED MODIFICATIONS
SAFETY AT JOBSITE
WORKING ON LOOSE GROUND
DISTANCE TO HIGH VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREA
SIGNALMAN'S SIGNAL AND SIGNS
EMERGENCY EXIT FROM OPERATOR'S CAB
ELECTROMAGNETIC INTERFERENCE
ASBESTOS DUST HAZARD PREVENTION
SAFETY MACHINE OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
SAFETY RULES FOR STARTING ENGINE
STARTING ENGINE IN COLD WEATHER
OPERATION
CHECKS BEFORE OPERATION
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS
SAFETY RULES FOR TRAVELLING
TRAVELLING ON SLOPES
OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
OPERATIONS ON SNOW
PARKING MACHINE
TRANSPORTATION
LOADING AND UNLOADING
SHIPPING THE MACHINE
BATTERY
STARTING ENGINE WITH BOOSTER CABLES
TOWING
SAFETY RULES FOR TOWING
LIFTING OBJECTS WITH BUCKET
SAFETY RULES FOR LIFTING OBJECTS
SAFETY MAINTENANCE INFORMATION
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
ACCUMULATOR
HANDLING GAS SPRING
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
WHEN USING HAMMER
WELDING WORKS
REMOVING BATTERY TERMINALS
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLE RECOIL SPRINGS
SAFETY RULES FOR HIGH-PRESSURE OIL

OPERATION
MACHINE VIEW ILLUSTRATIONS
OVERALL MACHINE VIEW
CONTROLS AND GAUGES
DETAILED CONTROLS AND GAUGES
MONITORING SYSTEM
Basic Operation of Machine Monitor
Basic Check Monitors
Caution Monitors
Emergency Monitors
Meter Display Portion
Monitor Switches Portion
Handling Function Switches
SWITCHES
CONTROL LEVERS AND PEDALS
CEILING WINDOW
WINDSHIELD
EMERGENCY ESCAPE HAMMER
DOOR LOCK
CAP WITH LOCK
DRINK BOX
MAGAZINE BOX
ASHTRAY
AIR CONDITIONER CONTROLS
Air Conditioner Control Panel
Method of Operation
Use Air Conditioner with Care
Air Conditioner Maintenance
RADIO
Control Panel
Controls of Radio
Use Radio with Care
Space for radio cassette
AUXILIARY ELECTRIC POWER
24V power source
12V power source
FUSE
FUSIBLE LINK
CONTROLLER
TOOL BOX
GREASE GUN HOLDER
MACHINE OPERATIONS AND CONTROLS
BEFORE STARTING ENGINE
Walk-around Checks
REFUELLING PUMP
Checks Before Starting
Adjustment
Seat Belt
Operations Before Starting Engine
STARTING ENGINE
AFTER STARTING ENGINE
Warming Up Engine
Warming Up Hydraulic Equipment
Operation After Completion Of Warming-Up Operation
STOPPING THE ENGINE
MACHINE OPERATION
Preparations for Moving the Machine
Moving Machine Forward
Moving Machine Backward
Stopping Machine
STEERING THE MACHINE
Steering
SWINGING
WORK EQUIPMENT CONTROLS AND OPERATIONS
WORKING MODE
PROHIBITED OPERATIONS
GENERAL OPERATION INFORMATION
TRAVELLING ON SLOPES
ESCAPE FROM MUD
Track on One Side Stuck
Tracks on Both Sides Stuck
RECOMMENDED APPLICATIONS
Backhoe Work
Shovel Work
Ditching Work
Loading Work
BUCKET REPLACEMENT AND INVERSION
Replacement
Inversion
PARKING MACHINE
CHECK AFTER SHUT OFF ENGINE
MACHINE INSPECTION AFTER DAILY WORK
LOCKING
TRANSPORTATION
TRANSPORTATION PROCEDURE
SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-8 AND PC230NHD-8
LOADING AND UNLOADING WITH TRAILER
Loading
Securing Machine
Unloading
LIFTING MACHINE
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
Fuel and Lubricants
Cooling System Coolant
Battery
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLES AND ACTIONS
RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
TOWING THE MACHINE
LIGHTWEIGHT TOWING HOLE
SEVERE JOB CONDITION
DISCHARGED BATTERY
Battery Removal and Installation
Battery Charges
Starting Engine with Booster Cables
OTHER TROUBLE
Electrical System
Chassis
Engine
Electronic Control System
Point of Contact to Telephone when Error Occurs

MAINTENANCE
MAINTENANCE INFORMATION
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
FUEL
COOLANT AND WATER FOR DILUTION
GREASE
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)
STORING OIL AND FUEL
FILTERS
EXPLANATION OF LUBRICATION CHART DECAL
ELECTRIC SYSTEM MAINTENANCE
WEAR PARTS
WEAR PARTS LIST
RECOMMENDED FUEL, COOLANT, AND LUBRICANT
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS LIST
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
MAINTENANCE PROCEDURE
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN INSIDE OF COOLING SYSTEM
CHECK AND TIGHTEN TRACK SHOE BOLTS
CHECK AND ADJUST TRACK TENSION
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND MAINTENANCE AIR CONDITIONER
WASH WASHABLE FLOOR
BLEEDING AIR FROM HYDRAULIC SYSTEM
CHECK BEFORE STARTING
EVERY 100 HOURS MAINTENANCE
LUBRICATING
EVERY 250 HOURS MAINTENANCE
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
EVERY 500 HOURS MAINTENANCE
LUBRICATING
LUBRICATE SWING CIRCLE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
REPLACE FUEL PRE-FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
EVERY 1000 HOURS MAINTENANCE
REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL
REPLACE FUEL MAIN FILTER CARTRIDGE
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK FAN BELT TENSION AND REPLACE FAN BELT
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CLEAN HYDRAULIC TANK STRAINER
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
EVERY 4000 HOURS MAINTENANCE
CHECK WATER PUMP
CHECK VIBRATION DAMPER
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
CHECK OPERATING CONDITION OF COMPRESSOR
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK
EVERY 8000 HOURS MAINTENANCE
REPLACE FUEL SPRAY PREVENTION CAP
REPLACE HIGH-PRESSURE PIPING CLAMP

