Komatsu PC210-8, PC210LC, PC210NLC-8, PC230NHD-8, PC240LC Service Manual

UEAM004904

Operation &
Maintenance Manual

PC210-8
PC210LC, PC210NLC-8
PC230NHD-8
PC240LC, PC240NLC-8

HYDRAULIC EXCAVATOR

SERIAL NUMBER

PC210, PC210LC, PC210NLC-8
PC230NHD-8
PC240LC, PC240NLC-8
PC240LC, PC240NLC-8

- K50001 and up

- K50001 and up

- K50001 and up

- 10001 and up

WARNING

Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.

FOREWORD

11

FOREWORD FOREWORD

FOREWORD 1

This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre­cautions in this manual must be followed at all times when performing operation and maintenance. Most acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Acci­dents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.

WARNING

Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.

Read this manual thoroughly and understand its contents fully.

Read the safety messages and safety labels given in this manu al carefully so that they shou ld be under­stood fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.

In case this manual should be lost or damaged, immediat ely contact Komatsu or your Komatsu distributor
to obtain a new copy.

When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.

In this manual, measurements are expressed in internationa l standard units (SI). For the reference pur­pose, weight units used in the p ast are also displayed in ( ).

Storage location fo r the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.

1-4

FOREWORD SAFETY INFORMATION

SAFETY INFORMATION 1

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa­tions.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to per­sonal injury or damage.

In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

DANGER

WARNING

CAUTION

Example of safety message using signal word

Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.

WARNING

When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are n ot locked, this may ca use a serious inju ry or
death.

Other signal words

In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to pro­tect the machine or to give information that is useful to know.

NOTICE

REMARKS

This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.

This word is used for information that is useful to know.

1-5

SAFETY INFORMATION FOREWORD

q Safety labels

Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.

This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety pr ocedur es.

Example of safety label using words

Safety labels using pictogram

Part No.

Safety pictograms use a picture to expre ss a level of hazard­ous condition equivalent to the signal word. These safety picto­grams use pictures in order to let the operator or maintenance
worker understand the level and type of h azardous condition at
all times. Safety pictograms show the type of hazardous condi­tion at the top or left side, and the method of avoiding the haz­ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.

Part No.

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precau­tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi­bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))

1-6

FOREWORD SAFETY INFORMATION

NOISE (PC210,210LC,210NLC, PC230NHD) 1

Two labels indicating the machine noise level are affixed on the machine.
q Sound pressure level at the operator’s station, measured

according to ISO6396 (Dynamic test method,simulated
working cycle).

69

q Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.

102

1-7

SAFETY INFORMATION FOREWORD

NOISE (PC240LC,240NLC) 1

Two labels indicating the machine noise level are affixed on the machine.
q Sound pressure level at the operator’s station, measured

according to ISO6396 (Dynamic test method,simulated
working cycle).

q Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC

1-8

FOREWORD SAFETY INFORMATION

Vibration levels 1

When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera­tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO

7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleratio n

value for the body is less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-

tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.

Operating condition:

Excavating (Digging-loading-rotating-unloading-rotating)

Guide to Reduce Vibration Levels on Machine 1

The following guides can help an operator of this machine to reduce the whole body vibration levels:

1. Use the correct equipment and attachments.

2. Maintain the machine accordin g to this manual

Q Tension of crawler (for crawler machines)
Q Brake and steering systems
Q Controls, hydraulic system and linkages

3. Keep the terrain where the machine is working and traveling in good condition

Q Remove any large rocks or obstacles
Q Fill any ditches and holes
Q Site manager should provide machine operators with machine and schedule time to maintain terrain con-

ditions

4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted

Q Adjust the seat and suspension for the weight and size of the operator
Q Wear seat belt
Q Inspect and maintain the seat suspension and adjustme nt mec ha nis ms

5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly

6. Adjust the machine speed and travel path to minimize the vibration level

Q When pushing with bucket or blade, avoid sudden loading; load gradually
Q Drive around obstacles and rough terrain conditions
Q Slow down when it is necessary to go over rough terrain
Q Make the curve radius of traveling path as large as possible
Q Travel at low speed when traveling around sharp curves

1-9

SAFETY INFORMATION FOREWORD

7. Minimize vibrations for long work cycle or long distance traveling

Q Reduce speed to prevent bounce
Q Transport machines long distances between worksites

8. The following guidelines can be effective to minimize risks of low back pain

Q Operate the machine only when you are in good health.
Q Provide breaks to reduce long periods of sitting in the same posture
Q Do not jump down from the cab or machine
Q Do not repeatedly handle and lift loads

1-10

FOREWORD INTRODUCTION

INTRODUCTION 1

This Komatsu machine is designed to be used mainly for the following work:

q Digging work
q Leveling work
q Ditching work
q Loading work
q Demolition work

See the section “RECOMMENDED APPLICATIONS (3-156)“ for further details.

DIRECTIONS OF MACHINE 1

(A) Front (E) Operator's seat
(B) Rear (F) Sprocket
(C) Left
(D) Right

In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.

1-11

INTRODUCTION FOREWORD

BREAKING-IN THE NEW MACHINE 1

NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How­ever, ope rating the machine under full load before bre aking the machine in can adverse ly affect the perf or­mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).

Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.

q Run the engine at idle for 15 seconds after starting it. Dur-

ing this time, do not operate the control levers or fuel con­trol dial.

q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts,

sudden acceleration, unnecessary sudden stops, and sud­den changes in direction.

