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
LINK DOWNLOAD
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
LINK DOWNLOAD
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