Komatsu PC210 Operation & Maintenance Manual Download Page 143

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2-99

PC210/240-ENG

16.6.3 ENGINE

•

( ): Always contact your Komatsu distributor when dealing with these items.

•

In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.

Problem

Main causes

Remedy

Engine oil pressure monitor
lights up

Steam is emitted from top part
of radiator (pressure valve)

Radiator water level monitor lights up

Engine does not start when
starting motor is turned

•

Engine oil pan oil level is low
(sucking in air)

•

Clogged oil filter cartridge

•

Defective tightening of oil
pipe joint, oil leakage from
damaged part

•

Defective engine oil pressure
sensor

•

Cooling water level low, water leak-
age

•

Loosen fan belt

•

Dirt or scale accumulated in cooling
system

•

Clogged radiator fin or damaged fin

•

Defective thermostat

•

Loose radiator filler cap (high altitude
operation)

•

Defective water level sensor

•

Lack of fuel

•

Air in fuel system

•

Defective fuel injection pump or noz-
zle

•

Starting motor cranks engine slug-
gishly

•

Preheating monitor does not light up

•

Defective compression

•

Defective valve clearance

•

Contaminated fuel

•

Lift pump not working

•

Fuel filter clogged

•

Fuel lines blocked

•

Add oil to specified
level, see “CHECK
BEFORE STARTING”

•

Replace cartridge, see
“EVERY 500 HOURS
SERVICE”

(• Check, repair)

(• Replace sensor)

•

Add cooling water, re-
pair, see “CHECK BE-
FORE STARTING”

•

Adjust fan belt tension,
see “EVERY 1000
HOURS SERVICE”

•

Change cooling water,
clean inside of cooling
system, see “WHEN
REQUIRED”

•

Clean or repair, see
“EVERY 500 HOURS
SERVICE”

(• Replace thermostat)
•

Tighten cap or replace
packing

(• Replace sensor)

•

Add fuel, see CHECK
“BEFORE STARTING”

•

Repair place where air
is sucked in, see
“EVERY 500 HOURS
SERVICE”

(• Replace pump or nozzle)

See ELECTRICAL
SYSTEM

(• Adjust valve clearance)
• Drain & clean fuel system
• Check/replace pump
• Change filters
• Check/blow out lines

16. TROUBLESHOOTING

Summary of Contents for PC210

Page 1: ... kept inside the cab for reference and periodically reviewed by all personel who will come into contact with the machine EEAM006003 Operation Maintenance Manual PC210 PC210LC 6K PC240LC PC240NLC 6K HYDRAULIC EXCAVATOR SERIAL NUMBER PC210 6K K32000 and up PC210LC 6K K32000 and up PC240LC 6K K32000 and up PC240NLC 6K K32000 and up WARNING PC210 PC210LC 6K PC240LC PC240NLC 6K EEAM006003 ...

Page 2: ......

Page 3: ...in serious injury or death Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance Some actions involved in operation and maintenance of the machine can cause a serious acci dent if they are not done in a manner described in this manual The procedures and precautions given in this manual apply only to intended uses of the ma chine If you use...

Page 4: ...y messages or labels usually describe precautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage of the machine YELLOW SAFETY TRIANGLE This is used on safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided This word might also be used for a hazard where the only result could be damage to the machi...

Page 5: ... 3 VIBRATION The weighted root mean square acceleration value to which the operator s arms are subjected does not exceed 2 5 m s The weighted root mean square acceleration value to which the operator s body is subjected does not exceed 0 5 m s These results were obtained by accelerometers during trench digging 2 SAFETY INFORMATION Ambient noise value Sound power level 95 27 EC 95 27 EC ...

Page 6: ...djusted and tested before shipment However operating the machine under severe conditions at the beginning can adversely affect the perform ance and shorten the machine life Be sure to break in the machine for the initial 100 hours as indicated by the hour meter During breaking in Idle the engine for 5 minutes after starting it up Avoid operation with heavy loads or at high speeds Sudden starting o...

Page 7: ...N On the upper side of the engine cylinder head cover 4 3 TABLE TO ENTER SERIAL NO AND DISTRIBUTOR 4 LOCATION OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR Machine serial No Engine serial No Manufacturers name Komatsu UK Ltd Address Durham Road Birtley Chester Le Street County Durham DH32QX United Kingdom Distributor Address Phone z ...

Page 8: ...0 6 PC210 240 ENG 4 4 MACHINE SERIAL PLATE MODEL SERIAL No MANUFACTURING YEAR WEIGHT ENGINE POWER MANUFACTURER Produced by Komatsu UK Ltd for Komatsu Ltd Tokyo Japan ...

Page 9: ... During maintenance 1 24 9 Position for attaching safety labels 1 28 OPERATION 10 General view 10 1 General view of machine 2 2 10 2 General view of controls and gauges 2 3 11 Explanation of components 11 1 Machine monitor 2 4 11 2 Meter 2 15 11 3 switches 2 16 11 4 Control levers pedals 2 20 11 5 Ceiling window 2 25 11 6 Front window 2 26 11 7 Door lock 2 28 11 8 Cap cover with lock 2 29 11 9 Lug...

Page 10: ...eck after finishing work 2 80 12 19 Stopping engine 2 81 12 20 Check after stopping engine 2 82 12 21 Locking 2 82 12 22 Overload warning device 2 82 13 Transportation 13 1 Loading unloading work 2 83 13 2 Precautions for loading 2 85 13 3 Precautions for transportation 2 86 13 4 Lifting the machine 2 86 14 Cold weather operation 14 1 Precaution for low temperature 2 87 14 2 Precautions after comp...

Page 11: ...ty critical parts 3 19 23 Maintenance schedule chart 3 22 23 1 Maintenance schedule chart 3 22 23 2 Maintenance interval when using hydraulic breaker 3 24 24 Service procedure 3 25 24 1 Initial 250 hours service 3 25 24 2 When required 3 26 24 3 Check before staring 3 42 24 4 Every 100 hours service 3 47 24 5 Every 250 hours service 3 51 24 6 Every 500 hours service 3 55 24 7 Every 1000 hours serv...

Page 12: ...storage 5 12 28 6 Specifications 5 12 28 7 First attachment with clam shell option 5 12 1 28 8 First and second attachment 5 12 2 29 Introduction of attachments 5 13 29 1 Specification use 5 13 29 2 Attachment installing combination table 5 15 29 3 Selection of track shoes 5 17 29 4 Selection of bucket teeth 5 18 29 5 Handling trapezoidal bucket 5 19 29 6 Handling extension arm 5 20 29 7 Handling ...

Page 13: ...C210 240 ENG SAFETY WARNING Read and follow all safety precautions Failure to do so may result in serious injury or death This safety section also contains precautions for optional equipment and attachments ...

Page 14: ...ver n See 12 16 PARKING THE MACHINE Improper use of safety features could result in serious bodily injury or death CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewellery and loose long hair They can catch on controls or in moving parts and cause serious injury or death Also do not wear oily cloths because they are flammable Wear a hard hat safety glasses safety shoes mask or gloves ...

Page 15: ...safety lock lever to the LOCK position then stop the engine and use the key to lock all the equipment Always take the key with you Work equipment posture See n 12 16 PARKING THE MACHINE MOUNTING AND DISMOUNTING NEVER jump on or off the machine NEVER get on or off a moving machine When mounting or dismounting always face the machine and use the handrails machine or track frame steps and track shoes...

Page 16: ...enter PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES Immediately after operations are stopped the engine coolant engine oil and hydraulic oil are at high temperatures and are still under pressure Attempting to remove the cap drain the oil or water or replace the filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when carrying out these ...

Page 17: ...achine with the wind to your back whenever possible Use an approved respirator if necessary CRUSHING OR CUTTING PREVENTION Do not enter or put your hand or arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machine and work equipment If the work equipment is operated the clearance will change and this may lead to serious damage ...

Page 18: ...es of work if there is any danger of being hit by falling or flying objects or of objects entering the operator s cab select and install a guard that matches the working conditions Be sure to close the front window before commencing work When carrying out the above operations make sure to keep all persons other than the operator outside the range of falling or flying objects Be particularly sure t...

Page 19: ...when the work equipment control lever is shifted to LOWER After the engine is stopped set the safety lock lever to the lock position and also lock the attachment pedal with the lock pin When releasing the pressure inside the work equipment circuit on machines equipped with an accumulator follow the procedure given in the inspection and maintenance section Method of releasing pressure n See 11 19 H...

Page 20: ...o sever or cut any of these lines Check the depth and flow of water before operating in water or crossing a river NEVER be in water which is in excess of the per missible water depth Permissible water depth See n 12 11 PRECAUTIONS FOR OPERATION FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flamma ble things accumulated on the engine compartment They could cause a fire Check f...

Page 21: ...UTIONS FOR MIRRORS WINDOWS AND LIGHTS Remove all dirt from the surface of the windows and lights to ensure that you can see well Adjust the rear view mirror so that you can see clearly from the operator s seat and always keep the surface of the mirror clean If any glass is broken replace it with a new part Check that the head lamps and working lamps are installed to match the operating conditions ...

Page 22: ...IRECTION BEFORE STARTING MACHINE Before operating the travel lever check the direction of the track frame If the sprocket is at the front the travel lever must be operated in the opposite direction Travel operations n See 12 4 TO MOVE THE MACHINE OFF CHECK THAT NO ONE IS IN THE AREA BEFORE SWINGING OR TRAVELLING IN REVERSE Always position a signalman in places in dangerous places or places where t...

Page 23: ...le and travel at low speed Never travel over obstacles which make the machine tilt strongly 10o or more TRAVELLING ON SLOPES Travelling on hills banks or slopes that are steep could result in the machine tipping over or slipping On hills banks or slopes carry the bucket closer to the ground approximately 20 to 30 cm 8 to 12 in above the ground In case of emergency quickly lower the bucket to the g...

Page 24: ... below between the machine and the electric cable The following actions are effective in preventing accidents 1 Wear shoes with rubber of leather soles 2 Use a signalman to give warning if the machine approaches too close to the electric cable If the work equipment should touch the electric cable the operator should not leave the operator s compart ment When carrying out operations near high volta...

Page 25: ...oads even a slight slope may cause the machine to slip to the side so always travel at low speed and avoid sudden starting stopping or turning When there has been heavy snow the road shoulder and objects placed beside the road are buried in the snow and cannot be seen so always carry out snow clearing operations carefully WORKING ON LOOSE GROUND Avoid operating your machine too close to the edge o...

Page 26: ...m on the right Piled soil on slope n See 12 12 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS OPERATIONS ON SLOPES PARKING THE MACHINE Park on level ground whenever possible If not possible block the tracks lower the bucket to the ground and thrust the bucket in the ground When parking on public roads provide fences and signs such as flags or lights on the machine to warn passersby to be careful Be ...

Page 27: ...re securely positioned and fastened and that the two sides are at the same level as one another Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from the machine tracks NEVER correct your steering on the ramps If necessary drive away from the ramps and climb again Swing the upper structure with extreme care on the trailer to avoid a possible accident cau...