1-12

FOREWORD PRODUCT INFORMATION

PRODUCT INFORMATION 1

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1

On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION 1

On the top of the engine cylinder head cover.
(The EPA auxiliary nameplate is on the top of the engine cylinder head cover.)

EPA: Environmental Protection Agency, U.S.A.

1-13

PRODUCT INFORMATION FOREWORD

SERVICE METER LOCATION 1

On top of the machine monitor

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1

Machine serial No.

Engine serial No.

Product Identification Number
Manufacturers name:

Address:

Distributor
Address

Phone

KOMATSU UK Ltd.
Durham Road
Birtley
Chester-Le street
County Durham DH32QX
United Kingdom

1-14

FOREWORD PRODUCT INFORMATION

MACHINE SERIAL PLATES 1

STANDARD SERIAL PLATE 1

MANUFACTURING YEAR

MODEL

SERIAL

WEIGHT

ENGINE POWER

PRODUCT ID
NUMBER

MANUFACTURER

MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER

Product Identification Number

MANUFACTURER

Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan

Komatsu UK Ltd, Birtley, Co Durham, United Kingdom

kg
kW

205-00-K1291

1-15

CONTENTS

CONTENTS

FOREWORD

FOREWORD.........................................................................................................................................................1-4

SAFETY INFORMATION......................................................................................................................................1-5

NOISE (PC210,210LC,210NLC, PC230NHD)............................................................................................1-7

NOISE (PC240LC,240NLC)........................................................................................................................ 1-8

VIBRATION LEVELS................................................ ... .... ... ... ....................................... ... ... .... ....................1-9

GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................ ..............................................1-9

INTRODUCTION................................................................................................................................................. 1-11

DIRECTIONS OF MACHINE .................................................................................................................... 1-11

BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-12

PRODUCT INFORMATION................................................................................................................................1-13

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...................................... 1-13

ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.......................................................................1-13

SERVICE METER LOCATION .................................................................................................................1-14

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-14

MACHINE SERIAL PLATES..................................................................................................................... 1-15

STANDARD SERIAL PLATE...........................................................................................................1-15

SAFETY

SAFETY INFORMATION......................................................................................................................................2-2

SAFETY LABELS.................................................................................................................................................2-4

LOCATION OF SAFETY LABELS..............................................................................................................2-4

SAFETY LABELS ..................... ... ....................................... ... ....................................... ... ... ........................2-5

SAFETY INFORMATION....................................................................................................................................2-12

SAFETY RULES.............................................................................................................................. 2-12

IF PROBLEMS ARE FOUND ..........................................................................................................2-12

WORKING WEAR AND PERSONAL PROTECTIVE ITEMS .......................................................... 2-12

FIRE EXTINGUISHER AND FIRST AID KIT ................................................................................... 2-12

SAFETY EQUIPMENT ....................................................................................................................2-13

KEEP MACHINE CLEAN.................................................................................................................2-13

KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................. 2-13

LEAVING OPERATOR'S SEAT WITH LOCK.................................................................................. 2-13

HANDRAILS AND STEPS...............................................................................................................2-14

MOUNTING AND DISMOUNTING...................................... ... ... ... .... ... ... ... ... .... ... ... ......................... 2-15

NO PERSONS ON ATTACHMENTS .............................. .......................................... .... ... ... ... ... .... .. 2-15

DO NOT GET CAUGHT IN ARTICULATED PORTION ............... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 2-15

BURN PREVENTION ......................................................................................................................2-15

1-16

CONTENTS

ACTION IF FIRE OCCURS .............................................................................................................2-17

WINDSHIELD WASHER FLUID...................................................................................................... 2-17

FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................2-17

ATTACHMENT INSTALLATION...................................................................................................... 2-17

ATTACHMENT COMBINATIONS ................................................................................................... 2-18

CAB WINDOW GLASSES............................................................................................................... 2-18

UNAUTHORIZED MODIFICATIONS............................................................................................... 2-18

SAFETY AT JOBSITE.............................................. .... ... ... ... .... ... ... ....................................... ......... 2-18

WORKING ON LOOSE GROUND .................................................................................................. 2-18

DISTANCE TO HIGH VOLTAGE CABLES ..................................................................................... 2-19

ENSURE GOOD VISIBILITY..................................................................... ... ... ... .... ... ... ... ... .... ... ... ... 2-19

VENTILATION FOR ENCLOSED AREA......................................................................................... 2-20

SIGNALMAN'S SIGNAL AND SIGNS ............................................................................................. 2-20

EMERGENCY EXIT FROM OPERATOR'S CAB ............................................................................ 2-20

ELECTROMAGNETIC INTERFERENCE........................ ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 2-20

ASBESTOS DUST HAZARD PREVENTION .................................................................................. 2-21

SAFETY MACHINE OPERATION...................................................................................................................... 2-22

STARTING ENGINE... .... ... ... ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ... ................................... 2-22

CHECKS BEFORE STARTING ENGINE..................................................................... ... ... .... ... ... ... 2-22

SAFETY RULES FOR STARTING ENGINE ................................................................................... 2-23

STARTING ENGINE IN COLD WEATHER ..................................................................................... 2-23

OPERATION............................................................................................................................................. 2-24

