Komatsu PC210,210LC,210NLC,240LC,240NLC-7K Hydraulic Excavator (K40001 and up) Shop Manual - UEBM001

This complete service repair workshop manual PDF download for the Komatsu PC210,210LC,210NLC,240LC,240NLC-7K Hydraulic Excavator (SN: K40001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

MACHINE MODEL - SERIAL NUMBER
PC210-7K - K40001 and up
PC210LC-7K - K40001 and up
PC210-NLC-7K - K40001 and up
PC240LC-7K - K40001 and up
PC240NLC-7K - K40001 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEBM001701
Total Pages : 668


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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PC200-7_Sec01.pdf
PC240LC-7K, PC240NLC-7K
DIMENSIONS
WORKING RANGES
DIMENSIONS
Working ranges
PC240LC-7K, PC240NLC-7K
SPECIFICATION DIMENSION DRAWINGS
PC210-7K, PC210LC-7K, PC210NLC-7K
DIMENSIONS
WORKING RANGES
DIMENSIONS
Working ranges
SPECIFICATIONS
PC210-7K, PC210LC-7K, PC210NLC-7K
WEIGHT TABLE
pc210-7K, pc210lc-7K, PC210NLC-7K
pc240LC-7K, pc240Nlc-7K
FUEL, COOLANT, AND LUBRICANTs

ENGINE RELATED PARTS
RADIATOR • OIL COOLER • AFTERCOOLER
POWER TRAIN
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FINAL DRIVE
SWING MACHINERY
PC210-7K, PC210LC-7K, PC210NLC-7K
SWING CIRCLE
PC210-7K, PC210LC-7K, PC210NLC-7K
PC240LC-7K, PC240NLC-7K
TRACK FRAME • RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
TRIPLE GROUSER SHOE
SWAMP SHOE
hydraulic equipment layout drawing
HYDRAULIC TANK
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HYDRAULIC PUMP
HPV95 + 95(PC210/LC/NLC-7K)
HPV95 + 95(PC240LC/NLC-7K)
LS VALVE
PC VALVE
LS(pc)-EPC VALVE
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CONTROL VALVE
pc210-7K, pc210lc-7K, PC210NLC-7K
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CONTROL VALVE
pc240LC-7K, pc240Nlc-7K
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MAIN RELIEF VALVE (PC210/LC/NLC-7K)
Function
MAIN RELIEF VALVE (PC240LC/NLC-7K)
Variable pressure compensation valve
CLSS
OUTLINE OF CLSS
SWING MOTOR
REVERSE PREVENTION VALVE
CENTER SWIVEL JOINT
TRAVEL MOTOR
TRAVEL JUNCTION VALVE
TRAVEL PPC SHUTTLE VALVE
VALVE CONTROL
WORK EQUIPMENT • SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE PPC VALVE
SOLENOID VALVE
PPC ACCUMULATOR
return oil filter
For Breaker
BOOM HYDRAULIC DRIFT PREVENTION VALVE
LIFT CHECK VALVE
attachment circuit selector valve
HYDRAULIC CYLINDER
pc210-7K, pc210lc-7K, PC210NLC-7K
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
pc240LC-7K, pc240Nlc-7K
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
work equipment
Pc210-7K, pc210lc-7K, PC210NLC-7K
Pc240LC-7K, pc240Nlc-7K
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1. DIMENSION OF ARM
2. Dimension of bucket
air conditioner
air conditioner piping
ENGINE CONTROL
Governor motor
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Engine throttle and pump controller
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ELECTRONIC CONTROL SYSTEM
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machine control system diagram
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mULTI MONITOR SYSTEM
SENSOR
PC240LC-7K, PC240NLC-7K
SELF PRESSURE REDUCING VALVE

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Flow control characteristic of PC valve (STD)

INSPECTION AND ADJUSTMENT OF ENGINE RPM
MEASUREMENT OF EXHAUST GAS COLOR
ADJUSTMENT OF VALVE CLEARANCE
MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
MEASUREMENT OF ENGINE OIL PRESSURE
ADJUSTMENT OF ENGINE SPEED SENSOR
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWIN...
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC240LC/NLC)
iNSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE(PC210/LC/NLC)
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc240lc/nlc)
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE(pc210/lc/nlc)
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
MEASUREMENT OF OIL LEAKAGE AMOUNT
AIR BLEEDING OF VARIOUS PARTS
INSPECTION PROCEDURES FOR DIODE
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Operation of Operator's Menu and Display (Outline)
Table for Service and Failure Code Nos.
Operation and Display of Service Menu
Table for Monitoring Items
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
Engine (PC240LC, 240NLC)

POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Classification of troubleshooting
Steps for troubleshooting
Failure-looking Phenomenon and Troubleshooting No.
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Connector table
CONNECTOR LOCATION STEREOGRAM
Monitor Panel System Circuit Diagram (M Circuit)
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Service Code in Electrical System (Abnormal data in Error History)
Service Code in Electrical System (Short-circuiting in normal rotation system of windshield wiper...
Service Code in Electrical System (Short-circuiting in reverse rotation system of windshield wipe...
Service Code in Electrical System (Short-circuiting in window washer drive system)
Service Code in Electrical System (Abnormal Windshield Wiper Motion)
Service Code in Electrical System (Abnormality in retracting windshield wiper)
Service Code in Electrical System (Short-circuiting in travel interlocking solenoid)
Service Code in Electrical System (Short-circuiting in swing and parking brake solenoid - in gove...
Service Code in Electrical System (Short-circuiting in merge/divide solenoid)
Service Code in Electrical System (Short-circuiting in 2-stage relief solenoid)
Service Code in Electrical System (Short-circuiting in travel speed shifting solenoid)
Service Code in Electrical System (Disconnection in travel interlocking solenoid)
Service Code in Electrical System (Disconnection in Swing Parking Brake Solenoid)
Service Code in Electrical System (Disconnection of merge/divide solenoid)
Service Code in Electrical System (Disconnection in 2-stage relief solenoid)
Service Code in Electrical System (Disconnection in travel speed shifting solenoid)
Service Code in Electrical System (Abnormality in inputting model code)
Service Code in Electrical System Disconnection of S-NET signal)
Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)
Service Code in Electrical System (Disconnection in LS-EPC solenoid system)
Service Code in Electrical System (Abnormality in F pump pressure sensor)
Service Code in Electrical System (Abnormality in R pump pressure sensor)
Service Code in Electrical System (Abnormality in Pressure sensor power source)
Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump contr...
Service Code in Electrical System (Short-circuiting in attachment return switching relay)
Service Code in Electrical System (Short-circuiting in PC-EPC Solenoid
Service Code in Electrical System (Disconnection in PC-EPC solenoid system)
Service Code in Electrical System (Disconnection in attachment return switching relay)
Service Code in Electrical Equipment (Short-circuiting in attachment oil flow rate adjusting EPC)...
Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC) (Mult...
Service Code in Electrical System (Incorrect nonvolatile memory data)
Service Code in Electrical System (Abnormality in governor potentiometer)
Service Code in Electrical System (Abnormality in fuel dial)
Service Code in Electrical System (Short-circuiting in battery relay)
Service Code in Electrical System (Step-out in governor motor)
Service Code in Electrical System (Disconnection in governor motor Phase A and B)
Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B)
Service Code in Electrical System ("Model Selection" function not provided yet)
Service Mode in Electrical System (Model selecting signal fault)
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
Failure Code in Mechanical System (Air cleaner clogging)
Failure Code in Mechanical System (Abnormally lowered charging voltage)
Failure Code in Mechanical System (Abnormally lowered engine oil pressure)
Failure Code in Mechanical System (Abnormally lowered engine oil level)
Failure Code in Mechanical System (Engine cooling water overheating)
Failure Code in Mechanical System (Abnormally lowered radiator water level)
Failure Code in Mechanical System (Hydraulic oil overheating)
20_501.pdf
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
E-1 Engine does not start (Engine does not rotate)
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
E-2 Engine stops while in operation
Electrical Circuit Diagram for Fuel Dial
E-3 Engine speed is irregular, or there is hunting
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
E-4 Engine does not stop
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
E-5 Auto-decelerator does not work
E-6 Auto engine warm-up device does not work
E-7 Preheater does not work
Electrical Circuit Diagram for Engine Preheater
E-8 All work equipment, swing and travel do not move
Electrical Circuit Diagram for PPC Lock Solenoid
E-9 One-touch Power Max Switch does not work
Electric Circuit Diagram for One-Touch Power Max. Switch
E-10 No display in monitor panel at all
Electrical Circuit Diagram for Power Source in Monitor Panel
E-11 Part of display on monitor panel is missing
E-12 Monitor panel displays contents irrelevant to the model
E-13 Fuel level monitor red lamp lights up while engine is running
Electrical Circuit Diagram for Fuel Level Sensor
E-14 Engine cooling water temperature gauge does not indicate correctly
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor
E-15 Hydraulic oil temperature gauge does not display correctly
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
E-16 Fuel gauge does not display correctly
Electrical Circuit Diagram for Fuel Level Sensor
E-17 Swing lock monitor does not display correctly
Electrical Circuit Diagram for Swing Lock Switch
E-18 When the monitor switch is operated, no display appears
E-19 Windshield wiper does not work
Electrical Circuit Diagram for Windshield Wiper Motor
E-20 Alarming buzzer cannot be cancelled
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
E-21 "Boom RAISE" is not correctly displayed in monitor function
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
E-22 "Boom LOWER" is not correctly displayed in monitor function
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
E-23 "Arm DIGGING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
E-24 "Arm DUMPING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
E-25 "Bucket DIGGING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
E-26 "Bucket DUMPING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
E-27 "SWING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
E-28 "TRAVEL" is not correctly displayed in monitor function
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
E-30 "Service" is not correctly displayed in monitor function
Electrical Circuit Diagram for Service PPC hydraulic Switch
E-31 Air Conditioner does not work
Electrical Circuit Diagram for Air Conditioner
E-32 Travel alarm does not sound
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
20_601.pdf
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H-1 All work equipment lack power, or travel and swing speeds are slow
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, travel or swing move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Auto-decelerator does not work
H-6 Fine control mode does not function
H-7 Boom moves slowly or lacks power
H-8 Arm moves slowly or lacks power
H-9 Bucket moves slowly or lacks power
H-10 Work equipment does not move in its single operation
H-11 Work equipment has a bit too fast hydraulic drift
H-12 Work equipment has big time lag
H-13 Other work equipment moves when relieving single circuit
H-14 One-touch power max. switch does not operate
H-15 In compound operation, work equipment with larger load moves slowly
H-16 In swing + boom RAISE operation, boom moves slowly
H-17 In swing + travel, travel speed drops sharply
H-18 Machine swerves in travel
H-19 Machine travels slowly
H-20 Machine cannot be easily steered or lacks power
H-21 Travel speed does not shift, or it is too slow or fast.
H-22 Track shoe does not turn (on one side only)
H-23 Machine does not swing
H-24 Swing acceleration is poor, or swing speed is slow
H-25 Excessive overrun when stopping swing
H-26 There is big shock when stopping swing
H-27 There is big abnormal noise caused when stopping swing
H-28 Swing natural drift is too big

HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DisassemblY and assemblY OF assemblIES
PRECAUTIONS WHEN PERFORMING OPERATION
STARTING MOTOR ASSEMBLY
REMOVAL
INSTALLATION
FUEL INJECTION PUMP ASSEMBLY
ENGINE FRONT SEAL
ENGINE REAR SEAL
CYLINDER HEAD ASSEMBLY
RADIATOR ASSEMBLY
HYDRAULIC OIL COOLER ASSEMBLY
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
FINAL DRIVE ASSEMBLY
FINAL DRIVE ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SWING MOTOR AND SWING MACHINERY ASSEMBLY
SWING MOTOR AND SWING MACHINERY ASSEMBLY
CARRIER ROLLER ASSEMBLY
TRACK ROLLER ASSEMBLY
IDLER ASSEMBLY
RECOIL SPRING ASSEMBLY
SPROCKET
TRACK SHOE ASSEMBLY
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON)
REMOVal AND EXPANsion OF ROAD LINERS
INSTALLation OF ROAD LINERS
SWING CIRCLE
ASSEMBLY
REVOLVING FRAME ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
HYDRAULIC TANK ASSEMBLY
CONTROL VALVE ASSEMBLY
CONTROL VALVE ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
WORK EQUIPMENT PPC VALVE ASSEMBLY
TRAVEL PPC VALVE ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
WORK EQUIPMENT ASSEMBLY
AIR CONDITIONER UNIT ASSEMBLY
COUNTERWEIGHT ASSEMBLY
OPERATOR’S CAB ASSEMBLY
MONITOR ASSEMBLY
GOVERNOR PUMP CONTROLLER ASSEMBLY

PC200-7_Sec90_Body.pdf
hydraulic circuit diagram (1/2)
PC210-7K, PC210LC-7K, pc210nlc-7K
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hydraulic circuit diagram (2/2)
PC210-7K, PC210lc-7K, PC210nLC-7K
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HYDRAULIC diagram (1/1)
pc240lc-7K, pc240nlc-7K
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electrical circuit diagram (1/4)
for multi monitor
pc210-7K, pc210lc-7K, pc210nlc-7K
pc240lc-7K, pc240nlc-7K
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electrical circuit diagram (2/4)
for multi monitor
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electrical circuit diagram (3/4)
for multi monitor
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electrical circuit diagram (4/4)
for multi monitor
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electrical circuit diagram for air conditioner
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