Page 28: ...ols across the terminals When removing or installing check which is the positive terminal and negative terminal Tighten the battery cap securely Tighten the battery terminals securely Loosened terminals can generate sparks and lead to an explosion When removing battery cap wear rubber groves to prevent electrolyte contact with skin STARTING WITH BOOSTER CABLES ALWAYS wear safety glasses or goggles...

Page 29: ... Do not use a chinked or frayed wire rope Do not straddle the towing cable or wire rope When connecting up a towing machine do not let anyone enter the area between the towing machine and the equipment being towed Set the towing machine and the towing connection of the equipment being towed in a straight line when connecting it Place pieces of wood between the wire ropes and body to protect them f...

Page 30: ...ormality in the stopper device HOOKING WIRE ROPE SECURELY TO HOOK When performing lifting operation securely hook the wire rope onto the special lifting hook PRECAUTIONS FOR MACHINE INSTALLATION After carrying out a preliminary inspection of ground conditions select a flat solid location Confirm that the machine can be safely operated without toppling or rolling PROHIBITED OPERATIONS OTHER THAN MA...

Page 31: ...eeze can be harmful to you and the environment you should therefore always follow the manufacturers instructions regarding storage handling and disposal HANDLING OF USED ENGINE OILS Avoid contact with used engine oils Refer to engine oils data sheet for handling and storage precautions HANDLING OF OILS For diesel oils hydraulic oils and oils used in the swing machinery PTO transmission axles and h...

Page 32: ... the operator s seat while lifting a load NEVER CARRY OUT EXCESSIVE OPERATIONS Operation exceeding machine performance may result in accident or failure Carry out lifting operation within specified load limit Never carry out operations which may damage the machine such as overload or over impact load Never drag a load laterally or longitudinally nor retract the arm otherwise a dangerous situation ...

Page 33: ...low quality faulty or makeshift tools could cause personal injury Tools n See 21 1 INTRODUCTION OF NECESSARY TOOLS PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Replace the following fire related components periodically Fuel system Fuel hose spilling hose and fuel tube cap Hydraulic system Pump outlet hose and front and rear pump branch hoses Replace these components periodically with new ones reg...

Page 34: ...ration with two workers One worker should sit in the operator s seat so that he can stop the engine immediately if necessary He should also be extremely careful not to touch any lever by mistake Touch the levers only when they have to be operated The worker carrying out the maintenance should be extremely careful not to touch or get caught in the moving parts RULES TO FOLLOW WHEN ADDING FUEL OR OI...

Page 35: ...he engine and allow the engine and radiator to cool down before adding the water Slowly loosen the caps to relieve pressure before removing the caps USE OF LIGHTING When checking fuel oil coolant or battery electrolyte always use lighting with anti explosion specifica tions If such lighting equipment is not used there is danger of explosion 8 PRECAUTIONS FOR OPERATION ...

Page 36: ...wer all movable work equipment to the ground or to their lowest position before performing service or repairs under the machine Always block the track shoes of the machine securely Never work under the machine if the machine is poorly supported KEEP THE MACHINE CLEAN Spilt oil or grease or scattered tools or broken pieces are dangerous because they may cause you to slip or trip Always keep your ma...

Page 37: ... fuel hoses or oil hoses If fuel or oil leaks it may cause a fire PRECAUTIONS WITH HIGH PRESSURE OIL Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out maintenance or inspection before completely releasing the internal pressure If oil is leaking under high pressure from small holes it is dangerous if the jet of high pressure oil hits your...

Page 38: ...NG Checking lubricating oil level adding oil n see 24 5 24 6 24 7 24 8 24 9 PERIODIC MAINTENANCE Changing oil replacing filters n see 24 5 24 6 24 7 24 8 24 9 PERIODIC MAINTENANCE PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION Grease is pumped into the track tension adjustment system under high pressure If the specified procedure for maintenance is not followed when making adj...

Page 39: ...ned from your machine in containers Never drain oil directly on the ground Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and others 8 PRECAUTIONS FOR OPERATION WARNING For reasons of safety always follow these safety precautions ...

Page 40: ... or replace them with a new label There are other labels in addition to the safety labels listed as follows so handle them in the same way Safety labels are available from your Komatsu distributor POSITION FOR ATTACHING SAFETY LABELS 9 POSITION FOR ATTACHING SAFETY LABELS k c b j h j f i g a d e ...

Page 41: ...e opera tion and mainte nance Follow instructions and warnings in manual and in labels on machine Keep the manual in machine cab near op erator If this manual is lost please contact your Komatsu distributor for a replacement When raising window lock it in place with lock pins on both sides Falling window can cause injury Always apply lock when leaving opera tor s seat 3 20Y 00 K2220 Emergency exit...

Page 42: ...ious injury or death can occur if machine or attachments are not kept safe distance away from electric lines Keeping out of moving area To prevent SEVERE IN JURY or DEATH do the following before moving machine or its attach ments Sound horn to alert people nearby Be sure no one is on or near machine or in the swing area Rotate cab for full view of travel path if it can be done safely Use spotter i...

Page 43: ...nd oil Hot water and oil hazard To prevent hot water and oil from spurting out Turn engine off Allow water to cool Slowly loosen cap to relieve pressure before remov ing Read opera tion manual before opera tion 11 20E 00 K1110 Warning for fall ing from upper structure Keep away from sides of machine Keep of counter weight Do not ride on machine when it is moving STOP Explosion hazard Keep away fro...

Page 44: ...1 32 PC210 240 ENG MEMO ...

Page 45: ...2 1 PC210 240 ENG OPERATION ...

Page 46: ...2 2 PC210 240 ENG 10 1 GENERAL VIEW OF MACHINE If directions are indicated in this section the refer to the directions shown by in the arrows in the diagram below 10 GENERAL VIEW ...

Page 47: ...heating monitor Swing lock monitor Engine oil replacement monitor Auto deceleration switch Active mode switch Display for clock and fault indication Engine water temperature gauge Engine water temperature monitor Engine oil pressure monitor Radiator water level monitor Air cleaner clogging monitor Overload caution monitor Working mode selector switch Power max swift slow down switch Travel speed s...

Page 48: ...ean ings of the displays 11 1 MACHINE MONITOR A BASIC CHECK ITEMS 11 1 1 This displays the basic items that should be checked before starting the engine If there is any abnormality the appropriate monitor lamp will flash NOTICE When carrying out checks before starting do not simply rely on the monitor Always refer to the periodic maintenance items or 12 OPERATION to carry out the checks 11 EXPLANA...

Page 49: ... items flash stop operations immediately then check and repair the appropriate location These are items which need to be observed while the engine is run ning If any abnormality occurs items which need to be repaired immedi ately are displayed If there is any abnormality the appropriate monitor lamp will flash to indicate the location of the abnormality and the buzzer will sound D METER DISPLAY PO...

Page 50: ...o carry out the checks 1 RADIATOR WATER LEVEL This warns that the radiator cooling water level is too low If the moni tor lamp flashes check the cooling water level in the radiator and reserve tank and add water 2 ENGINE OIL LEVEL This warns that the oil level in the engine oil pan is too low If the monitor lamp flashes check the oil level in the engine oil pan and add oil C y B y A y C x C c C c ...

Page 51: ...rging system while the engine is running If the monitor lamp flashes check the V belt ten sion If any abnormality is found see 16 6 OTHER TROUBLE REMARK While the starting switch is ON the lamp will remain lit and will go off once the engine is started 2 FUEL LEVEL If the fuel drops below 25 litres 6 6 US gal 5 5 UK gal the lamp will flash Top up the fuel before this 3 AIR CLEANER CLOGGING This wa...

Page 52: ...engine at low idling until the engine wa ter temperature gauge enters the green range 2 RADIATOR WATER LEVEL If the radiator water level drops the monitor lamp flashes Stop the engine check the radiator water level and add water if necessary 3 ENGINE OIL PRESSURE If the engine oil pressure drops below the normal pressure the moni tor lamp flashes At this item stop the engine and inspect it accordi...

Page 53: ...ng switch is turned to HEAT position and flashes after about 30 seconds to show that the pre heating is completed The monitor lamp will go off after about 10 seconds 2 SWING LOCK MONITOR This informs the operator that the swing lock is being actuated Actu ated Lights up When the swing lock switch is turned ON ACTUATED the monitor lamp lights up When the swing lock override switch is turned on this...

Page 54: ...d range b lights if the engine water temperature is reduced and the fuel control dial is turned to the low idling position the display will be cancelled 4 FUEL GAUGE This gauge indicates the amount of fuel in the fuel tank If the fuel level is normal during operation the green range will light up If only the red range lights up during operation there is less than 25 litres 6 6 US gal 5 5 UK gal of...

Page 55: ...hour is rounded off for 0 to 14 minutes and rounded up for 45 to 59 minutes Examples 10 14 becomes 10 00 rounded off 10 45 becomes 11 00 rounded up When SET switch 4 is pressed at the time signal or standard clock the correct time is obtained 4 When the correct time is reached press clock switch y This com pletes clock setting If the machine has a fault error information appears while the starting...

Page 56: ...mode lights up This is used for levelling or grading work L O lifting operation mode lights up This is used for fine control operations B O breaker operation mode lights up This is used for breaker work When starting the engine G O general operation mode is auto matically selected Each time the switch is pressed the mode selection changes NOTICE When the breaker is used never select the H O heavy ...

Page 57: ...he machine is travelling the machine may deviate even when travelling in a straight line To prevent this always stop the machine before operating the travel speed switch This is used to select the three travel speeds Lo lights up Low speed travel Mi lights up Mid range speed travel Hi lights up High speed travel When the engine is started the travel speed is automatically set to Lo When travelling...

Page 58: ...and general operation mode only the speed is reduced while the knob button is being pressed When the engine is started the power max lamp lights up Each time this switch on the monitor panel is pressed the mode is switch 5 ACTIVE MODE SWITCH SELECTOR SWITCH The active mode is effective for quick leveling operations or deep digging and loading operations Lamp lights up Active mode is actuated Lamp ...

Page 59: ...ours of the machine Set the periodic maintenance intervals using this display The hour meter ad vances while the engine is running even if the machine is not travelling The meter will advance by 1 for each hour of operation regardless of the engine speed 11 EXPLANATION OF COMPONENTS ...

Page 60: ...n This is the engine start position Keep the key at this position during cranking Immediately after starting the engine release the key which will automatically return to the ON position HEAT preheat position When starting the engine in winter set the key to this position When the key is set to the HEAT position the pre heating monitor lights up Keep the key at this position until the monitor lamp...

Page 61: ...f the swing lock switch is located at the ON position Be careful concerning this point This switch is used to lock the upper structure so that it cannot swing ON position actuated The swing lock is always applied and the upper structure will not swing even if the swing is operated In this condition the swing lock lamp lights up OFF position cancelled The swing lock is applied only when the swing c...

Page 62: ...he button at the tip of the right work equipment control lever is pressed the horn will sound 10 KNOB BUTTON The button at the tip of the left work equipment control lever is used to actuate the power max swift slow down functions Press the button once single click and keep it depressed In the heavy duty and general operation modes the power max function actuates for max 8 5 seconds and the swift ...