CHECKS BEFORE OPERATION............................. .... ... ... ... .... ... .......................................... ......... 2-24

SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................................................ 2-24

SAFETY RULES FOR TRAVELLING.............................................................................................. 2-25

TRAVELLING ON SLOPES............................................................................................................. 2-26

OPERATIONS ON SLOPES ........................................................................................................... 2-27

PROHIBITED OPERATIONS................................ ... .... ... ... ... ....................................... ... ... .... ... ... ... 2-27

OPERATIONS ON SNOW............................................................................................................... 2-29

PARKING MACHINE....................................................................................................................... 2-29

TRANSPORTATION................................................................................................................................. 2-30

LOADING AND UNLOADING.......................................................................................................... 2-30

SHIPPING THE MACHINE.............................. ... ....................................... ... ... ... .... ... ... ... ... .... ... ...... 2-31

BATTERY ................................................................................................................................................. 2-32

STARTING ENGINE WITH BOOSTER CABLES............................................................................ 2-33

TOWING................................................................................................................................................... 2-34

SAFETY RULES FOR TOWING ..................................................................................................... 2-34

LIFTING OBJECTS WITH BUCKET............................... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ............................. 2-35

SAFETY RULES FOR LIFTING OBJECTS..................................................................................... 2-35

SAFETY MAINTENANCE INFORMATION........................................................................................................ 2-36

WARNING TAG..................................................................... .... ... ... ... ... .... ... ... ................................ 2-36

KEEP WORK PLACE CLEAN AND TIDY ....................................................................................... 2-36

APPOINT LEADER WHEN WORKING WITH OTHERS.................... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 2-36

STOP ENGINE BEFORE CARRYING OUT MAINTENANCE......................................................... 2-37

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................ 2-38

PROPER TOOLS ............................................................................................................................ 2-38

1-17

CONTENTS

ACCUMULATOR............................................................................................................................. 2-39

HANDLING GAS SPRING.. ... .... ... ... ... .... ... ... ... ....................................... ... ... .... ... ... ... .... ..................2-39

PERSONNEL...................................................................................................................................2-40

ATTACHMENTS.............................................................................................................................. 2-40

WORK UNDER THE MACHINE...................................................................................................... 2-40

NOISE..............................................................................................................................................2-41

WHEN USING HAMMER ................................................................................................................2-41

WELDING WORKS .........................................................................................................................2-41

REMOVING BATTERY TERMINALS..............................................................................................2-41

SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..... 2-42

DO NOT DISASSEMBLE RECOIL SPRINGS................................................................................. 2-42

SAFETY RULES FOR HIGH-PRESSURE OIL ...............................................................................2-42

OPERATION

MACHINE VIEW ILLUSTRATIONS .....................................................................................................................3-2

OVERALL MACHINE VIEW........................................................................................................................ 3-2

CONTROLS AND GAUGES....................................................................................................................... 3-3

DETAILED CONTROLS AND GAUGES..............................................................................................................3-4

MONITORING SYSTEM.............................................................................................................................3-4

BASIC OPERATION OF MACHINE MONITOR ................................................................................ 3-5

BASIC CHECK MONITORS..............................................................................................................3-9

CAUTION MONITORS ................. ... ... ....................................... ... .... ... ... ... ... ................................... 3-11

EMERGENCY MONITORS ............................................. .... ... ... ....................................... ... ... ... .... .. 3-14

METER DISPLAY PORTION...........................................................................................................3-16

MONITOR SWITCHES PORTION .................. .......................................... ...................................... 3-23

HANDLING FUNCTION SWITCHES......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ......................... 3-32

SWITCHES...............................................................................................................................................3-68

CONTROL LEVERS AND PEDALS .........................................................................................................3-73

CEILING WINDOW...................................................................................................................................3-76

WINDSHIELD ........................................................................................................................................... 3-76

EMERGENCY ESCAPE HAMMER .......................................................................................................... 3-82

DOOR LOCK ............................................................................................................................................ 3-82

CAP WITH LOCK......................................................................................................................................3-83

DRINK BOX .............................................................................................................................................. 3-85

MAGAZINE BOX.......... ... ... .... ...................................... .... ... ... ....................................... ... ... ......................3-85

ASHTRAY.................................................................................................................................................3-85

AIR CONDITIONER CONTROLS.............................................................................................................3-86

AIR CONDITIONER CONTROL PANEL ......... ... .... ... ... ... .... ... .......................................... ... ............3-86

METHOD OF OPERATION............................................. .... ... ....................................... ... ... ... ... .... ..3-91

USE AIR CONDITIONER WITH CARE........................................................................................... 3-98

AIR CONDITIONER MAINTENANCE .................... ... ... ... .... ... ... ... .... ... ... ... ... .... ............................... 3-98

RADIO....................................................................................................................................................... 3-99

CONTROL PANEL ..........................................................................................................................3-99

CONTROLS OF RADIO ................................................................................................................3-101

USE RADIO WITH CARE.............................................................................................................. 3-103

1-18

CONTENTS

SPACE FOR RADIO CASSETTE.................................................................................................. 3-103

AUXILIARY ELECTRIC POWER.......................... ....................................... ... .... ... ... ... .... ... ... ... ... .... ....... 3-104

24V POWER SOURCE ................................................................................................................. 3-104

12V POWER SOURCE ................................................................................................................. 3-104

FUSE ...................................................................................................................................................... 3-105