SPECIFICATIONS
SPECIFICATIONS
MONOBOOM WORKING RANGE
PC210-8 WORKING RANGE (2-PIECE BOOM)
PC230-8 WORKING RANGE (2-PIECE BOOM)
PC240-8 WORKING RANGE (2-PIECE BOOM)
EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC, PC230NHD-8
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
EXPLANATION OF LIFTING CAPACITY CHART PC240LC, PC240NLC-8
PC240LC-8
PC240NLC-8
EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC-8, pc230nhd-8 2 PIECE BOOM
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-8 2 PIECE BOOM)
PC240LC-8, PC240NLC-8 2 PIECE BOOM

ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS FOR SAFETY
PRECAUTIONS WHEN SELECTING
READ THE INSTRUCTION MANUAL THOROUGHLY
PRECAUTIONS WHEN REMOVING OR INSTALLING
PRECAUTIONS WHEN USING
HYDRAULIC QUICK COUPLER PIPING
LOCATIONS
OPERATION
BUCKET WITH HOOK
HOOK CONDITION
PROHIBITED OPERATIONS
MACHINE READY FOR ATTACHMENT
LOCATIONS
HYDRAULIC CIRCUIT
Switching Hydraulic Circuit
Adjusting Oil Flow
Switching Between Breaker and General Attachment
Hydraulic Circuit Connection
Oil Flow Path
Replace Additional Breaker Filter Element
Replace Additional Breaker Pilot Filter Element
ATTACHMENT REMOVAL AND INSTALLATION
Attachment Removal
Attachment Installation
ATTACHMENT OPERATIONS
When Using Breaker
When Using General Attachment Such as Crusher
LONG TERM STORAGE
SPECIFICATIONS
ATTACHMENT GUIDE
COMBINATIONS OF WORK EQUIPMENT
SELECTION OF TRACK SHOES
METHOD OF SELECTING SHOES
SELECTION OF BUCKET TEETH
METHOD OF SELECTING TEETH
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH
HANDLING OF RUBBER PAD SHOE AND ROAD LINER
Working Environment
Working Conditions
Storage and Maintenance
Extent of Damage to Rubber
Check Road Liner
Replace Road Liner
TRAPEZOIDAL BUCKET
HANDLING EXTENSION ARM
HANDLING CLAMSHELL BUCKET
CONTROLS (AUXILIARY HYDRAULIC CIRCUITS)
CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING
CRUSHER CONTROL PEDAL FOR ROTATION
RECOMMENDED ATTACHMENT OPERATIONS
HYDRAULIC BREAKER
PC210/230-8 2-PC BOOM
FEATURES OF 2-PIECE BOOM & ARM
OPERATION
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE
Lifting
TESTING AND ADJUSTING
PERODIC MAINTENANCE
TRANSPORTATION
LUBRICATING
Every 500 Hours
PC240-8 2-PC BOOM
FEATURES OF 2-PIECE BOOM & ARM
OPERATION
TESTING AND ADJUSTING
TRANSPORTATION
PC240-8 STRAIGHT BOOM
GENERAL VIEW OF MACHINE
CAUTION ITEMS
CONTROL (AUXILIARY HYDRAULIC CIRCUITS)
CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING
CRUSHER CONTROL BUTTON FOR ROTATION
CEILING WINDOW WIPER SWITCH (3)
WORKING RANGE (PC 240 STRAIGHT BOOM)
TRANSPORTATION (Straight Boom equipment)
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS
SUPER LONG FRONT BOOM AND ARM PC210/240-8
OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM
WORKING MODES
CHECKS BEFORE STARTING
USING SUPER LONG FRONT
METHOD OF WORK
WHEN TRAVELLING
CONTROL LEVERS, PEDALS
‘WEEDCUTTER’ MACHINE CONTROL LEVERS, PEDALS
RIGHT CONTROL LEVER BUTTONS (5 & 6)
LEFT WORK EQUIPMENT CONTROL LEVER (7 & 8)
ATTACHMENT FLOW SELECTOR (9)
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE
INSTALLATION OF SUPPORTING LINK
TRANSPORTATION OF SUPER LONG FRONT MACHINE
WORKING RANGE OF SUPER LONG FRONT
LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT
LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT
LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT
LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT
MAINTENANCE
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT
EVERY 50 HOURS SERVICE
LUBRICATING
EVERY 100 HOURS SERVICE
LUBRICATING

INDEX
Numerics
<A
<B
<C
<D
<E
<F
<G
<H
<I
<K
<L
<M
<N
<O
<P
<R
<S
<T
<V
<W
<Y

COLOPHON

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