Page 63: ...d when there is an abnormality in the pump control system TVC valve system error The abnormality must be re paired immediately 15 SWING LOCK OVERRIDE SWITCH When normal Switch is down When abnormal When the monitor display shows E03 swing brake system error the brake is cancelled and it becomes possible to swing the upper structure when this switch is moved up so normal operations can be carried o...

Page 64: ...ot placed securely in the LOCK position the control levers may not be properly locked Check that the situation is as shown in the diagram When the safety lock lever is raised take care not to touch the work equipment control lever If the safety lock lever is not properly locked at the upper position the work equipment and swing will move creating a potentially dangerous situation When the safety l...

Page 65: ... it by mis take the machine will move suddenly and this may lead to a serious accident With the track frame facing to the near the machine will move in the reverse direction by forward travelling and in the for ward direction by reverse travelling When the travel lever is used check to see if the track frame is facing forward or backward If the sprocket is located to the rear the track frame is fa...

Page 66: ... so be careful when operating the levers This lever is used to operate the boom and bucket Boom operation Bucket operation y RAISE c DUMP x LOWER v CURL N Neutral When the lever in this position the boom and the bucket will be retained in the position in which they stop For levers b c and d the engine speed changes as follows be cause of the auto deceleration mechanism When the travel lever and wo...

Page 67: ...ed When the pedal is depressed the attachment is actuated The right hand switch panel has a ten position thumb wheelswitch This allows nine values of flow for the right hand foot pedal and no flow at position zero When selecting switch positions the RH foot pedal must be fully released before beginning work at the new flow setting Please note your prefered switch position against attacment used fo...

Page 68: ... pedal 6 SELECTOR VALVES FOR BREAKER AND GENERAL ATTACHMENT crusher etc Contact dealer to set left hand boom piping relief pressure When using the breaker and the general attachment Crusher etc turn the rotors of the 3 way valves y to change over according to the following illustration The marks indicating the port direction are stamped on the 3 way valve NOTICE Perform work only after the engine ...

Page 69: ...r an ceiling window movement by pulling lock x located on both sides then push up and open the ceiling window grasping grip y When closing Close the ceiling window grasping grip y and lock it with lock x If the lock cannot be applied open and close the ceiling window again 11 EXPLANATION OF COMPONENTS ...

Page 70: ... the operator s compartment When opening WARNING When the front window is open there is danger that it will fall so always lock it with left and right lock pins A 1 Place the work equipment on flat ground and stop the engine 2 Securely lock the safety lock lever 3 Confirm that the wiper is stored inside the right frame 4 Pull lock pins A at the top left and right sides of the front window to the i...

Page 71: ... be careful not to get your hand caught 1 Place the work equipment on a flat ground and stop the engine 2 Securely lock the safety lock lever 3 Release the lock pin A 4 Hold the grip at the bottom of the front window with your left hand and the grip at the top with your right hand release the lock of catch C with your right thumb then pull the top grip slowly and lower the front window When releas...

Page 72: ...part of the front window at the rear of the operator s cab and lock with lock pins E Notice Do not operate lower wiper if fitted when front window bottom is removed 11 7 DOOR LOCK Use the door lock to fix the door in position after opening it 1 The door will become fixed in place when it is pressed against catch y 2 To release the lock press knob x down at the left side of the opera tor s seat to ...

Page 73: ...clockwise align the match mark on the cap with the rotor groove then remove the cap To lock the cap 1 Turn the cap into place 2 Turn the key and take the key out Insert the key as far as it will go If the key is turned before it is in serted all the way it may break 11 8 2 METHOD OF OPENING AND CLOSING COVER WITH LOCK cover with Iock To open the cover locked cover 1 Insert the key 2 Turn it counte...

Page 74: ...e Purpose Lever position 2 Air outlet selector slider The operator can select a suitable outlet as required Purpose Lever position Air outlets For complete defrosting of the front window set the selector to the mid point of its strofe 11 EXPLANATION OF COMPONENTS Internal air circulation This is used when wishing to quickly warm the cab External air intake This is used for fresh air intake or to r...

Page 75: ...rms operator s feet Defroster is available when air outlet slider is in the position shown marked A DEFROSTER B FEET 11 12 AIR CONDITIONER OPTION Description The optional air conditioner can be used to cool heat de humidify operators cab 1 HEAT CONTROL SLIDER By sliding control lever a to the right red the air passing through the airconditioner unit will be warmed In heating mode fresh ambient tem...

Page 76: ...witch functions as an ON OFF switch for the air con ditioner system Notice The fan selector switch d must be selected to position 1 2 or 3 before air condition can be operated 11 EXPLANATION OF COMPONENTS Sending air to lower area of operator s seat and defrosting lower part of front window Sending air to upper area of operator s seat and defrosting upper part of front window 3 Inlet air control s...

Page 77: ... During cooling ventilate the air from time to time If operator is smoking during cooling eyes may occasionally smart In this case temporarily change the switch to ventilation cooling to ex haust the smoke When cooling for a long time period select ventilation cooling once an hour Avoiding excessive cooling If the operator feels somewhat cool when entering a cooled cab the temperature temperature ...

Page 78: ... a garage always fully retract the antenna to avoid the possibility of breakage 11 13 3 PRECAUTION OF USE To avoid safe operation adjust the volume level so that external noise is still audible Ensure no water is splashed over the speaker case or cab radio auto turning to prevent unexpected malfunction Never use solution such as benzine or tinners to clean the dial or buttons These should be wiped...

Page 79: ...0A Governor Pump controller x 10 A Solenoid valves c 20 A Air Conditioner motor v 20 A Right head lamp Work lamps Boom LH RH Engine room lamp Heated seat b 20 A Cigarette lighter Heater Window washer Left knob button n 10 A Horn m 15 A Wiper controller h 20 A Cab mounted work lamps x3 Beacon j 20 A Lower wiper Refuelling pump j 10 A Key switch signal k 15 A Work lamps Left hand deck counterweight ...

Page 80: ... If a fault occurs in the controller do not attempt repair but con sult your Komatsu distributor 11 17 TOOL BOX This is used for keeping the tools 11 18 REFUELLING PUMP Option WARNING Do not bring fire or sparks near the fuel 1 When the machine is operated on sites with no fuel container and pump the machine may be refuelled using the refuelling pump a if fitted from fuel barrels The refuelling pu...

Page 81: ...n the accumulator or expose it to flame or fire Do not weld any boss to the accumulator When disposing of the accumulator it is necessary to re lease the gas from the accumulator so please contact your Komatsu distributor This machine is equipped with the accumulator in the control circuit The accumulator is a device to store the pressure in the control circuit and when it is installed the control...

Page 82: ...EE position Move the work equipment control lever and attachment control pedal full to the back and forth right and left so as to release the pressure in the control circuit 4 Move the safety lock lever to the lock position Lock the control lever and attachment control pedal The pressure however will not be completely released so when the accumulator is removed in the control circuit gradually loo...

Page 83: ... and under the machine to check for loose nut or bolts or leakage of oil fuel or coolant and check the condition of the work equipment and hydraulic system Check also for loose wiring play and collection of dust at places which reach high temperatures Always carry out the items in this section before starting the engine each day 1 Check for damage wear play in work equipment cylinders linkage hose...

Page 84: ...r guard for dam age wear loose bolts or leaks of oil from rollers 6 Check for damage to handrail loose bolts Repair any damage and tighten any loose 7 Check for damage to gauges monitor loose bolts Check that there is no damage to the gauges and monitor in the operator s cab If any abnormality is found replace the parts Clean off any dirt on the surface 8 Clean rear view mirror check for damage Ch...

Page 85: ...r level is low add water through the water filler of reserve tank x to the FULL level 2 After adding water tighten the cap securely 3 If the reserve tank becomes empty first inspect for water leaks and then fill the radiator and the reserve tank with water CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 1 Open the engine hood 2 Remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G full...

Page 86: ...When adding fuel never let the fuel overflow This may cause a fire If spilling fuel thoroughly clean up any spillage 1 Use sight gauge G on the front face of the fuel tank to check that the tank is full 2 If the fuel level is not within the sight gauge add fuel through filler port F while watching sight gauge G Fuel capacity 340 l 89 8 US gal 74 8 UK gal For details of the fuel to use see 20 USE O...

Page 87: ...ch control le ver for work equipment and travel to the full stroke in all directions to release the internal pressure 3 Open the pump room door on the right side of the machine Check sight gauge G The oil level is normal if between the H and L marks NOTICE Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause oil to spurt out 4 If the level is below the...

Page 88: ...eck also for loose terminals and tighten any loose parts Check the following points carefully Battery Starting motor Alternator Please contact your Komatsu distributor for investigation and correc tion of the cause CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR Drain water sediment A fuel sedimentor is mounted in pump compartment Entrapped sedi ment water can be seen trough the glass bowl 1 Loose...

Page 89: ...not affect relative position of seat and wrist control levers B Fore and aft adjustment of seat Pull lever b up After the seat is set to the desired position release the lever NOTE This operation will affect relative position of seat and wrist control levers C Adjustment of seat tilting angle Pull lever c up After the seat back is set to the optimum position for easy operation release the lever 12...

Page 90: ... clockwise the suspension becomes harder and when turned anti clockwise softer Adjust the dial so that the sus pension best matching the operator s weight is selected G Lumbar adjustment Turn knop m to adjust lumbar supports ADJUSTMENT OF MONITOR PANEL ANGLE Turn the monitor panel so that the operator can view the monitor with ease When adjusting the angle the panel should be set to the desired po...

Page 91: ...osition then carry out the following checks y The buzzer will sound for approx 1 sec and the following monitors and gauges will light up for approx 3 sec Radiator water level monitor c Engine oil level monitor v Hydraulic oil level monitor b Charge level monitor n Fuel level monitor m Engine water temperature monitor h Engine oil pressure monitor i Engine water temperature gauge j Fuel gauge k Eng...

Page 92: ...e other monitors will go out Engine water temperature gauge j Fuel gauge k 2 Press lamp switch o to turn on the head lamps If the lamp switch do not light up there is probably a broken bulb or disconnection in the wiring so contact your Komatsu distributor for repairs 12 OPERATION ...

Page 93: ...motor rotating continuously for more than 20 seconds If the engine will not start wait for at least 2 minutes before try ing to start the engine again 1 Set fuel control dial a at the low idling MIN position 2 Turn the key in starting switch b to the START position The engine will start 3 When the engine starts release the key in starting switch b The key will return automatically to the ON positi...

Page 94: ...repeat from step 2 and after waiting for about 2 minutes When starting in low temperatures do as follows 1 Set fuel control dial y at the low idling MIN position 2 Hold the key in starting switch x at the HEAT position and check that preheating monitor c lights up After about 30 seconds preheating monitor lamp c will flash for about 10 seconds to indicate that preheating is finished REMARK The mon...

Page 95: ...ng switch b to the START position to start the engine Ambient temperature Preheating time Above 0o C 0o C to 10o C 20 seconds 10o C to 20o C 30 seconds 4 When the engine starts release the key in starting switch b The key will return automatically to the ON position 12 OPERATION ...