FUSIBLE LINK.......................................... ... ... ... ....................................... ... ... .... ... ................................. 3-106

CONTROLLER ....................................................................................................................................... 3-106

TOOL BOX.............................................................................................................................................. 3-106

GREASE GUN HOLDER........................................................................................................................ 3-106

MACHINE OPERATIONS AND CONTROLS................................................................................................... 3-107

BEFORE STARTING ENGINE ............................................................................................................... 3-107

WALK-AROUND CHECKS............................................................................................................ 3-107

REFUELLING PUMP.............................................................................................................................. 3-108

CHECKS BEFORE STARTING............................. ... .... ... ... ... .......................................... .............. 3-109

ADJUSTMENT............................................................................................................................... 3-116

SEAT BELT ................. ... .... ...................................... .... ... ... ....................................... ... ... .............. 3-120

OPERATIONS BEFORE STARTING ENGINE ............................................................................. 3-121

STARTING ENGINE... .... ... ... ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ... ................................. 3-123

AFTER STARTING ENGINE.................................................................................................................. 3-126

WARMING UP ENGINE ................................................................................................................3-127

WARMING UP HYDRAULIC EQUIPMENT................................................................................... 3-129

OPERATION AFTER COMPLETION OF WARMING-UP OPERATION....................................... 3-135

STOPPING THE ENGINE ...................................................................................................................... 3-137

MACHINE OPERATION........................................... ... ....................................... ... ... ... .... ... ... ... .............. 3-138

PREPARATIONS FOR MOVING THE MACHINE......................................................................... 3-138

MOVING MACHINE FORWARD................................................................................................... 3-139

MOVING MACHINE BACKWARD................................................................................................. 3-140

STOPPING MACHINE..................................................... ... ... .... ...................................... ... .... ....... 3-141

STEERING THE MACHINE.................................................................................................................... 3-142

STEERING .................................................................................................................................... 3-142

SWINGING ............................................................................................................................................. 3-144

WORK EQUIPMENT CONTROLS AND OPERATIONS ........................................................................ 3-145

WORKING MODE................................................................................................................................... 3-147

PROHIBITED OPERATIONS ...... ...................................... .... ... ... ... .... ... ...................................... ........... 3-149

GENERAL OPERATION INFORMATION ................................ ... ... .... ... ... ... ... .... ... ... ... ........................... 3-151

TRAVELLING ON SLOPES.................................................................................................................... 3-153

ESCAPE FROM MUD............................................................................................................................. 3-155

TRACK ON ONE SIDE STUCK..................................................................................................... 3-155

TRACKS ON BOTH SIDES STUCK.............................................................................................. 3-155

RECOMMENDED APPLICATIONS........................................................................................................ 3-156

BACKHOE WORK......................................................................................................................... 3-156

SHOVEL WORK............................................................................................................................ 3-156

DITCHING WORK........................................................................... ... ... .... .................................... 3-156

LOADING WORK .......................................................................................................................... 3-157

BUCKET REPLACEMENT AND INVERSION........................................................................................ 3-158

REPLACEMENT....................................................................................................................

........ 3-158

INVERSION................................................................................................................................... 3-160

1-19

CONTENTS

PARKING MACHINE ............. ...................................... .... ... ....................................... ... ..........................3-161

CHECK AFTER SHUT OFF ENGINE.....................................................................................................3-163

MACHINE INSPECTION AFTER DAILY WORK....................................................................................3-163

LOCKING................................................................................................................................................3-163

TRANSPORTATION......................................................................................................................................... 3-164

TRANSPORTATION PROCEDURE....................................................................................................... 3-164

SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-8 AND PC230NHD-8 .................... 3-164

LOADING AND UNLOADING WITH TRAILER ......................................................................................3-166

LOADING.......................................................................................................................................3-167

SECURING MACHINE ..................................................................................................................3-170

UNLOADING .................................................................................................................................3-174

LIFTING MACHINE.................................................................................................................................3-176

COLD WEATHER OPERATION ......................................................................................................................3-178

COLD WEATHER OPERATION INFORMATION................................................................................... 3-178

FUEL AND LUBRICANTS ............... ... .... ...................................... .... ... ... ... ....................................3-178

COOLING SYSTEM COOLANT.................................................................................................... 3-178

BATTERY ...................................................................................................................................... 3-179

AFTER DAILY WORK COMPLETION.................................................................................................... 3-180

AFTER COLD WEATHER SEASON ......................................................................................................3-180

LONG TERM STORAGE..................................................................................................................................3-181

BEFORE STORAGE . ... ... ... .... ...................................... .... ... ... ....................................... ... ... .... ................3-181

DURING STORAGE ................. ... ... .... ...................................... .... ... ... ... ................................................. 3-181

AFTER STORAGE.... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... ................................................. 3-182

STARTING MACHINE AFTER LONG-TERM STORAGE ...................................................................... 3-182

TROUBLES AND ACTIONS ............................................................................................................................ 3-183

RUNNING OUT OF FUEL ......................................................................................................................3-183

PHENOMENA THAT ARE NOT FAILURES........................................................................................... 3-183

TOWING THE MACHINE ......................... ... ....................................... ... .... ... ... ... ... .... .............................3-184

LIGHTWEIGHT TOWING HOLE .................................................. ... ... ... ....................................... ... ....... 3-185

SEVERE JOB CONDITION .................................................................................................................... 3-185

