EBOOK – Shop manual Komatsu PC210-8 & PC240

Index
UEN00093-07

Organization
list of the shop manual
……………………………………………………………………………
2

Table of
contents……………………………………………………………………………………………………….
4

Foreword
and general information UEN00094-00

Foreword
and general information ………………………………………………………………………………….
2

Safety
notice
…………………………………………………………………………………………………………….
2

How to
read the shop manual……………………………………………………………………………………..
6

Explanation
of terms for maintenance standard
……………………………………………………………. 8

Handling
electric equipment and hydraulic component …………………………………………………..
10

How to
read electric wire
code…………………………………………………………………………………….
18

Method
of disassembling and connecting push-pull type coupler …………………………………….
21

Standard
tightening torque
table………………………………………………………………………………….
24

Conversion
table……………………………………………………………………………………………………….
28

01
Specification

Specification
and technical data UEN00095-02

Specification
and technical data
……………………………………………………………………………………..
2

Specification
dimension
drawings………………………………………………………………………………..
2

Working
range diagram
……………………………………………………………………………………………..3

Specifications……………………………………………………………………………………………………………
4

Weight
table……………………………………………………………………………………………………………..
8

Table of
fuel, coolant and lubricants
…………………………………………………………………………….
12

10
Structure, function and maintenance standard

Engine
and cooling system UEN00096-01

Engine
and cooling system ……………………………………………………………………………………………
2

Engine
related
parts…………………………………………………………………………………………………..
2

Radiator,
oil cooler, aftercooler and fuel
cooler………………………………………………………………
3

Diesel
Particulate Filter
…………………………………………………………………………………………………
4

Diesel Particulate
Filter – Component
Parts…………………………………………………………………..
5

System
Description……………………………………………………………………………………………………
6

Regeneration
……………………………………………………………………………………………………………
6

Power
train UEN00097-00

Power
train
………………………………………………………………………………………………………………….
2

Power
train……………………………………………………………………………………………………………….
2

Final
drive
………………………………………………………………………………………………………………..
4

Swing
machinery ………………………………………………………………………………………………………
6

Swing
circle………………………………………………………………………………………………………………
10

Undercarriage
and frame UEN00098-00

Undercarriage
and frame ………………………………………………………………………………………………
2

Track
frame and recoil spring
……………………………………………………………………………………..
2

Idler…………………………………………………………………………………………………………………………
4

Carrier
roller……………………………………………………………………………………………………………..
6

Track
roller
……………………………………………………………………………………………………………….
7

Track
shoe
……………………………………………………………………………………………………………….
8

Hydraulic
system, Part 1 UEN00099-01

Hydraulic
system, Part 1
……………………………………………………………………………………………….
2

Hydraulic
equipment layout drawing…………………………………………………………………………….
2

Hydraulic
tank and filter
……………………………………………………………………………………………..
4

Hydraulic
pump…………………………………………………………………………………………………………
5

Hydraulic
pump…………………………………………………………………………………………………………
6

Pilot
oil filter
……………………………………………………………………………………………………………..
29

00 Index
and foreword UEN00093-07

PC210,
230, 240-8 5

Hydraulic
system, Part 2 UEN00100-00

Hydraulic
system, Part 2 ……………………………………………………………………………………………….
2

Control
valve…………………………………………………………………………………………………………….
2

CLSS
………………………………………………………………………………………………………………………
15

Functions
and operation by
valve………………………………………………………………………………..
20

Hydraulic
system, Part 3 UEN00160-04

Hydraulic
system, Part 3
……………………………………………………………………………………………….
3

Swing
motor……………………………………………………………………………………………………………..
3

Centre
swivel joint
…………………………………………………………………………………………………….
12

Travel
motor……………………………………………………………………………………………………………..
15

PPC
valve………………………………………………………………………………………………………………..
26

Valve
control
…………………………………………………………………………………………………………….
46

ATT EPC
Valve Assembly ………………………………………………………………………………………….
48

Solenoid
valve
………………………………………………………………………………………………………….
50

PPC
Accumulator ……………………………………………………………………………………………………..
52

Return
oil filter
………………………………………………………………………………………………………….
53

Attachment
circuit selector valve
…………………………………………………………………………………
54

Quick
coupler control valve – For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and
PC240

K50001~K50303……………………………………………………………………………………………………….
56

Quick
coupler control valve – For PC210 K51095 – K53243, PC230 K50114 – K50286 and
PC240

K50304 –
K51093.)
……………………………………………………………………………………………………
58

Quick
coupler control valve – For PC210 K53424 and up, PC230 K50287 and up and PC240