Page 96: ... move the levers suddenly Always carry out the warming up operation This will help to extend the machine life Do not suddenly accelerate the engine before the warming up operation is completed Do not run the engine at low idling or high idling continuously for more than 20 minutes This will cause leakage of oil from the turbocharger oil supply piping If it is necessary to run the engine at idling ...

Page 97: ...d earlier NOTICE When the work equipment is retracted take care that it does not interfere with the machine body or ground 6 After carrying out the warming up operation check that each gauge and monitor lamp is in the following condition Engine water temperature gauge g Inside green range Fuel gauge h Inside green range Engine water temperature monitor i OUT Radiator water level monitor j OUT Engi...

Page 98: ... temperature or hydraulic oil temperature are low after the automatic warming up operation warm the engine up further as follows NOTICE When the hydraulic oil is at a low temperature do not carry out operations or move the levers suddenly Always carry out the warming up operation This will help to extend the machine life Do not suddenly accelerate the engine before the warming up operation is comp...

Page 99: ... bucket control lever e and arm control lever f slowly to move the bucket cylinder and arm cylinder to the end of their stroke 6 Operate the bucket for 30 seconds and the arm for 30 seconds in turn fully for 5 minutes REMARK Turn swing lock switch c ON ACTUATED and operate the lever to make the oil temperature rise more quickly NOTICE When the work equipment is retraced take care that it does not ...

Page 100: ...ER Arm operation IN vn OUT Bucket operation CURL vn DUMP Swing operation LEFT vn RIGHT Travel Lo operation FORWARD vn REVERSE REMARK If the above operation is not carried out there may be a delay in response when starting or stopping each actuator so continue the op eration until it becomes normal 9 Use working mode switch b on the monitor panel to switch to the working mode to be used 12 OPERATIO...

Page 101: ...n emergency to lower the engine speed to low idling cancel the automatic warming up operation as follows 1 Turn fuel control dial a to the full speed MAX position and hold it for 3 seconds 2 When fuel control dial a is returned to the low idling MIN position the engine speed will drop 12 OPERATION ...

Page 102: ...nnel from the machine and the area Clear all obstacles from the path of the machine If the lever is moved inside the deceleration range engine speed will rise suddenly Operate the levers carefully 1 Set swing lock switch a to the ON actuated position and confirm that swing lock monitor lamp b lights up 2 Turn fuel control dial c towards the full speed position to increase the engine speed 3 Set sa...

Page 103: ...vicinity 12 4 2 MOVING MACHINE BACKWARD WARNING Before operating the travel levers check the direction of the track frame If the sprocket is at front the operation of the track levers is reversed When moving off check that the area around the machine is safe and sound the horn before moving Clear all personnel from the machine and the area Clear all obstacles from the path of the machine Use extre...

Page 104: ...20 in from the ground 4 Operate right and left travel levers e or right and left travel pedals f as follows When the sprocket is at the rear of the machine Pull levers e backward slowly or depress the rear part of pedals f slowly to move the machine off When the sprocket is at the front of the machine Push levers e forward slowly or depress the front part of pedals f slowly to move the machine off...

Page 105: ...ning Operate two travel levers a as follows Changing direction of machine when stopped When turning to the left Push the right travel lever forward to travel left when travelling for ward and pull it back to turn left when travelling in reverse REMARK When turning to the right operate the left travel lever in the same way Steering when travelling left and right travel levers both operated in same ...

Page 106: ... turn When turning left using counter rotation pull the left travel lever back and push the right travel lever forward REMARK When turning to the right using counter rotation pull the right travel lever back and push the left travel lever forward 12 OPERATION ...

Page 107: ...ert chocks underneath the wheels As an additional safety measure thrust the bucket into the ground If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accident Before leaving the operator s compartment always set the safety lock lever securely to the LOCK position 1 Put the left and right travelling and steering levers a in...

Page 108: ...is safe 1 Before operating the swing turn swing lock switch a OFF CAN CELLED NOTICE Check that swing lock lamp b goes out at the same time 2 Operate the left work equipment control lever c to swing the upper structure 3 When not operating the swing turn the swing lock switch a ON ACTUATED 12 OPERATION b a c ...

Page 109: ... on the right When the levers are released they automati cally return to the neutral position and the work equipment is held in place If the work equipment control lever is returned to the neutral posi tion when the machine is stopped even if the fuel control dial is set to FULL the auto deceleration mechanism will act to reduce the engine speed to a mid range speed REMARK If the levers are operat...

Page 110: ...n it is turned ON lights up the working mode display does not change When the lamp goes out the system returnes to the original working mode REMARK Use the active mode with the fuel control dial turned to the MAX position If it is not at the MAX position it will be impossible to achieve a suitable increase in the work equipment speed Active power max function When digging deep and loading or rock ...

Page 111: ...ive power max function ef fectively for heavy and quick work The load sensing function is installed to the active mode If the machine is set to the active power max however the load sensing function is turned off and the engine speed returns to full speed to increase the speed of the work equipment Function Advantages in work Since digging forces of arm and bucket are increased working speed is in...

Page 112: ...ype of work using working mode selector switch NOTICE Never carry out breaker operation in heavy duty operation mode H O as this may result in breakage of hydraulic equipment 12 OPERATION Power max Swift slow down Working mode Applicable work power up speed down Power Set pressure Speed Set pressure Heavy duty operation Large amount of digging mode H O and loading in a short time General operation...

Page 113: ... starting switch is turned ON the power up lamp turns on When SET switch is pressed once the speed down lamp turns on and the power up lamp goes out and when pressed again the oppo site occurs 2 When the left knob button is given a single click keep depressed after initially pressing power keeps increasing while depressed However power up automatically completes after 8 5 seconds 12 OPERATION N MI...

Page 114: ...he work equipment Prohibited operations using travel force Do not leave the bucket dug into the ground and use the travel force to excavate This will bring excessive force to bear on the rear of the machine Precautions when operating hydraulic cylinders to end of stroke If the cylinder is operated to the end of its stroke during operations force will be brought to bear on the stopper inside the cy...

Page 115: ...up by some other means This will not only reduce damage to the machine but make for better economy Sudden lever shifting during HI speed travel prohibited a Never carry out sudden lever shifting as this may cause sudden starting b Avoid sudden lever shifting from forward to reverse or vice versa c Avoid sudden lever shifting change such as sudden stopping from near top speed lever release operatio...

Page 116: ... locks travel at Mi or Lo speed When Hi speed travelling set the idler in the forward direction PERMISSIBLE WATER DEPTH NOTICE When driving the machine out of water if the angle of the ma chine exceeds 15o the rear of upper structure will go under water and water will be thrown up by the radiator fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not ...

Page 117: ... Turning or operating the work equipment when working on slopes may cause the machine to lose its balance and turn over so avoid such operations It is particularly dangerous to swing downhill when the bucket is loaded If such operations have to be carried out pile soil to make platform on the slope so that the machine can be kept hori zontal when operating Do not travel on slopes of over 30o as th...

Page 118: ...ulling force of the arm to help the machine travel uphill If engine stops If the engine stops when travelling uphill lower the bucket to the ground stop the machine then start the engine again Precautions on slopes If the engine stops when the machine is on a slope never use the left work equipment control lever to carry out swing operations The up per structure will swing under its own weight Do ...

Page 119: ...the bucket also NOTICE When using the boom or arm to raise the machine always have the bottom of the bucket in contact with the ground Never push with the teeth The angle between the boom and arm should be 90 to 110 The same applies when using the inverting bucket 12 14 2 WHEN BOTH SIDES ARE STUCK When both tracks are stuck in mud and the machine will not move lay boards as explained above and dig...

Page 120: ... within the above range rather than going all the way to the extreme end of the cylinder stroke 12 15 2 SHOVEL WORK A shovel is suitable for excavating at a position higher than the ma chine Shovel work is performed by attaching the bucket in the reverse direction 12 15 3 DITCHING WORK Ditching work can be performed efficiently by attaching a bucket to match the width of the ditch and then setting...

Page 121: ...place the bucket so that it is in light contact with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to remove the pins 2 Remove the stopper bolts and nuts then remove pins A and B and remove the bucket NOTICE After removing the pins make sure that they do not become contami nated with sand or mud and that the seals of bushing on...

Page 122: ...ud and that the seals of bushing on both sides do not become damaged 3 Install the bucket inversely After the bucket is inversed correct the inclination and direction of the retaining pin holes a and b and stabilise the bucket securely 4 Align the arm with holes a and the link with holes b then coat with grease and install pins A and B REMARK Install the O rings into retaining hole a of the arm an...

Page 123: ...erneath the wheels As an additional safety measure thrust the bucket into the ground If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accident Before leaving the operator s compartment always set the safety lock lever securely to LOCK position 1 Put left and right levers a in the neutral position The machine stops 2 Turn...

Page 124: ...izontally until the bottom touches the ground 4 Set safety lock lever c in the LOCK position 12 18 CHECK AFTER FINISHING WORK Check the engine water temperature engine oil pressure and fuel level on the monitor 12 OPERATION H O G O F O L O B O ...

Page 125: ...gine apart from an emergency In particular if the engine has overheated do not abruptly stop it but run it at medium speed to allow it to cool gradually then stop it 1 Run the engine at low idling speed for about 5 minutes to allow it go gradually cool down 2 Turn the key in starting switch a to the OFF position and stop the engine 3 Remove the key from starting switch a 12 OPERATION a ...

Page 126: ...e following places a Door of operator s cab Always remember to close the window b Fuel tank filler port c Engine hood d Battery box cover e Left side door of the machine f Right side door of the machine REMARK Use the starting switch key to open and close all these places 12 22 OVERLOAD WARNING DEVICE Excavators are provide and with this device to warm the operator about tipping over while lifting...

Page 127: ... ramps If it is necessary to change direction drive off the ramps and correct the direction then drive on to the ramps again When turning the machine on the trailer the machine s foot ing is unstable so carry out the operation slowly Always check that the door on the cab is locked regardless of whether it is open or closed Do not open or close the door on ramps or on a platform This may cause a su...

Page 128: ...t in the direction of the ramps lower the work equipment as far as possible without letting it hit the trailer then travel slowly to load or unload the machine When on the ramps do not operate any lever other than the travel lever 6 Load the machine correctly in the specified position on the trailer REMARK When the work equipment is installed load the machine from the front when the work equipment...

Page 129: ...and remove the key from the starting switch 3 Lock all the control levers securely with the safety lock lever 4 When transporting the machine place rectangular timber under neath the front and rear track shoes to prevent the machine from moving about Also hold it down with chains or rope Be particularly careful to ensure that the machine does not slip sideways NOTICE When transporting the machine ...

Page 130: ...fting a vehicle Otherwise the machine may be unbalanced Lifting a machine must be performed on a flat place with the following procedure 1 Start the engine and set the machine in the position shown in the figure at the right boom at the top stroke and arm bucket fully re tracted Direct the top revolving super structure straight forward idler side 2 Set the safety lock lever in the lock position 3 ...

Page 131: ...th an antifreeze Do not mix one antifreeze with a different brand For details of the antifreeze mixture when changing the coolant see 24 2 WHEN REQUIRED Use a Permanent Antifreeze ethylene glycol mixed with corrosion inhibitor antifoam agent etc meeting the standard requirements as shown below With permanent antifreeze no change of coolant is re quired for a year If it is doubtful that an availabl...