DISCHARGED BATTERY ......................................................................................................................3-186

BATTERY REMOVAL AND INSTALLATION ................................................................................ 3-186

BATTERY CHARGES ...................................................................................................................3-187

STARTING ENGINE WITH BOOSTER CABLES..........................................................................3-188

OTHER TROUBLE ......................... .... ... ... ... ....................................... ... .... ... .......................................... 3-190

ELECTRICAL SYSTEM.................................................................................................................3-190

CHASSIS.......................................................................................................................................3-191

ENGINE......................................................................................................................................... 3-192

ELECTRONIC CONTROL SYSTEM ...... ... ... ... ... .... ... ... ... .... ... ....................................... ... ... ... ... .... 3-194

POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS............................................ 3-194

MAINTENANCE

MAINTENANCE INFORMATION ......................................................................................................................... 4-2

1-20

CONTENTS

OUTLINE OF SERVICE........................................................................................................................................ 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ... ... ... .... ... ... .................................. 4-5

OIL..................................................................................................................................................... 4-5

FUEL.................................................................................................................................................. 4-6

COOLANT AND WATER FOR DILUTION ........................................................................................ 4-6

GREASE............................................................................................................................................ 4-7

CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)......................................................... 4-7

STORING OIL AND FUEL................................................................................................................. 4-8

FILTERS............................................................................................................................................ 4-8

EXPLANATION OF LUBRICATION CHART DECAL................................................................................. 4-9

ELECTRIC SYSTEM MAINTENANCE.....................................................................................................4-11

WEAR PARTS.................................................................................................................................................... 4-12

WEAR PARTS LIST.................................................................................................................................. 4-12

RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-13

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU

GENUINE OIL........................................................................................................................................... 4-15

TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 4-16

TIGHTENING TORQUE LIST......................... ... ... .... ... ... ... .... ... ... ....................................... ... ... ... ............. 4-16

SAFETY CRITICAL PARTS............................................................................................................................... 4-17

SAFETY CRITICAL PARTS LIST............................................................................................................. 4-17

MAINTENANCE SCHEDULE............................................................................................................................. 4-18

MAINTENANCE SCHEDULE CHART......................................................................................................4-18

MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................................................... 4-20

MAINTENANCE PROCEDURE.......................................................................................................................... 4-21

INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................... 4-21

INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)................................... 4-21

WHEN REQUIRED................................................................................................................................... 4-22

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................... ... .... ... ... ... ... .... ... ... ... 4-22

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-27

CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-30

CHECK AND ADJUST TRACK TENSION ...................................... ... ... .... ... ... ... .... ... ... ... ................ 4-31

REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ..................................................................... 4-33

REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................ 4-36

ADJUST BUCKET CLEARANCE.................................................................................................... 4-37

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................. 4-38

CHECK AND MAINTENANCE AIR CONDITIONER ............................. .... ... ... ... .... ... ... ... ... .... ... ... ... 4-39

WASH WASHABLE FLOOR............................................................................................................ 4-40

BLEEDING AIR FROM HYDRAULIC SYSTEM .............................. ................................................ 4-43

CHECK BEFORE STARTING .................................................................................................................. 4-45

EVERY 100 HOURS MAINTENANCE....................................................................................................

.. 4-46

LUBRICATING................................................................................................................................. 4-46

EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-48

CHECK LEVEL OF BATTERY ELECTROLYTE ...... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-48

1-21

CONTENTS

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..................................... 4-50

EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-51

LUBRICATING.................................................................................................................................4-51

LUBRICATE SWING CIRCLE ......... ... ....................................... ... .... ... ... ....................................... .. 4-52

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................4-53

REPLACE FUEL PRE-FILTER CARTRIDGE..................................................................................4-55

CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................................4-57

CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL
COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)
4-58

CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................................ 4-60

REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.............................................................4-61

CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL......................................................4-62

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-63

EVERY 1000 HOURS MAINTENANCE....................................................................................................4-64

REPLACE HYDRAULIC OIL FILTER ELEMENT............................................................................ 4-64

CHANGE OIL IN SWING MACHINERY CASE................................................................................ 4-65

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.........................................................................4-66

REPLACE FUEL MAIN FILTER CARTRIDGE ............. ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 4-67

CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS................................4-68

REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-69

CHECK FAN BELT TENSION AND REPLACE FAN BELT.............................................................4-69

CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)............4-69

EVERY 2000 HOURS MAINTENANCE....................................................................................................4-70

CHANGE OIL IN FINAL DRIVE CASE ............................................................................................ 4-70

CLEAN HYDRAULIC TANK STRAINER .........................................................................................4-71

CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL

CIRCUIT)......................................................................................................................................... 4-72

CHECK ALTERNATOR, STARTING MOTOR................................................................................. 4-75

CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................................................4-75

EVERY 4000 HOURS MAINTENANCE....................................................................................................4-76

CHECK WATER PUMP................................................................................................................... 4-76

CHECK VIBRATION DAMPER .......................................................................................................4-76

REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)..............................................................4-77

CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER4-78

CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.............. 4-78

CHECK OPERATING CONDITION OF COMPRESSOR................................................................4-79

EVERY 5000 HOURS MAINTENANCE....................................................................................................4-80

CHANGE OIL IN HYDRAULIC TANK.............................................................................................. 4-80