K51094
and up
…………………………………………………………………………………………………………
60

Hydraulic
cylinder
……………………………………………………………………………………………………..
62

Work
equipment UEN00101-00

Work
equipment …………………………………………………………………………………………………………..
2

Dimensions
of components
………………………………………………………………………………………..
2

Cab and
its attachments UEN00102-00

Cab and
its attachments………………………………………………………………………………………………..
2

Air
conditioner piping
…………………………………………………………………………………………………
2

Electrical
system UEN00103-03

Electrical
system
………………………………………………………………………………………………………….
2

Engine
control…………………………………………………………………………………………………………..
2

Electrical
control
system…………………………………………………………………………………………….
10

Monitor
system …………………………………………………………………………………………………………
36

Sensor
…………………………………………………………………………………………………………………….
67

PPC
Levers
……………………………………………………………………………………………………………..
70

KOMTRAX
terminal
system………………………………………………………………………………………..
72

Auto
Grease system UEN00104-00

Outline
of Auto Grease
System………………………………………………………………………………………2

Assembly
…………………………………………………………………………………………………………………
3

Components
…………………………………………………………………………………………………………….
3

The
Greasing Cycle…………………………………………………………………………………………………..
6

Introduction………………………………………………………………………………………………………………
7

20
Standard value table

Standard
service value table UEN00227-01

Standard
service value table
………………………………………………………………………………………….
2

Standard
value table for engine related parts
……………………………………………………………….. 2

Standard
value table for chassis related
parts……………………………………………………………….
4

30
Testing and adjusting

Testing
and adjusting, Part 1 UEN00228-05

Testing
and adjusting, Part 1………………………………………………………………………………………….
3

Tools
for testing, adjusting, and troubleshooting
…………………………………………………………… 3

UEN00093-07
00 Index and foreword

6 PC210,
230, 240-8

Measuring
engine speed
……………………………………………………………………………………………
6

Measuring
intake air pressure (boost pressure)
……………………………………………………………. 7

Checking
exhaust gas
colour………………………………………………………………………………………
8

Adjusting
valve clearance
…………………………………………………………………………………………..
9

Measuring
compression
pressure………………………………………………………………………………..
11

Measuring
blow-by
pressure……………………………………………………………………………………….
13

Measuring
engine oil
pressure…………………………………………………………………………………….
14

Handling
fuel system parts
…………………………………………………………………………………………15

Releasing
residual pressure from fuel
system……………………………………………………………….
15

Measuring
fuel pressure
…………………………………………………………………………………………….
16

Measuring
fuel return rate and leakage
………………………………………………………………………..
18

Bleeding
air from fuel circuit
……………………………………………………………………………………….
20

Checking
fuel circuit for
leakage………………………………………………………………………………….
22

Checking
and adjusting air conditioner compressor belt
tension……………………………………… 23

Measuring
swing circle bearing
clearance…………………………………………………………………….
24

Checking
and adjusting track shoe tension
…………………………………………………………………..
25

Measuring
and adjusting oil pressure in work equipment, swing, and travel
circuits…………… 27

Measuring
control circuit basic pressure ………………………………………………………………………
31

Measuring
and adjusting oil pressure in pump PC control circuit
…………………………………….. 32

Measuring
and adjusting oil pressure in pump LS control circuit………………………………………
36

Measuring
solenoid valve output pressure
……………………………………………………………………
42

Measuring
PPC valve output pressure …………………………………………………………………………
45

Adjusting
play of work equipment and swing PPC valves
………………………………………………. 47

Measuring
and adjusting quick coupler control valve output pressure – For PC210 K50001
-K53423, PC230 K50001 – K50286 and PC240 K50001 – K51093
…………………………………… 48

Measuring
and adjusting quick coupler control valve output pressure – For PC210 K53424
and up,

PC230
K50287 and up and PC240 K51094 and up ……………………………………………………….
49

Checking
parts which cause hydraulic drift of work equipment
……………………………………….. 50

Releasing
residual pressure fromhydraulic circuit
………………………………………………………… 52

Measuring
oil
leakage………………………………………………………………………………………………..
53

Bleeding
air from each
part…………………………………………………………………………………………
56

Checking
cab tipping stopper
……………………………………………………………………………………..
59

Adjusting
mirrors……………………………………………………………………………………………………….
60

Testing
and adjusting, Part 2 UEN00229-01

Testing
and adjusting, Part 2
………………………………………………………………………………………….
2

Special
functions of machine monitor …………………………………………………………………………..
2

Testing
and adjusting, Part 3 UEN00230-00

Testing
and adjusting, Part 3
………………………………………………………………………………………….
2

Handling
high-voltage circuit of engine controller
………………………………………………………….. 2

Preparation
work for troubleshooting of electrical system
………………………………………………. 3

Procedure
for testing
diodes……………………………………………………………………………………….7

Pm
Clinic service
………………………………………………………………………………………………………
9

40
Troubleshooting

General
information on troubleshooting UEN00231-03

Points
to remember when troubleshooting
……………………………………………………………………
2

Sequence
of events in troubleshooting…………………………………………………………………………
3

Check
before
troubleshooting……………………………………………………………………………………..
4

Classification
and procedures for troubleshooting………………………………………………………….
5

How to
read electric wire
code…………………………………………………………………………………….
9

Connection
table for connector pin numbers …………………………………………………………………
12

T-boxes
and T-adapters table
……………………………………………………………………………………..
43

Troubleshooting
by failure code (Display of code), Part 1 UEN00240-01

Failure
codes table
……………………………………………………………………………………………………
3

Before
carrying out troubleshooting when failure code is
displayed…………………………………. 8

Information
in troubleshooting
table……………………………………………………………………………..
14

Failure
code [989L00] Engine Controller Lock Caution 1
……………………………………………….. 16