Page 132: ...e capacity of the battery will also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table 20o C 00 C 10o C 20o C 100 1...

Page 133: ...ery capacity drops markedly in low temperatures cover the battery or remove it from the machine keep it in a warm place and install it again the next morning If electrolyte level is found low add distilled water in the morning before beginning work Do not add the water after the day s work so as to prevent fluid in the battery from freezing in the night 14 3 AFTER COLD WEATHER When season changes ...

Page 134: ...d cover it with canvas etc Completely fill the fuel tank lubricate and change the oil before stor age Apply a thin coat of grease to metal surface of the hydraulic piston rods Disconnect the negative terminals of the battery and cover it or re move it from the machine and store it separately If the ambient temperature is expected to drop below 0o C always add antifreeze to the cooling water Lock e...

Page 135: ...ER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation request your Komatsu distributor for service Carry out the following procedure when taking the machine out of long term storage Wipe off the grease from the hydraulic cylinder rods Add oil and grease to all places 15 4 STARTING MACHINE AFTER LONG TERM STORAGE When starting the machine after a long...

Page 136: ...or the weight of the machine that is being towed If the machine sinks in mud and cannot get out under its own power or if the drawbar pull of the excavator is being used to tow a heavy object use a wire rope as shown in the diagram on the right Place pieces of wood between wire ropes and body to prevent damage to ropes and body At this time never use the towing hole which is intended only for ligh...

Page 137: ...tery or do anything that will cause sparks Battery electrolyte is dilute sulphuric acid and it will attack your clothes and skin If it gets on your clothes or on your skin wash it immediately off with large amounts of water If it gets in your eyes wash it out with fresh water and consult a doctor When handling battery always wear protective goggles When removing the battery first disconnect the ca...

Page 138: ... injury Make sure that there is no mistake in the booster cable con nections The final connection is to the revolving frame but sparks will be generated when this is done so connect to a place as far as possible from the battery However avoid con necting the cable to the work equipment as conduction is poor Use care when removing the cables from the machine that has been started Do not allow the c...

Page 139: ...er clip of booster cable B to the positive terminal of the normal machine 4 Connect one clip of booster cable B to the negative terminal of the normal machine 5 Connect the other clip of booster cable B to the engine block of the problem machine Starting the engine 1 Make sure the clips are firmly connected to the battery terminals 2 Start the engine of the normal machine and keep it to run at hig...

Page 140: ...Remove one clip of booster cable B from the engine block of the problem machine 2 Remove the other clip of booster cable B from the negative termi nal of the normal machine 3 Remove one clip of booster cable A from the positive terminal of the normal machine 4 Remove the other clip of booster cable A from the positive termi nal of the problem machine 16 TROUBLESHOOTING ...

Page 141: ...t Oil pressure monitor does not light up when engine is stopped starting switch at ON position Outside of electrical heater is not warm when touched by hand Defective wiring Defective adjustment of fan belt tension Defective alternator Defective wiring Defective alternator Defective wiring Insufficient battery charge Insufficient battery charge Insufficient battery charge Defective starting motor ...

Page 142: ...ied level see CHECK BEFORE STARTING Adjust track tension see WHEN REQUIRED Add oil to specified level see CHECK BEFORE STARTING Problem Main causes Remedy Speed of travel swing boom arm bucket is slow Pump generates abnormal noise Excessive rise in hydraulic oil temperature Track comes off Abnormal wear of sprocket Bucket rises slowly does not rise 16 6 2 CHASSIS Always contact your Komatsu distri...

Page 143: ...altitude operation Defective water level sensor Lack of fuel Air in fuel system Defective fuel injection pump or noz zle Starting motor cranks engine slug gishly Preheating monitor does not light up Defective compression Defective valve clearance Contaminated fuel Lift pump not working Fuel filter clogged Fuel lines blocked Add oil to specified level see CHECK BEFORE STARTING Replace cartridge see...

Page 144: ...ective nozzle Defective compression Defective turbocharger Defective nozzle Low grade fuel being used Overheating Damage inside muffler Excessive valve clearance Add oil to specified level see CHECK BEFORE STARTING Change to specified fuel Clean or replace see WHEN REQUIRED Replace nozzle See defective compression above Clean or replace turbo charger Replace nozzle Change to specified fuel Refer t...

Page 145: ...rake using the swing lock switch In this case immediately have the swing brake system inspected by your Komatsu distributor EO5 Governor system error Governor will not execute the control function Manually operate the governor lever To fix the the governor lever at the full stroke position use the retaining bolt holes on bracket In this case immedi ately have the governor system inspected by your ...

Page 146: ...2 102 PC210 240 ENG ...

Page 147: ...3 1 PC210 240 ENG MAINTENANCE ...

Page 148: ...ng the machine clean Always keep the machine clean This makes is easier to find parts causing problems Keep in particular grease fittings breathers and oil level gauges clean and avoid foreign matters from getting in them Be careful of hot water and oil Draining hot oils and coolants and removing their filters immediately after the engine stops are hazardous Allow the engine to cool If the oil has...

Page 149: ...oil for cleaning parts Keep flame or cigarette light away from light oil Clamp faces When O rings or gaskets are removed clean the clamp faces and replace the 0 rings and gaskets with new ones Be sure to fit 0 rings and gaskets when assembling Objects in your pockets Keep your pockets free of loose objects which can fall out and drop into the machinery especially when you work on the machinery whi...

Page 150: ...tes do as follows Inspect the air cleaner clogging monitor to see whether the air cleaner is blocked up Clean the air cleaner at shorter intervals than specified Clean the radiator core frequently to avoid clogging Clean and replace the fuel filter frequently Clean electrical components especially the starting motor and alternator to avoid accumulation of dust Avoid mixing oils Never mix oils of d...

Page 151: ...n and Maintenance Manual Even if the oil is not dirty always replace the oil after the specified interval Oil corresponds to blood in the human body so always be careful when handling it to prevent any impurities water metal particles dirt etc from getting in The majority of problems with machine are caused by the entry of such impurities Take particular care not to let any impurities get in when ...

Page 152: ...ge amounts of calcium and other impurities so if it is used scale will stick to the engine and radiator and this will cause defective heat exchange and overheating Do not use water that is not suit able for drinking When using anti freeze always observe the precautions given in the Operation and Maintenance Manual Komatsu machines are supplied with Komatsu original anti freeze in the coolant when ...

Page 153: ...y during long term storage be sure to use in the order of first in first out use the oldest oil or fuel first 18 1 6 FILTERS Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Operation and Maintenance Manual However when working in severe condi...

Page 154: ...r rod end Grease refer to 24 4 1 10 Bucket cylinder foot pin Grease refer to 24 4 1 11 Bucket cylinder rod end Grease refer to 24 4 1 12 Bucket link coupling pin Grease refer to 24 4 1 13 Arm bucket coupling pin Grease refer to 24 4 1 14 Arm link coupling pin Grease refer to 24 4 1 15 Link coupling pin Grease refer to 24 4 1 16 Final drive oil Check level refer to 24 5 1 Change oil refer to 24 8 1...

Page 155: ... other than these specified by Komatsu Be careful to keep the electric system free of water when washing the machine or when it rains Since the controller for the control system may cause malfunction due to external wave interference before installing a radio receiver and a walkie talkie or citizen band consult your Komatsu distributor When working on the seashore carefully clean the electric syst...

Page 156: ...ssure so when loosening the plug or screw or the hose joint do not stand in front of the part Loosen it slowly to release the internal pressure before removing it When carrying out inspection or maintenance of the hydraulic circuit always bleed the air from the hydraulic tank to remove the internal pressure Periodic maintenance includes the inspection of the hydraulic oil level replacement of the ...

Page 157: ...rentheses are to be replaced at the same time Item Part No Part name Q ty Replacement frequency Hydraulic oil filter 07063 51210 Element 1 Every 500 hours service 07000 05180 O ring 1 Engine oil filter 6736 51 5140 Cartridge 1 Every 500 hours service Primary fuel filter 6732 71 6120 Cartridge 1 Every 500 hours service Secondary fuel filter 6732 71 6110 Cartridge 1 Every 500 hours service Hydraulic...

Page 158: ... 87 US gal 4 88 UK gal PC240 23 2 l 6 16 US gal 5 13 UK gal 166 l 43 8 US gal 36 5 UK gal PROPER SELECTION OF FUEL COOLANT AND LUBRICANTS ASTM D975 No 1 40 22 4 14 32 50 68 86 104 F 40 30 20 10 0 10 20 30 40 C 20 USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE SAE 10W SAE 10W 30 KIND AMBIENT TEMPERATURE CAPACITY RESERVOIR OF FLUID Specified Refill Engine oil pan Swing machinery ca...

Page 159: ...ge oil according to the following table if fuel sulphur content is above 0 5 Fuel sulphur content I Change interval of oil in engine oil pan 0 5 to 1 0 1 2 of regular interval 1 0 to 1 5 1 4 of regular interval Specified capacity Total amount of oil including oil for components and oil in piping Refill capacity Amount of oil needed to refill system during normal inspection and maintenance Abbrevia...

Page 160: ...D 5 BP Vanellus C3 Gear oil EP Energrease LS EP2 Antifreeze 6 CALTEX RPM delo 400 Universal thuban Marfak all purpose 2 AF engine coolant EP Turbomax EPX 7 CASTROL RX super Hypoy MS3 Anti freeze CRD Hypoy B Spheerol EPL2 Hypoy C 8 CHEVRON Delo 400 Universal gear Ultra duty grease 2 9 CONOCO Fleet motor oil Universal gear Super sta grease lubricant 10 ELF Multiperformance 3C Tranself EP Glacelf Per...

Page 161: ...ti purpose 4140 707L White bearing summer coolant grease 15 PETROFINA FINA kappa TD FINA potonic N FINA marson EPL2 FINA tamidor 16 SHELL Rimula X Spirax EP Alvania EP grease Spirax heavy duty Sunoco ultra prestige Sunoco antifreeze 17 SUN Sunoco GL5 2EP and summer Sun prestige 742 coolant 18 TEXACO Ursa super plus Multigear Multifak EP2 Code 2055 startex Ursa premium Starplex 2 antifreeze coolant...

Page 162: ...4 SAE10W 30 EO 1030 TRANSMISSION OIL CD SAE10W TO 10 GEAR BOX OIL CD SAE10W STO 10 HEAVY DUTY CD SAE30 TO 30 CD SAE50 TO 50 HYDRAULIC OIL CD SAE10W HO 10 BIO HYDRAULIC OIL SAE10W BO 10 GREASE LG N2 BIO GREASE BIO R2 ANTI FREEZE AF 03 BIO ANTI FREEZE BIO AF 0 20 USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ...

Page 163: ...ead and cross head type 3 Socket wrench 09020 10282 Applicable width across flats set 10 mm 13 mm 14 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm 32 mm Extension Handle Joint Ratchet handle bar 4 Wrench 09002 03641 Applicable width across flats 36 mm 41 mm 5 Pliers 09036 00150 6 Filter Wrench 09019 08035 7 Grease Pump 07950 10450 For greasing work 8 Nozzle 07951 11400 9 Grease cartridge 07950 90403 Lith...