EVERY 8000 HOURS MAINTENANCE....................................................................................................4-81

REPLACE FUEL SPRAY PREVENTION CAP................................................................................4-81

REPLACE HIGH-PRESSURE PIPING CLAMP .............................................................................. 4-81

SPECIFICATIONS

SPECIFICATIONS................................................................................................................................................ 5-2

MONOBOOM WORKING RANGE .................................................................................................... 5-4

1-22

CONTENTS

PC210-8 WORKING RANGE (2-PIECE BOOM)............................................................................... 5-6

PC230-8 WORKING RANGE (2-PIECE BOOM)............................................................................... 5-6

PC240-8 WORKING RANGE (2-PIECE BOOM)............................................................................... 5-6

EXPLANATION OF LIFTING CAPACITY CHART

PC210, PC210LC, PC210NLC, PC230NHD-8............................................ .......................................... ..... 5-8

PC210-8............................................................................................................................................. 5-9

PC210LC-8...................................................................................................................................... 5-10

PC210NLC-8 ................................................................................................................................... 5-11

PC230NHD-8................................................................................................................................... 5-12

EXPLANATION OF LIFTING CAPACITY CHART

PC240LC, PC240NLC-8........................................................................................................................... 5-13

PC240LC-8...................................................................................................................................... 5-14

PC240NLC-8 ................................................................................................................................... 5-15

EXPLANATION OF LIFTING CAPACITY CHART

PC210, PC210LC, PC210NLC-8, PC230NHD-8 2 PIECE BOOM ........................................................... 5-16

PC210-8........................................................................................................................................... 5-17

PC210LC-8...................................................................................................................................... 5-18

PC210NLC-8 ................................................................................................................................... 5-19

PC230NHD-8................................................................................................................................... 5-20

EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-8 2 PIECE BOOM) .......................... 5-21

PC240LC-8, PC240NLC-8 2 PIECE BOOM............................................................................................. 5-22

ATTACHMENTS AND OPTIONS

GENERAL PRECAUTIONS FOR SAFETY.......................................................................................................... 6-2

PRECAUTIONS WHEN SELECTING....................... ... ... .......................................... ... ............................... 6-2

READ THE INSTRUCTION MANUAL THOROUGHLY.............................................................................. 6-2

PRECAUTIONS WHEN REMOVING OR INSTALLING............................................................................. 6-2

PRECAUTIONS WHEN USING................... ... ... ... .... ... ... ... .... ... ... ... ....................................... ... ... .... ........... 6-3

HYDRAULIC QUICK COUPLER PIPING............................................................................................................. 6-4

LOCATIONS...................................................................................................................................... 6-4

OPERATION...................................................................................................................................... 6-5

BUCKET WITH HOOK ......................................................................................................................................... 6-7

HOOK CONDITION.................................................................................................................................... 6-7

PROHIBITED OPERATIONS ...... ...................................... .... ... ... ... .... ... ...................................... ............... 6-7

MACHINE READY FOR ATTACHMENT ............................................................................................................. 6-8

LOCATIONS............................................................................................................................................... 6-8

HYDRAULIC CIRCUIT.............................................................................................................................. 6-13

SWITCHING HYDRAULIC CIRCUIT............................................................................................... 6-13

ADJUSTING OIL FLOW.................................. ... ... ... .... ... ... ....................................... ... ... ... ............. 6-13

SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT........................................... 6-13

HYDRAULIC CIRCUIT CONNECTION ........................................................................................... 6-14

OIL FLOW PATH............................................................................................................................. 6-15

REPLACE ADDITIONAL BREAKER FILTER ELEMENT................................................................ 6-16

REPLACE ADDITIONAL BREAKER PILOT FILTER ELEMENT .................................................... 6-18

1-23

CONTENTS

ATTACHMENT REMOVAL AND INSTALLATION.................................................................................... 6-20

ATTACHMENT REMOVAL..............................................................................................................6-20

ATTACHMENT INSTALLATION...................................................................................................... 6-22

ATTACHMENT OPERATIONS................................................................................................................. 6-24

WHEN USING BREAKER ............................................................................................................... 6-24

WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER.................................................. 6-26

LONG TERM STORAGE.......................................................................................................................... 6-27

SPECIFICATIONS.................................................................................................................................... 6-27

ATTACHMENT GUIDE.......................................................................................................................................6-28

COMBINATIONS OF WORK EQUIPMENT.............................................................................................. 6-28

SELECTION OF TRACK SHOES.............................................................................................................6-31

METHOD OF SELECTING SHOES ................................................................................................ 6-31

SELECTION OF BUCKET TEETH ........ ... ... .... ... ....................................... ... ... ... ...................................... 6-32

METHOD OF SELECTING TEETH................................................................................................. 6-32

STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH...........6-32

HANDLING OF RUBBER PAD SHOE AND ROAD LINER ......................................................................6-33

WORKING ENVIRONMENT............................................................................................................6-33

WORKING CONDITIONS................................................................................................................6-33

STORAGE AND MAINTENANCE .......................... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 6-34

EXTENT OF DAMAGE TO RUBBER..............................................................................................6-34

CHECK ROAD LINER ..................................................................................................................... 6-34

REPLACE ROAD LINER........................................................ ... ....................................... ... ... ... ...... 6-34

TRAPEZOIDAL BUCKET ......................... ... .... ...................................... .... ... ... ... ... .... ... ............................6-35

