Komatsu Hydraulic Excavator PC210,210LC,210NLC PC240LC,240NLC-7K Shop Manual PDF

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Komatsu Hydraulic Excavator PC210,210LC,210NLC PC240LC,240NLC-7K Shop Manual UEBM0017 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC210,210LC,210NLC PC240LC,240NLC-7K Shop Manual UEBM0017 – PDF DOWNLOAD

Language : English
Pages :668
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC210,210LC,210NLC PC240LC,240NLC-7K Shop Manual UEBM0017 – PDF DOWNLOAD

MACHINE MODEL         SERIAL NUMBER
PC210-7K 00                   K40001 AND UP 00
PC210LC-7K 00              K40001 AND UP 00
PC210-NLC-7K 00         K40001 AND UP 00
PC240LC-7K 00              K40001 AND UP 00
PC240NLC-7K 00          K40001 AND UP 00

PC200-7_Sec01pdf 0
PC240LC-7K, PC240NLC-7K 10
DIMENSIONS 10
WORKING RANGES 10
DIMENSIONS 11
Working ranges 11
PC240LC-7K, PC240NLC-7K 14
SPECIFICATION DIMENSION DRAWINGS 8
PC210-7K, PC210LC-7K, PC210NLC-7K 8
DIMENSIONS 8
WORKING RANGES 8
DIMENSIONS 9
Working ranges 9
SPECIFICATIONS 12
PC210-7K, PC210LC-7K, PC210NLC-7K 12
WEIGHT TABLE 16
pc210-7K, pc210lc-7K, PC210NLC-7K 16
pc240LC-7K, pc240Nlc-7K 18
FUEL, COOLANT, AND LUBRICANTs 20
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ENGINE RELATED PARTS 22
RADIATOR • OIL COOLER • AFTERCOOLER 23
POWER TRAIN 24
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FINAL DRIVE 26
SWING MACHINERY 28
PC210-7K, PC210LC-7K, PC210NLC-7K 28
SWING CIRCLE 32
PC210-7K, PC210LC-7K, PC210NLC-7K 32
PC240LC-7K, PC240NLC-7K 33
TRACK FRAME • RECOIL SPRING 34
IDLER 36
CARRIER ROLLER 38
TRACK ROLLER 39
TRACK SHOE 40
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE 40
TRIPLE GROUSER SHOE 43
SWAMP SHOE 43
hydraulic equipment layout drawing 44
HYDRAULIC TANK 46
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HYDRAULIC PUMP 48
HPV95 + 95(PC210/LC/NLC-7K) 48
HPV95 + 95(PC240LC/NLC-7K) 50
LS VALVE 55
PC VALVE 55
LS(pc)-EPC VALVE 68
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CONTROL VALVE 72
pc210-7K, pc210lc-7K, PC210NLC-7K 73
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CONTROL VALVE 88
pc240LC-7K, pc240Nlc-7K 88
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MAIN RELIEF VALVE (PC210/LC/NLC-7K)107
Function107
MAIN RELIEF VALVE (PC240LC/NLC-7K)108
Variable pressure compensation valve109
CLSS111
OUTLINE OF CLSS111
SWING MOTOR112
REVERSE PREVENTION VALVE117
CENTER SWIVEL JOINT119
TRAVEL MOTOR120
TRAVEL JUNCTION VALVE130
TRAVEL PPC SHUTTLE VALVE132
VALVE CONTROL134
WORK EQUIPMENT • SWING PPC VALVE136
TRAVEL PPC VALVE140
SERVICE PPC VALVE149
SOLENOID VALVE152
PPC ACCUMULATOR154
return oil filter155
For Breaker155
BOOM HYDRAULIC DRIFT PREVENTION VALVE156
LIFT CHECK VALVE161
attachment circuit selector valve162
HYDRAULIC CYLINDER164
pc210-7K, pc210lc-7K, PC210NLC-7K164
BOOM CYLINDER164
ARM CYLINDER164
BUCKET CYLINDER164
pc240LC-7K, pc240Nlc-7K166
BOOM CYLINDER166
ARM CYLINDER166
BUCKET CYLINDER166
work equipment168
Pc210-7K, pc210lc-7K, PC210NLC-7K169
Pc240LC-7K, pc240Nlc-7K170
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1 DIMENSION OF ARM172
2 Dimension of bucket176
air conditioner178
air conditioner piping178
ENGINE CONTROL179
Governor motor183
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Engine throttle and pump controller185
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ELECTRONIC CONTROL SYSTEM188
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machine control system diagram190
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mULTI MONITOR SYSTEM214
SENSOR237
PC240LC-7K, PC240NLC-7K 30
SELF PRESSURE REDUCING VALVE103
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STANDARD VALUE TABLE FOR ENGINE RELATED PARTS242
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS243
Flow control characteristic of PC valve (STD)256
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INSPECTION AND ADJUSTMENT OF ENGINE RPM258
MEASUREMENT OF EXHAUST GAS COLOR260
ADJUSTMENT OF VALVE CLEARANCE261
MEASUREMENT OF COMPRESSION PRESSURE263
MEASUREMENT OF BLOW-BY PRESSURE264
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING265
MEASUREMENT OF ENGINE OIL PRESSURE267
ADJUSTMENT OF ENGINE SPEED SENSOR268
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION268
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM269
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS270
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION271