Page 164: ...1 4 1 35 0 15 9 73 1 03 8 13 31 4 2 9 3 2 0 3 23 2 2 1 10 17 65 7 6 8 6 7 0 7 48 5 5 0 12 19 112 9 8 11 5 1 0 82 6 7 2 14 22 177 19 18 0 2 0 131 14 16 24 279 29 28 5 3 206 21 18 27 383 39 39 3 282 29 20 30 549 58 56 6 405 43 22 32 745 78 76 8 549 58 24 36 927 98 94 5 10 684 72 27 41 1320 140 135 15 973 100 30 46 1720 190 175 20 1270 140 33 50 2210 240 225 25 1630 180 36 55 2750 290 280 30 2030 210...

Page 165: ...ion of the parts simply by periodic maintenance so they should always be replaced after a fixed time has passed regardless of their condition This is necessary to ensure that they always maintain their function completely However if these parts show any abnormality before the replacement interval has passed they should be repaired or replaced immediately If the hose clamps show any deterioration s...

Page 166: ...r lift pump 1 3 Spill hose engine tank 5 4 Pump outlet hose Pump to control valve 2 5 Turbocharger lubriciating hose 1 6 Work equipment hose arm cylinder line Boom Foot Sec n 2 7 Work Equipment hose arm cylinder inlet 2 SAFETY CRITICAL PARTS 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Every 2 years or 4000 hours which ever comes sooner 3 2 1 3 1 b v ...

Page 167: ...3 21 PC210 240 ENG 22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS m n ...

Page 168: ... bucket clearance 3 39 Check window washer fluid level add fluid 3 40 Check and adjust air conditioner Option 3 41 Replace additional breaker filter element option 3 40 CHECK BEFORE STARTING Check coolant level add water 3 42 Check oil level in engine oil pan add oil 3 42 Check fuel level add fuel 3 43 Check oil level in hydraulic tank add oil 3 44 Check air cleaner for clogging 3 45 Check electri...

Page 169: ...in swing machinery case add oil 3 48 Drain water and sediment from fuel tank 3 49 Clean fresh air intake heater filter 3 49 EVERY 250 HOURS SERVICE Check oil level in final drive case add oil 3 51 Check level of battery electrolyte 3 52 Lubricate swing circle 2 points 3 53 Check air conditioner compressor belt tension adjust 3 54 EVERY 500 HOURS SERVICE Replace fuel cartridges 3 55 Check swing pin...

Page 170: ...ydraulic tank strainer 3 66 Clean check turbocharger 3 67 Check alternator starting motor 3 67 Check vibration damper 3 67 Change antifreeze 3 67 Check and adjust valve clearance 3 67 EVERY 4000 HOURS SERVICE Check water pump 3 68 EVERY 5000 HOURS SERVICE Change oil in hydraulic tank 3 69 23 2 MAINTENANCE WHEN USING HYDRAULIC BREAKER For machines equipped with a hydraulic breaker the hydraulic oil...

Page 171: ... 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours REPLACE FUEL FILTER CARTRIDGE For details of the method of replacing or maintaining see the section on EVERY 500 HOURS SERVICE 24 SERVICE PROCEDURE ...

Page 172: ...ir less than 700 kPa 7 kg cm2 100 psi to element c from inside along its folds then direct it from outside along its folds and again from inside 1 Replace the outer element if it has been cleaned 6 times repeatedly or used throughout a year Replace the inner element at the same time 2 Replace both inner and outer elements when the monitor lamp y start flashing soon after installing the cleaned out...

Page 173: ...her v or the wing nut x with new parts if they are broken 8 Remove the evacuator valve b and clean it with compressed air After cleaning install it Replacing the inner element 1 Firsts remove the cover and the outer element and then remove the inner element 2 To prevent dust from getting in use a clean cloth or tape to cover the air connector outlet side 3 Clean the air cleaner body interior then ...

Page 174: ...hine Never remove the radiator cap when the engine is at oper ating temperature At operating temperature the coolant is under pressure Steam blowing up from the radiator could cause personal injury Allow the engine to cool until the radiator filler cap is cool enough to touch with your hand Remove the filler cap slowly to allow pressure to be relieved 24 2 2 CLEAN INSIDE OF COOLING SYSTEM WARNING ...

Page 175: ...1 10 2 11 1 Amount of water l 17 1 15 5 14 2 13 1 12 0 11 1 PC240 Min C 5 10 15 20 25 30 atmospheric temperature F 23 14 5 4 13 22 Amount of antifreeze l 5 4 7 0 8 4 9 6 10 7 11 65 Amount of water l 17 4 16 3 14 4 13 7 12 6 11 65 WARNING Antifreeze is flammable so keep it away from any flame Use city water for the cooling water If river water well water or other such water supply must be used cont...

Page 176: ...ter so that the radiator is always full While flushing water through the system watch carefully that the water inlet hose does not come out of the radiator water filler 6 After flushing stop the engine open drain valve x and drain plug c then close it again after all the water has drained out 7 After draining the water clean with a flushing agent We recommend use of a Komatsu genuine cleaning agen...

Page 177: ...emove the air in the cooling water run for five minutes at low idling then for another five minutes at high idling When doing this leave radiator cap a off 14 After draining off the cooling water of reserve tank d clean the in side of the reserve tank and refill the water between FULL and LOW level 15 Stop the engine wait for about three minutes add cooling water up to near the radiator water fill...

Page 178: ...g 1 Tighten first to a tightening torque of 390 40 Nm 40 4 kgm 290 30Ib ft then check that the nut and shoe are in close contact with the link mating surface 2 After checking tighten a further 120o 10o Order for tightening Tighten the bolts in the order shown in the diagram After tightening check that the nut and shoe are in close contact with the link mating sur face 24 SERVICE PROCEDURE ...

Page 179: ...k tension so as to maintain the standard tension Carry out the check and adjustment under the same conditions as when operating on jobsites where the track becomes clogged with mud measure with the track clogged with mud Inspection 1 Raise the chassis with the boom and arm When doing this operate the levers slowly 2 Measure the clearance between the bottom of the track frame and the top of the tra...

Page 180: ... tension is not relieved by this proce dure please contact your Komatsu distributor When increasing tension Prepare a grease gun 1 Pump in grease through grease fitting b with a grease gun 2 To check that the correct tension has been achieved move the ma chine backwards and forwards 3 Check the track tension again and if the tension is not correct adjust it again 4 Continue to pump in grease until...

Page 181: ... grease does not come out smoothly move the machine back wards and forwards a short distance 4 Tighten plug y 5 To check that the correct tension has been achieved move the ma chine backwards and forwards 6 Check the track tension again and if the tension is not correct ad just it again 24 2 5 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season once a year contact your Komatsu d...

Page 182: ...stop the engine and apply the locks securely to the levers 1 Untighten nuts e and bolts c and remove side cutters a and b 2 Clean cutter mounting face on bucket side plate 3 Check nuts and bolts and replace if damaged 4 Fit new side cutters 5 Tighten bolts to 110 10 kgm NOTICE When side cutters are not being used shrouds f should be fitted to prevent wear of the bucket side plate 24 SERVICE PROCED...

Page 183: ...ut lock pin b 3 After removing lock pin b check for any damage and replace if nec essary 4 Clean the surface of adapter c and remove the soil from it with a knife 5 Check the plug d for damaged rubber and replace if necessary In stall plug as shown ensuring it seats correctly TOOTH SIZE MAX ALLOWABLE DEPTH 27 37 3 2 mm 6 Clean the inside of point a then install it to adapter c If there is mud stuc...

Page 184: ... bucket tooth always check the following 1 After the lock pin has been knocked in check that it is being secured by the plug 2 Lightly hit lock pin 2 in the reverse direction from which it was hit in 3 Lightly hit the tip of the point from above and below and hit its sides from right and left 4 Confirm that tip of the plug is located in the recess of the pin The life of the point can be lengthened...

Page 185: ...position 2 Measure the amount of play A Measurement is easier of you move the bucket to one side or the other so all the play can be measured in one place In the diagram this is on the left hand side Use a gap clearance gauge for easy and accurate measurement REMARK When removing the pins place the bucket so that it is in light contact with the ground If the bucket is lowered strongly to the groun...

Page 186: ...should be varied depending on atmospheric temperature replenish washer fluid at the following mixture ratio taking temperature into account Operation area Mixture ratio Freezing and season temperature Normal Pure washer fluid 1 3 water 2 3 10 C 14 F Winter in cold region Pure washer fluid 1 2 water 1 2 20 C 4 F Winter in extremely cold region Pure washer fluid 30 C 22 F Pure washer fluid comes in ...

Page 187: ...ckages in piping Check in off season When not being used for a long period operate the cooler for 3 to 5 min utes once a month to supply lubricant to each component of the compres sor Inspection and maintenance items list for cooler Inspection and Maintenance maintenance items Contents interval Refrigerant gas Filling quantity Twice a year spring and autumn Condenser Clogging of fin Every 500 hour...

Page 188: ...ater through the water filler of reserve tank a to the FULL level 2 After adding water tighten the cap securely 3 If the reserve becomes empty first inspect for water leaks and then fill the radiator and the reserve tank with water 24 3 2 CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 1 Open the engine hood 2 Remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G fully in the oil gauge...

Page 189: ...ire If spilling fuel thoroughly clean up any spillage 1 Use sight gauge G on the rear face of the fuel tank to check that the tank is full 2 If the fuel level is not within the sight gauge add fuel through filler port F while watching sight gauge G Fuel capacity 310 81 8 US gal 68 2 UK gal For details of the fuel to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 3 A...

Page 190: ...ontrol le ver work equipment and travel to full stroke in all directions to re lease the internal pressure 3 Open the door on the right side of the machine Check sight gauge G The oil level is normal if between the H and L marks NOTICE Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause the oil to spurt out 4 If the level is below the L mark remove th...

Page 191: ...ECK ELECTRIC WIRING If the fuse blows frequently or there are traces of short circuiting in the electric wiring always locate and repair the cause Check for damage of the fuse and any sign of disconnection or short circuit in the electric wiring Check also for loose terminals and tighten any loose parts Check the following points carefully Battery Starting motor Alternator Please contact your Koma...

Page 192: ...chine Entrapped sediment and water can be seen through the the glass bowl 1 Loosen drain plug a and drain water and sediement until none is visible in bowl 2 Tighten drain plug A Fuel B Water sediment CHECK FOR WATER IN PRIMARY FUEL FILTER DRAIN WATER A primary fuel filter is fitted on the engine Drain the water from the primary fuel filter by turning cap at the bottom of the filter 24 SERVICE PRO...

Page 193: ...t the work equipment in the greasing posture below then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off any old grease that was pushed out 1 Boom cylinder foot pin 2 points 2 Boom foot pin 2 points 3 Boom cylinder rod end 2 points 4 Arm cylinder foot pin 1 point 24 SERVICE PROCEDUR...