HANDLING EXTENSION ARM.................................................................................................................6-36

HANDLING CLAMSHELL BUCKET .........................................................................................................6-37

CONTROLS (AUXILIARY HYDRAULIC CIRCUITS).......................................................................6-38

CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING..................... ... ... ... .... ... ... ... ... .... .. 6-39

CRUSHER CONTROL PEDAL FOR ROTATION............ .... ... ... ... .... ... ... ... ... .... ............................... 6-40

RECOMMENDED ATTACHMENT OPERATIONS............................................................................................. 6-41

HYDRAULIC BREAKER...........................................................................................................................6-41

PC210/230-8 2-PC BOOM..................................................................................................................................6-46

FEATURES OF 2-PIECE BOOM & ARM .................................................................................................6-46

OPERATION.............................................................................................................................................6-46

BEFORE STORAGE POSTURE WHEN LEAVING MACHINE.......................................................6-48

LIFTING...........................................................................................................................................6-48

TESTING AND ADJUSTING ...........................................................................................................6-49

PERODIC MAINTENANCE .............................................................................................................6-49

TRANSPORTATION................................................................................................................................. 6-50

LUBRICATING.......................................................................................................................................... 6-51

EVERY 500 HOURS........................................................................................................................6-51

PC240-8 2-PC BOOM......................................................................................................................................... 6-52

FEATURES OF 2-PIECE BOOM & ARM .................................................................................................6-52

OPERATION.............................................................................................................................................6-53

TESTING AND ADJUSTING ..........................................................................................................

.6-55

TRANSPORTATION................................................................................................................................. 6-56

1-24

CONTENTS

PC240-8 STRAIGHT BOOM .............................................................................................................................. 6-57

GENERAL VIEW OF MACHINE..................................................................... .... ... ... ... .... ... ... ... ... ............. 6-57

CAUTION ITEMS...................................................................................................................................... 6-57

CONTROL (AUXILIARY HYDRAULIC CIRCUITS) .................................................................................. 6-58

CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING............................................................. 6-59

CRUSHER CONTROL BUTTON FOR ROTATION.................................................................................. 6-60

CEILING WINDOW WIPER SWITCH (3) .................................................................................................6-61

WORKING RANGE (PC 240 STRAIGHT BOOM).................................................................................... 6-62

TRANSPORTATION (STRAIGHT BOOM EQUIPMENT)......................................................................... 6-63

HANDLING MACHINES EQUIPPED WITH KOMTRAX.................................................................................... 6-64

BASIC PRECAUTIONS................................................................ ... ... ... .... ... ... ... .... ... ... ................... 6-64

SUPER LONG FRONT BOOM AND ARM PC210/240-8

OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM .................................................. 7-2

WORKING MODES.................................................................................................................................... 7-3

CHECKS BEFORE STARTING............................. ....................................... ... ... .... ... ... ... ... .... ... ... ... .. 7-4

USING SUPER LONG FRONT ......................................................................................................... 7-5

METHOD OF WORK......................................................................................................................... 7-6

WHEN TRAVELLING ........................................................................................................................ 7-6

CONTROL LEVERS, PEDALS................................................................................................................... 7-7

‘WEEDCUTTER’ MACHINE CONTROL LEVERS, PEDALS ................................... ... .... ... ... ... ... .... ... ... ... 7-10

RIGHT CONTROL LEVER BUTTONS (5 & 6) ................................................................................ 7-10

LEFT WORK EQUIPMENT CONTROL LEVER (7 & 8) .................................................................. 7-11

ATTACHMENT FLOW SELECTOR (9)........................................................................................... 7-12

TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE ........................................................ 7-13

INSTALLATION OF SUPPORTING LINK ....................................................................................... 7-13

TRANSPORTATION OF SUPER LONG FRONT MACHINE.......................................................... 7-14

WORKING RANGE OF SUPER LONG FRONT....................................................................................... 7-15

LIFTING CAPACITY PC210 LC 15 M SUPER LONG FRONT................................................................. 7-16

LIFTING CAPACITY PC210 NLC 15 M SUPER LONG FRONT.............................................................. 7-17

LIFTING CAPACITY PC240 LC 18 M SUPER LONG FRONT................................................................. 7-18

LIFTING CAPACITY PC240 NLC 18 M SUPER LONG FRONT.............................................................. 7-19

MAINTENANCE.................................................................................................................................................. 7-20

SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT.......... ......... 7-20

EVERY 50 HOURS SERVICE.................................................................................................................. 7-21

LUBRICATING................................................................................................................................. 7-21

EVERY 100 HOURS SERVICE............................................................................................................... 7-22

LUBRICATING................................................................................................................................. 7-22

1-25

CONTENTS

INDEX

COLOPHON

1-26

SAFETY

12

WARNING

Please read and make sure that you fully understand the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.