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWIN272
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE276
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC240LC/NLC)277
iNSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC210/LC/NLC)280
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc240lc/nlc)283
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc210/lc/nlc)287
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE291
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE294
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE295
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT296
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT297
MEASUREMENT OF OIL LEAKAGE AMOUNT298
AIR BLEEDING OF VARIOUS PARTS300
INSPECTION PROCEDURES FOR DIODE302
SPECIAL FUNCTION OF MULTI-MONITOR PANEL303
Operation of Operator’s Menu and Display (Outline)305
Table for Service and Failure Code Nos310
Operation and Display of Service Menu312
Table for Monitoring Items315
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM327
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POINTS TO REMEMBER WHEN TROUBLESHOOTING340
SEQUENCE OF EVENTS IN TROUBLESHOOTING341
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE342
CHECKS BEFORE TROUBLESHOOTING350
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING351
Classification of troubleshooting351
Steps for troubleshooting351
Failure-looking Phenomenon and Troubleshooting No352
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM356
Connector table356
CONNECTOR LOCATION STEREOGRAM362
Monitor Panel System Circuit Diagram (M Circuit)368
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller370
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller372
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS374
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INFORMATION CONTAINED IN TROUBLESHOOTING TABLE395
Service Code in Electrical System (Abnormal data in Error History)391
Service Code in Electrical System (Short-circuiting in normal rotation system of windshield wiper404
Service Code in Electrical System (Short-circuiting in reverse rotation system of windshield wipe406
Service Code in Electrical System (Short-circuiting in window washer drive system)408
Service Code in Electrical System (Abnormal Windshield Wiper Motion)410
Service Code in Electrical System (Abnormality in retracting windshield wiper)412
Service Code in Electrical System (Short-circuiting in travel interlocking solenoid)310
Service Code in Electrical System (Short-circuiting in swing and parking brake solenoid – in gove416
Service Code in Electrical System (Short-circuiting in merge/divide solenoid)418
Service Code in Electrical System (Short-circuiting in 2-stage relief solenoid)420
Service Code in Electrical System (Short-circuiting in travel speed shifting solenoid)422
Service Code in Electrical System (Disconnection in travel interlocking solenoid)424
Service Code in Electrical System (Disconnection in Swing Parking Brake Solenoid)426
Service Code in Electrical System (Disconnection of merge/divide solenoid)428
Service Code in Electrical System (Disconnection in 2-stage relief solenoid)430
Service Code in Electrical System (Disconnection in travel speed shifting solenoid)432
Service Code in Electrical System (Abnormality in inputting model code)388
Service Code in Electrical System Disconnection of S-NET signal)325
Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)440
Service Code in Electrical System (Disconnection in LS-EPC solenoid system)262
Service Code in Electrical System (Abnormality in F pump pressure sensor)442
Service Code in Electrical System (Abnormality in R pump pressure sensor)444
Service Code in Electrical System (Abnormality in Pressure sensor power source)446
Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump contr448
Service Code in Electrical System (Short-circuiting in attachment return switching relay)449
Service Code in Electrical System (Short-circuiting in PC-EPC Solenoid450
Service Code in Electrical System (Disconnection in PC-EPC solenoid system)452
Service Code in Electrical System (Disconnection in attachment return switching relay)454
Service Code in Electrical Equipment (Short-circuiting in attachment oil flow rate adjusting EPC)456
Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC) (Mult457