Page 194: ...coupling pin 1 points 24 4 2 CHECK OIL LEVEL IN SWING MACHINERY CASE ADD OIL The oil is at high temperature immediately after the machine has been operated Wait for the oil to cool down before carry ing out this check 1 Remove dipstick G and wipe the oil from the dipstick with a cloth 2 Insert dipstick G fully in the guide 3 When dipstick G is pulled out if the oil level is between the H and L mar...

Page 195: ...a at the bottom of the tank and drain the sediment and water that has accumulated at the bottom together with fuel When doing this be careful not to get fuel on yourself 4 When only clean fuel comes out close drain valve a NOTICE Never use trichlene for washing the inside of the tank 24 4 4 CLEAN FRESH AIR INTAKE FILTER 1 Remove 4 wing nuts b from partition c and remove cover a 2 Access to filter ...

Page 196: ...n this interval Clean recirculation air filter air conditioner option only 1 Remove 4 bolts on the upper side of the luggage tray and remove bracket a 2 Remove 4 bolts on the lower side and lift away luggage tray b If radio is fitted disconnect radio connector first by removing radio us ing special tools provided 3 Pull filter elements c out of air conditioner housing 4 Clean as fresh air intake f...

Page 197: ...the TOP mark and plug P perpen dicular to the ground surface 2 Remove plug F using the handle When the oil level reaches a point 10 mm below the bottom of the plug hole the correct amount of oil has been added 3 If the oil level is to low install plug F operate the travel levers and drive forward or in reverse to rotate the sprocket one turn Then repeat Step 2 to check again 4 If the oil is still ...

Page 198: ...x cover on the right side of the machine 2 Remove cap a and check that the electrolyte is at the specified level 10 to 12 mm 0 40 tot 0 47 in above the plate If the electrolyte level is low add distilled water to the specified level If the battery electrolyte is spilled have dilute sulphuric acid added 3 Clean the air hole in the battery cap then tighten the cap securely When adding distilled wate...

Page 199: ...ATE SWING CIRCLE 2 points 1 Lower the work equipment to the ground 2 Using a grease pump pump in grease through the grease fittings shown by arrows 3 After greasing wipe off all the old grease that was pushed out 24 SERVICE PROCEDURE ...

Page 200: ...ts and bolts b 2 Carefully lever compressor housing as shown to tighten belt to within tightness criteria Tighten lower bolt to hold in position 3 Tighten upper bolt 4 Check each pulley for damage wear of the v groove and wear of the v bolt In particular be sure to check the v belt is not touching the bottom of the v groove 5 Replace belt if it has stretched leaving no allowance for adjustment or ...

Page 201: ...ter wrench turn primary fuel filter cartridge a counterclockwise to remove it Repeat for secondary fuel filter car tridge b 3 Clean the filter holder fill new filter cartridges with clean fuel coat the packing surface with engine oil then install them to the filter holder 4 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it up 1 2 of a ...

Page 202: ... on the lift pump if the fuel solenoid valve is energised 4 Air can be vented from both pumps through the fuel drain manifold line by operating the starting motor When using the starting motor to vent the system do not engage it for more than 30 seconds at a time wait two 2 minutes between engagements It is necessary to put the engine in the RUN position Be cause the engine may start be sure to fo...

Page 203: ...se and check that the height of the grease in the portion where the pinion passes is at least 28 mm 1 1 in Add more grease if necessary 3 Check if the grease is milky white If it is milky white it is necessary to change the grease Please contact your Komatsu distributor The total amount of grease is 21 l 18 9 kg 5 5 US gal 4 6 UK gal 41 7 lb 4 Install cover x with bolts y 24 SERVICE PROCEDURE ...

Page 204: ... after stopping the engine a large amount of oil will come out so wait for 10 minutes before starting the operation 6 Clean the filter holder coat the packing surface of a new filter car tridge with engine oil and fill the filters with clean lubricating oil or coat it thinly with grease then install it to the filter holder REMARK Confirm that no remnants of old packing still adhere to the filter h...

Page 205: ...ed air At the same time clean the net in front of the oil cooler Clean the condenser fins on machines equipped with the air conditioner The condenser is mounted on the front of the cooling package Steam or water may be used instead of compressed air After clean ing fix the cover with bolts a 3 Check the rubber hose Replace with a new one if the hose is found to have cracks or to be hardened by age...

Page 206: ...fore replacing the breather ele ment When removing the oil filler cap turn it slowly to release the internal pressure then remove it carefully 1 Remove the cover over the hydraulic tank and remove the cap of oil filter F 2 Replace element a inside the cap with a new one WARNING 24 SERVICE PROCEDURE ...

Page 207: ...dy drain the oil then tighten the drain valve again 3 Remove dipstick G and bleeding plug a Add the specified amount of engine oil through gauge hole F For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4 After refilling install bleeding plug a 5 Wipe off oil on the dipstick with a cloth 6 Insert dipstick G into the gauge pipe thoroughly and th...

Page 208: ...s up to near the bottom of more plug hole it is normal If insufficient remove the plug F and add oil through the hole of plug F up to the bottom of the plug hole G For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE NOTICE If excess oil is supplied drain it to the specified amount to avoid overheating 3 Install plug G and F 4 Close the door 24 7...

Page 209: ...nd install the cover 9 To bleed the air start the engine according to 12 2 STARTING EN GINE and run the engine at low idling for 10 minutes 10 Stop the engine REMARK Operate the machine after halting for more than 5 minutes to liminate bubbles in the oil inside the tank 11 Check for oil leakage and wipe off any spilled oil When the hydraulic breaker is installed the hydraulic oil deteriorates ear ...

Page 210: ...ts defected under hand pressure Check the tensioner bearing Replace bearing if damaged Check fan hub With the drive belt removed rotate fan hub The fan hub should spin freely without excessive end play Check the fan hub bearing Replace bearing if damaged 24 7 8 CHECK FAN BELT TENSION Measure the belt deflection at the longest span of the belt Maximum deflection 9 5 12 7 mm 3 8 1 2 inch If tension ...

Page 211: ...drained oil Min 4 2 l capacity Refill capacity 4 2 l 1 11 US gal 0 92 UK gal Handle 1 Set the TOP mark at the top with the TOP mark and plug P perpen dicular to the ground surface 2 Set a container under plug P to catch the oil 3 Remove plug P and F with the handle and drain the oil REMARK Check the O rings in the plugs for damage If necessary replace with new ones 4 Screw in plug P 5 Add engine o...

Page 212: ...ve it carefully 1 Loosen 4 bolts then remove cover a When doing this the cover may fly out under the force of spring b so push the cover down when removing the bolts 2 Pull up the top of rod c and remove spring b and strainer d 3 Remove the dirt stuck to strainer d then wash it in clean diesel oil or flushing oil If strainer d is damaged replace it with a new one 4 Refit strainer d by inserting it...

Page 213: ...tarted frequently carry out inspection every 1000 hours 24 8 5 CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber If any cracks or peeling are found contact your Komatsu distributor to have the parts replaced 24 8 6 CHANGE ANTIFREEZE Follow the procedure of 24 2 2 CLEAN INSIDE OF COOLING SYS TEM for draining and refilling the cooling system 24 8 7...

Page 214: ...250 500 1000 and 2000 hours should be carried out at the same time 24 9 1 CHECK WATER PUMP Check that there is oil leakage or clogging of the drain hole If any abnormality is found contact your Komatsu distributor for disaaaembly and repair or replacement 24 SERVICE PROCEDURE ...

Page 215: ...repare a handle for the socket wrench set 1 Swing the upper structure so that the drain plug under the hydraulic tank comes at the middle of the left or right track 2 Retract the arm and bucket cylinders to the stroke end then lower the boom and put the bucket teeth in contact with the ground 3 Lock the safety lock lever and stop the engine 4 Remove the cap of oil filler F over the hydraulic tank ...

Page 216: ...AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE NOTICE When the hydraulic breaker is installed the hydraulic oil dete riorates earlier than in normal bucket digging work Therefore re place the hydraulic oil according to the chart at the right 7 After replacing hydraulic oil and cleaning or replacing filter element and strainer bleed air from the circuit according to the following pro cedure 24 SER...

Page 217: ...e pump is operated without filling the pump case with hy draulic oil abnormal heat will be generated and this may lead to premature damage of the pump 2 Starting engine Start the engine according to 12 2 STARTING THE ENGINE Keep run ning the engine at low idling for 10 minutes and carry out the following procedure 3 Bleeding air from cylinders 1 Run the engine at low idling and extend and retract ...

Page 218: ...d uniformly to the left and right NOTICE If the air is not bled from the swing motor the bearings of the motor may be damaged 5 Bleeding air from travel motor only after draining oil from travel motor case 1 Run the engine at low idling loosen air bleeding plug a and if oil flows out tighten the air bleed plug 2 Keep the engine running at low idling and swing the work equip ment 90 to bring it to ...

Page 219: ... while running the engine at low idling NOTICE If the attachment bleeding procedure is specified by the manu facturer bleed the attachment according to such procedure 7 Operation 1 After completion of bleeding the air stop the engine and wait for at least 5 minutes before starting operations In this way the air bubbles are removed from the oil inside the hydraulic tank 2 Check for any leakage of o...

Page 220: ...3 74 PC210 240 ENG ...

Page 221: ...4 1 PC210 240 ENG SPECIFICATIONS ...

Page 222: ...OE Triple grouser shoe standard 600mm 700mm 24 in width 28 in width ENGINE Model Komatsu S6D102E diesel engine Flywheel horsepower SAEJ1349 Net 99 kW 133 HP 2000 rpm Gross 104 kW 140 HP 2000 rpm Starting motor 24 V 5 5 kW Alternator 24 V 55A Battery STD 12 V 95 Ah x 2 pieces Large capacity opt 12 V 140 AH x 2 pieces Low speed 3 0 km h 1 9 MPH Middle speed 4 1 km h 2 5 MPH High speed 5 5 km h 3 4 M...

Page 223: ... 3 PC210 240 ENG PC210 6K PC210LC 6 The values given are the values for PC210 6K Values for PC210LC 6K In case where there are no values given in the values are the same as for PC210 6K 25 SPECIFICATIONS ...

Page 224: ...0 240 ENG PC210 6K PC210LC 6K 1 The mark indicates the dimensions for shovel operation 2 Never allow other person than the operator to enter the swing range Max swing range Max digging radius 25 SPECIFICATIONS ...

Page 225: ... Triple grouser shoe standard 600mm 700mm 600mm 24 in width 28 in width 24 in width ENGINE Model Komatsu SA6D102E diesel engine Flywheel horsepower SAEJ1349 Net 118 kW 158 HP 2100 rpm Gross 124 kW 166 HP 2100 rpm Starting motor 24 V 5 5 kW Alternator 24 V 55A Battery STD 12 V 95 Ah x 2 pieces Large capacity opt 12 V 140 AH x 2 pieces 25 SPECIFICATIONS Low speed 3 0 km h 1 8 MPH Middle speed 4 1 km...

Page 226: ...4 6 PC210 240 ENG 25 SPECIFICATIONS PC240NLC 6K The values given are the values for PC240NLC 6K ...

Page 227: ... PC210 240 ENG 25 SPECIFICATIONS PC240 6K PC240LC 6K The values given are the values for PC240 6K values are for PC240LC 6K In case when there are no values given in the values are the same as for PC240 6K ...