SAFETY INFORMATION SAFETY

SAFETY INFORMATION 2

SAFETY LABELS................................................................................................................................................ 2-42

LOCATION OF SAFETY LABELS.................................. ....................................... ... .... ... ... ... .... ..................2-42

SAFETY LABELS.........................................................................................................................................2-52

SAFETY INFORMATION

Safety rules................................................................................................................................................ 2-122

If problems are found.................................................................................................................................2-122

Working wear and personal protective items.............................................................................................2-122

Fire extinguisher and first aid kit ................................................................................................................ 2-122

Safety equipment.......................................................................................................................................2-132

Keep machine clean................................................................................................................................... 2-132

Keep operator's compartment clean .......................................................................................................... 2-132

Leaving operator's seat with lock............................................................................................................... 2-132

Handrails and steps ..................... ... ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ... ..........................2-142

Mounting and dismounting.........................................................................................................................2-152

No persons on attachments.......................................................................................................................2-152

Do not get caught in articulated portion .............................. ... ... ... ....................................... ... ....................2-152

Burn prevention..........................................................................................................................................2-152

Fire prevention and explosion prevention..................................................................................................2-162

Action if fire occurs.....................................................................................................................................2-172

Windshield washer fluid ..................... ....................................... ... .... ... ... ... .... ... ... ... ... .... ... ..........................2-172

Falling objects, flying objects and intruding objects prevention ................................................................. 2-172

Attachment installation. ... ... ... .... ... ... ... .... ... ... ... .... ...................................... .... ... ... ... ... .... ... ..........................2-172

Attachment combinations.................................... ... ....................................... ... ... ... ... .... ... ... .......................2-182

Cab window glasses ....................... ... .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ..........................2-182

Unauthorized modifications ........................................................................................................................ 2-182

Safety at jobsite..........................................................................................................................................2-182

Working on loose ground........................................................................................................................... 2-182

Distance to high voltage cables .................................................................................................................2-192

Ensure good visibility .................................................................................................................................2-192

Ventilation for enclosed area......................................................................................................................2-202

Signalman's signal and signs.......................... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ............................................. 2-202

Emergency exit from operator's cab ..........................................................................................................2-202

Asbestos dust hazard prevention...............................................................................................................2-212

SAFETY MACHINE OPERATION ....................................................................................................................2-222

STARTING ENGINE..................................................................................................................................2-222

Checks before starting engine ............................................................................................................2-222

Safety rules for starting engine ...........................................................................................................2-232

Starting engine in cold weather...........................................................................................................2-232

OPERATION.............................................................................................................................................. 2-242

Checks before operation.....................................................................................................................2-242

Safety rules for changing machine directions ..................................................................................... 2-242

Safety rules for traveling .....................................................................................................................2-252

Traveling on slopes............................................................................................................................. 2-262

Operations on slopes................................................................... ... ... .... ... ... ... ... ................................. 2-272

Prohibited operations.......................................................................................................................... 2-272

Operations on snow........................................................................ ... .... ... ... ... ... .................................2-292

Parking machine...................................... .... ... ... ... ... .... ... ... ... .... ..........................................................2-292

TRANSPORTATION..................................................................................................................................2-302

Loading and unloading........................................................................................................................2-302

Shipping the machine .........................................................................................................................2-312

BATTERY...................................................................................................................................................2-322

Battery hazard prevention..................... ... .... ... ... ... ... .... ...................................... .... ... ... ... ....................2-322

2-2

SAFETY SAFETY INFORMATION

Starting engine with booster cables.................................................................................................... 2-332

TOWING ....................................................................................................................................................2-342

Safety rules for towing ........................................................................................................................ 2-342

LIFTING OBJECTS WITH BUCKET.......................................................................................................... 2-352

Safety rules for lifting objects.............................................................................................................. 2-352

SAFETY MAINTENANCE INFORMATION....................................................................................................... 2-362

Warning tag................................................................................................................................................ 2-362

Keep work place clean and tidy................................................... ... ... .... ... ... ... ... .... ... ... ... .... ... .................... 2-362

Appoint leader when working with others .................................................................................................. 2-362

Stop engine before carrying out maintenance ........................................................................................... 2-372

Two workers for maintenance when engine is running.............................................................................. 2-382

Proper tools........................ ...................................... .... ... ... ... ..................................................................... 2-382

Accumulator............................................................................................................................................... 2-392

Handling gas spring................................................................................................................................... 2-402

Personnel................................................................................................................................................... 2-402

Attachments............................................................................................................................................... 2-402

Work under the machine.................................... ....................................... ... ... ... .... ... ... ... .... ....................... 2-402

Noise.......................................................................................................................................................... 2-412

When using hammer.................................................................................................................................. 2-412

Welding works.......................... ....................................... ... ... .... ... .............................................................. 2-412

Removing battery terminals....................................................................................................................... 2-412

Safety first when using high-pressure grease to adjust track tension........................................................ 2-422

Do not disassemble recoil springs............................................................................................................. 2-422

Safety rules for high-pressure oil ............................................................................................................... 2-422

Precaution for high fuel pressure............................................................................................................... 2-432

Safety handling high-pressure hoses.... ... .... ... ... ... ....................................... ... ... .... .................................... 2-432

Precaution for high voltage ........................................................................................................................ 2-432

Waste materials ......................................................................................................................................... 2-432

Air conditioner maintenance ...................................................................................................................... 2-442

Compressed air.......................................................................................................................................... 2-44

Periodic replacement of safety critical parts .............................................................................................. 2-442

2

2-3

SAFETY LABELS SAFETY

SAFETY LABELS 2

The following warning signs and safety labels are used on this machine.

q Be sure that you fully understand the correct position and content of labels.
q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always

keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels
to peel off.

q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same

way.

q If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the p art

numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

LOCATION OF SAFETY LABELS 2

2-4

e

c

b

a

d

f

A