Service Code in Electrical System (Incorrect nonvolatile memory data)458
Service Code in Electrical System (Abnormality in governor potentiometer)460
Service Code in Electrical System (Abnormality in fuel dial)462
Service Code in Electrical System (Short-circuiting in battery relay)464
Service Code in Electrical System (Step-out in governor motor)466
Service Code in Electrical System (Disconnection in governor motor Phase A and B)468
Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B)361
Service Code in Electrical System (“Model Selection” function not provided yet)472
Service Mode in Electrical System (Model selecting signal fault)473
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling)357
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)358
Failure Code in Mechanical System (Air cleaner clogging)475
Failure Code in Mechanical System (Abnormally lowered charging voltage)476
Failure Code in Mechanical System (Abnormally lowered engine oil pressure)478
Failure Code in Mechanical System (Abnormally lowered engine oil level)479
Failure Code in Mechanical System (Engine cooling water overheating)480
Failure Code in Mechanical System (Abnormally lowered radiator water level)481
Failure Code in Mechanical System (Hydraulic oil overheating)482
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INFORMATION CONTAINED IN TROUBLESHOOTING TABLE408
Relative Electrical Circuit Diagram484
E-1 Engine does not start (Engine does not rotate)485
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging487
E-2 Engine stops while in operation310
Electrical Circuit Diagram for Fuel Dial488
E-3 Engine speed is irregular, or there is hunting489
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging312
E-4 Engine does not stop491
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging492
E-5 Auto-decelerator does not work493
E-6 Auto engine warm-up device does not work494
E-7 Preheater does not work495
Electrical Circuit Diagram for Engine Preheater496
E-8 All work equipment, swing and travel do not move497
Electrical Circuit Diagram for PPC Lock Solenoid498
E-9 One-touch Power Max Switch does not work499
Electric Circuit Diagram for One-Touch Power Max Switch499
E-10 No display in monitor panel at all500
Electrical Circuit Diagram for Power Source in Monitor Panel500
E-11 Part of display on monitor panel is missing501
E-12 Monitor panel displays contents irrelevant to the model440
E-13 Fuel level monitor red lamp lights up while engine is running502
Electrical Circuit Diagram for Fuel Level Sensor502
E-14 Engine cooling water temperature gauge does not indicate correctly503
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor503
E-15 Hydraulic oil temperature gauge does not display correctly504
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor504
E-16 Fuel gauge does not display correctly505
Electrical Circuit Diagram for Fuel Level Sensor505
E-17 Swing lock monitor does not display correctly506
Electrical Circuit Diagram for Swing Lock Switch272
E-18 When the monitor switch is operated, no display appears508
E-19 Windshield wiper does not work509
Electrical Circuit Diagram for Windshield Wiper Motor510
E-20 Alarming buzzer cannot be cancelled511
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch511
E-21 “Boom RAISE” is not correctly displayed in monitor function512
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch306
E-22 “Boom LOWER” is not correctly displayed in monitor function513
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch513
E-23 “Arm DIGGING” is not correctly displayed in monitor function514
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch514
E-24 “Arm DUMPING” is not correctly displayed in monitor function515
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch515
E-25 “Bucket DIGGING” is not correctly displayed in monitor function516
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch516
E-26 “Bucket DUMPING” is not correctly displayed in monitor function517
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch353
E-27 “SWING” is not correctly displayed in monitor function518
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches519
E-28 “TRAVEL” is not correctly displayed in monitor function520
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm521
E-29 “Travel Differential Pressure” is not correctly displayed in monitor function522
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch523