Page 228: ...G PC240 6K PC240LC 6K PC240NLC 6K 1 The mark indicates the dimensions for the shovel operation 2 Never allow other persons than the operator to enter the swing range Max swing range Max digging radius 25 SPECIFICATIONS ...

Page 229: ... d Hydraulic pressure Nom 36 2 MPa WORKING Max 37 2 MPa HOLDING CIRCUIT WORKING CONDITIONS WITH BUCKET 680 kg 0 9m3 CECE IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacit...

Page 230: ...Hydraulic pressure Nom 36 2 MPa WORKING Max 37 2 MPa HOLDING CIRCUIT WORKING CONDITIONS WITH BUCKET 750kg 1 1m3 CECE IF OBJECT HANDLING IS PERFORMED WITH OTHER TOOL INSTALLED THE WEIGHT DIFFERENCE OF THE TOOL SHALL BE DEDUCTED FROM THE VALUES OF THIS TABLE WITH FULLY EXTENDED BUCKET CYLINDER ON A COMPACT HORIZONTAL LEVEL GROUND WITH 600 mm WIDTH SHOE Loads do not exceed 87 of hydraulic capacity or...

Page 231: ...4 11 PC210 240 ENG 25 SPECIFICATIONS ...

Page 232: ...4 12 PC210 240 ENG ...

Page 233: ...5 1 PC210 240 ENG OPTIONS ATTACHMENTS ...

Page 234: ...ion is carried out by two or more workers determine signals and follow these dur ing the operation When carrying heavy objects more than 25 kg 55 Ib use a crane When removing heavy parts always support the part before removing it When lifting such heavy parts with a crane always pay careful attention to the position of the centre of gravity It is dangerous to carry out operations with the load kep...

Page 235: ...e stops completely so there is danger of mistaking the distance and hitting some thing Always operate so that there is an ample margin to the stopping point Furthermore the hydraulic drift also becomes larger when the work equipment is stopped in mid air it will gradually move down under its own weight Always follow the correct procedure when installing the boom and arm If the correct procedure is...

Page 236: ...tions reduce the engine speed and use the lifting operation mode Depending on the posture of the work equipment there is danger that the wire or load may slip off the hook Always be careful to main tain the correct hook angle to prevent this from happening Never steer the machine while lifting a load If the bucket with hook is turned and used for operations it will hit the arm during dumping opera...

Page 237: ...raulic oil flows B STOP Hydraulic oil stops Set this valve to the STOP position when remov ing or installing attachments 2 SELECTOR VALVE This switches the flow of the hydraulic oil For attachments to be mounted and the direction of the 3 way valve C see 28 2 HYDRAULIC CIRCUIT 28 MACHINES READY FOR ATTACHMENTS y x A B C ...

Page 238: ...the manufacturer regarding the relation between pedal operation and attachment movement when the attachment is mounted Use the attachment only after confirming the above Flow from the left hand second attachment pedal can be modified by adjusting the stroke limiting bolts located under the pedal 4 ACCUMULATOR WARNING The accumulator is filled with high pressure nitrogen gas and it is extremely dan...

Page 239: ... general attachment Crusher etc turn the rotor of the 3 way valve a to change over according to the follow ing illustration The marks indicating the port direction are stamped on the 3 way valve NOTICE Perform work only after the engine is stopped and the work equip ment and machine body are in a stable posture on the ground 28 MACHINES READY FOR ATTACHMENTS a ...

Page 240: ...the stop valve piping 2 places left and right Take care not to lose or damage the removed parts 2 Connect attachment tubes b supplied by the attachment manufac turer to the end from which the plug was removed in step 1 PATH OF OIL The direction of operation of the pedal and the path of the oil are as shown in the diagram below 28 MACHINES READY FOR ATTACHMENTS ...

Page 241: ... 3 times to release hydraulic system pressure Ensure oil temperature is low 4 Remove the hoses on the attachment side Install the blind plugs to the two outlets a Install blind plugs to the attachment hoses to prevent entry of dirt during dismounting and storage 5 Dismount the attachment by removing the retaining pins 2 pins Then mount the bucket For the bucket mounting procedure see 12 15 REPLACE...

Page 242: ...orth right and left to eliminate the internal pressure in the hydraulic circuit 4 After confirming low oil temperature remove the blind plug from the outlet and inlet port respectively Take care that no dust mud etc adheres to the hose mouthpiece portions If O ring is damaged replace it with a new one Connect attachment hoses to arm tubes and store the blind plugs in a clean dry place 5 Turn the r...

Page 243: ...KER When the front portion of the pedal is depressed the breaker is actu ated Select the working mode for breaker B O Precautions when using Check that the stop valve is at the FLOW position Check that the selector valve is at the position for using the breaker For details of the oil path see 28 2 HYDRAULIC CIRCUIT For other precautions when using the breaker see the instruction manual provided by...

Page 244: ...ent is not to be used for a long period do as follows Set the stop valve to the STOP position Install the blind plugs and O rings to the arm and tubes If the pedal is operated when there is no breaker or general attach ment installed it will cause overheating and other problems 28 6 SPECIFICATIONS Hydraulic specifications Max flow when flow is joined 191 x 2 liter min 50 x 2 US gal min 42 x 2 UK g...

Page 245: ...et cylinder circuit with the bucket cylinder disable by the two arm mounted stop valves Left hand side exemple shown below The first attachment circuit right hand cab pedal can be used to rotate grabs with a rotary function with the revo frame mounted 3 way valve set to 2 way flow see section 11 6 Fine control of rotation can be achieved by adjusting the maximum output of the first attachment usin...

Page 246: ...elow The second attachment when fitted is permanently set in two way flow with full flow 2 pump output and full system pressure Attachment pressures can be modified by your local dealer on request and can have different pressures for left hand and righthand piping by modifying the relief valves in the main control valve portions When handling attachments please follow the same procedure and precau...

Page 247: ...CE 1 19 m3 1 06 m3 Outside width 1350 mm Track shoes PC210 Triple grouser shoe width 700 mm 28 Triple grouser shoe width 800 mm 31 4 Track shoes PC210LC Short arm Arm length 2400 mm 7 10 Max digging depth 6095 mm 20 Short arm Arm length 1800 mm 5 11 Max digging depth 18 Head guard In place where there is danger of falling rocks always install the head guard to protect the operator FOPS FRONT GUARD...

Page 248: ... width 800 mm 31 4 Triple grouser shoe width 900 mm 35 4 Track shoes PC240NLC Triple grouser shoe width 700 mm 28 Triple grouser shoe width 800 mm 31 4 Short arm Arm length 2500 mm 8 2 Max digging depth 6370 mm 20 11 Short arm Arm length 2000 mm 6 7 Max digging depth 5870 mm 19 3 Long arm Arm length 3500 mm 11 6 Max digging depth 7350 mm 24 1 Head guard In place where there is danger of falling ro...

Page 249: ... is recommended that the strengthened bucket with high durabil ity and high wear resistance be employed NOTICE When the extension arm is equipped if the bucket is drawn tot the machine body the arm interferes with the body Operate the extension arm carefully When the boom is fully lowered during oblique digging the boom interferes with the undercarriage Operate the boom carefully BUCKET AND ARM CO...

Page 250: ...When the boom is fully lowered during oblique digging the boom interferes with the undercarriage Operate the boom carefully BUCKET AND ARM COMBINATION SAE PCSA CECE Without side cutters Bucket capacity heaped Width Weight with side cutters No of teeth Arm 2 0 m 6 7 3 05 m 10 3 3 j 4 5 j j 5 0 95 m3 0 86 m3 1050 mm 666 kg 1 30 m3 1 12 m3 1450 mm 800 kg 0 49 m3 0 45 m3 650 mm 513 kg 1 19 m3 1 07 m3 ...

Page 251: ... Specifications A B C A B C C A B C A B C C 600 triple grouser 700 triple grouser 800 triple grouser 600 triple grouser 700 triple grouser 800 triple grouser 900 triple grouser 600 triple grouser 700 triple grouser 800 triple grouser 600 triple grouser 700 triple grouser 800 triple grouser 900 triple grouser Category Specifications PC240NLC 6K B C 700 triple grouser 800 triple grouser 29 3 SELECTI...

Page 252: ...ing teeth Long life teeth Jobsites where wear life is demanded such as when loading hard rocks Jobsites where no penetration is needed such as when working with crushed rock after blasting or ripping Jobsites where heavy duty operations are carried out such as hitting or pulling up rocks with the tips of the teeth Self sharpening teeth Jobsites demanding penetration such as digging and loading san...

Page 253: ...te of the bucket vertical The guide plate B to check this position is installed beside the bucket pins Accordingly hold this plate horizontal when digging Ditch gradient of 45o Attached the bucket only or the movable plate by selecting the re lated ditch holes Perform digging by the above method Ditch gradient of 40o or 38o Attached the bucket only or the movable plate by selecting the re lated di...

Page 254: ...rated When the extension arm is equipped use the narrow bucket bucket width 750 mm 30 in and 560 mm 22 in without the side cutter Since the standard bucket causes body instability and the bucket interferes with the operator s cab when retracting the arm do not mount the standard bucket Work in hard soil or rocky terrain will shorten the life of the extension arm the boom and the arm It is better n...

Page 255: ...ve the bucket cylinder pressure then set the lever to the neutral position This can temporally stop the rotation PRECAUTIONS WHEN USING For safety always avoid abrupt travelling swing and stopping Make the teeth of the bucket vertical in digging Do not swing the bucket to crush the rock or to cut through soil Do not use the bucket for hammering or pulling out piles etc Before leaving the machine o...

Page 256: ...CATION Crushed rock Demolition work Road construction This attachment can be used for a wide range of work including demolition of buildings breaking up of road surfaces tunnel work break ing up slag rock crushing and breaking operations in quarries Keep the chisel pushed perpendicularly against the impact surface when carrying out breaking operations When applying impact push the chisel against t...

Page 257: ...s adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly to prevent using the impact force when there is no resistance MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of...

Page 258: ...Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 30 EXTENDING MACHINE SERVICE LIFE 5 24 ...

Page 259: ...N METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Impact operations using attachment Impact operations using swing force Overloading work equipment during lifting and loading operations...

Page 260: ... To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Operations using the swing force Operations using one side of work equipment Pushing fork into ground surface to jack up and change direction of ma chi...

Page 261: ... etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Operations using the swing force Grabbing a object using buckets on only one side Closing the sub bucket with the boom and ...

Page 262: ...f the hydraulic cylinder MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Operations using the swing force Operations using one side of work equipment Catching and dragging with...

Page 263: ...ower MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Operations using cutting tip on one side only Impact operation with no load Twisting operations at end of cylinder stroke S...

Page 264: ...ving in piles at corners etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Forward or swing motion while grasping a pile Lifting more than two piles at the same time Work oth...

Page 265: ... well as river and canal work agricultural civil engi neering work and site preparation MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that opera tions are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm 2 in to spare Abrupt lever operation Travelling with a...

Page 266: ...5 34 PC210 240 ENG 5 32 ...

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Komatsu PC210, Operation & Maintenance Manual

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