EBOOK - Shop manual Komatsu PC210-8 & PC240-8


Shop Manual, contents binder, binder label and tabs UEN00084-07
00 Index and foreword
Index UEN00093-07q
Foreword and general information UEN00094-00
01 Specification
Specification and technical data UEN00095-02
10 Structure, function and maintenance standard
Engine and cooling system UEN00096-01
Power train UEN00097-00
Undercarriage and frame UEN00098-00
Hydraulic system, Part 1 UEN00099-01
Hydraulic system, Part 2 UEN00100-00
Hydraulic system, Part 3 UEN00160-04q
Work equipment UEN00101-00
Cab and its attachments UEN00102-00
Electrical system UEN00103-03
Auto Grease system UEN00104-00


CONTENTS:

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

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