E-30 “Service” is not correctly displayed in monitor function524
Electrical Circuit Diagram for Service PPC hydraulic Switch525
E-31 Air Conditioner does not work526
Electrical Circuit Diagram for Air Conditioner526
E-32 Travel alarm does not sound527
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm528
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SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS530
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE532
H-1 All work equipment lack power, or travel and swing speeds are slow533
H-2 Engine speed sharply drops or engine stalls534
H-3 No work equipment, travel or swing move535
H-4 Abnormal noise is heard from around hydraulic pump535
H-5 Auto-decelerator does not work536
H-6 Fine control mode does not function536
H-7 Boom moves slowly or lacks power537
H-8 Arm moves slowly or lacks power538
H-9 Bucket moves slowly or lacks power539
H-10 Work equipment does not move in its single operation539
H-11 Work equipment has a bit too fast hydraulic drift540
H-12 Work equipment has big time lag541
H-13 Other work equipment moves when relieving single circuit541
H-14 One-touch power max switch does not operate485
H-15 In compound operation, work equipment with larger load moves slowly542
H-16 In swing + boom RAISE operation, boom moves slowly542
H-17 In swing + travel, travel speed drops sharply542
H-18 Machine swerves in travel543
H-19 Machine travels slowly544
H-20 Machine cannot be easily steered or lacks power310
H-21 Travel speed does not shift, or it is too slow or fast489
H-22 Track shoe does not turn (on one side only)547
H-23 Machine does not swing548
H-24 Swing acceleration is poor, or swing speed is slow549
H-25 Excessive overrun when stopping swing550
H-26 There is big shock when stopping swing551
H-27 There is big abnormal noise caused when stopping swing551
H-28 Swing natural drift is too big315
Sec 30pdf 0
HOW TO READ THIS MANUAL555
REMOVAL AND INSTALLATION OF ASSEMBLIES555
DisassemblY and assemblY OF assemblIES556
PRECAUTIONS WHEN PERFORMING OPERATION557
STARTING MOTOR ASSEMBLY559
REMOVAL559
INSTALLATION559
FUEL INJECTION PUMP ASSEMBLY560
ENGINE FRONT SEAL564
ENGINE REAR SEAL566
CYLINDER HEAD ASSEMBLY568
RADIATOR ASSEMBLY574
HYDRAULIC OIL COOLER ASSEMBLY576
ENGINE AND HYDRAULIC PUMP ASSEMBLIES578
FINAL DRIVE ASSEMBLY584
FINAL DRIVE ASSEMBLY585
SKETCHES OF SPECIAL TOOLS592
SWING MOTOR AND SWING MACHINERY ASSEMBLY593
SWING MOTOR AND SWING MACHINERY ASSEMBLY594
CARRIER ROLLER ASSEMBLY601
TRACK ROLLER ASSEMBLY602
IDLER ASSEMBLY603
RECOIL SPRING ASSEMBLY606
SPROCKET608
TRACK SHOE ASSEMBLY609
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON)609
REMOVal AND EXPANsion OF ROAD LINERS611
INSTALLation OF ROAD LINERS612
SWING CIRCLE613
ASSEMBLY613
REVOLVING FRAME ASSEMBLY614
CENTER SWIVEL JOINT ASSEMBLY616
CENTER SWIVEL JOINT ASSEMBLY618
HYDRAULIC TANK ASSEMBLY619
CONTROL VALVE ASSEMBLY621
CONTROL VALVE ASSEMBLY624
HYDRAULIC PUMP ASSEMBLY627
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT630
WORK EQUIPMENT PPC VALVE ASSEMBLY631
TRAVEL PPC VALVE ASSEMBLY632
HYDRAULIC CYLINDER ASSEMBLY633
WORK EQUIPMENT ASSEMBLY639
AIR CONDITIONER UNIT ASSEMBLY642
COUNTERWEIGHT ASSEMBLY645
OPERATOR’S CAB ASSEMBLY646
MONITOR ASSEMBLY648
GOVERNOR PUMP CONTROLLER ASSEMBLY649
PC200-7_Sec90pdf 0
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PC200-7_Sec90_Bodypdf 0
hydraulic circuit diagram (1/2)653
PC210-7K, PC210LC-7K, pc210nlc-7K653
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hydraulic circuit diagram (2/2)655
PC210-7K, PC210lc-7K, PC210nLC-7K655
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HYDRAULIC diagram (1/1)657
pc240lc-7K, pc240nlc-7K657
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electrical circuit diagram (1/4)659
for multi monitor659
pc210-7K, pc210lc-7K, pc210nlc-7K659
pc240lc-7K, pc240nlc-7K659
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electrical circuit diagram (2/4)661
for multi monitor661
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electrical circuit diagram (3/4)663
for multi monitor663
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electrical circuit diagram (4/4)665
for multi monitor665
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electrical circuit diagram for air conditioner667
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IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24