Komatsu PC210, 210LC-6K, PC240LC, PC240NLC-6K Service Manual

EEBM001801

PC210, 210LC-6K
PC240LC,
PC240NLC-6K

MACHINE MODEL SERIAL NUMBER

PC210, 210LC-6K K32001 and up
PC240LC, 240NLC-6K K32001 and up

• This shop manual may contain attachements and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require. Materials and specifications
are subject to change without notice

• PC210, 210LC-6k mount the S6D102E-1 engine;
PC240LC, 240NLC-6k mount the SA6D102E-1 engine.
for details of the engine, see the 102 Service Engine Shop Manual.

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CONTENTS

No. of page

01 GENERAL.......................................................................................... 01-1

10 STRUCTURE AND FUNCTION.............................................. 10-1

20 TESTING AND ADJUSTING .................................................... 20-1

30 DISASSEMBL Y AND ASSEMBLY ........................................ 30-1

40 MAINTENANCE STANDARD.................................................. 40-1

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SAFETY SAFETY NOTICE

SAFETY

SAFETY NOTICE

IMPORT ANT SAFETY NOTICE

Proper service and repairs extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both sepcially
designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompaning these symbols should always be followed carefully . If any
dangerous situation arises or may possibly arise, first consider safety , and take the necessary
actions to deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance carefully BE­FORE operating the machine.

1. Before carrying out any greasing or re­pairs, read all the precautions given on the
decals which are fixed to the machine.

2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.

• Always wear safety glasses when hit-

ting parts with a hammer.

• Always wear safety glasses when

grinding parts with a grinder, etc.

3. If welding repairs are needed, always have
a trained, experienced welder carry out the
work. When carrying out welding work, al­ways wear welding gloves, apron, glasses,
cap and other clothes suited for welding
work.

6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the ar­eas provided for smoking. Never smoke while
working.

PREP ARA TIONS FOR WORK.

7. Before adding the oil or making any repairs
park the machine on hard, level ground, and
block the wheels or tracks to prevent the ma­chine from moving.

8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the wrok equipment from fall­ing. In addition, be sure to lock all the control
levers and hang warning signs on them.

9. When disassembling or assembling, support
the machine with blocks, jacks or stands before
starting work.

4. When carrying out any operation with two
or more workers, always agree on the op­erating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR signs on the
controls in the operator's compartment.

5. Keep all tools in good condition and learn
the correct way to use them.

00-6

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10. Remove all mud and oil from the steps or other
paces used to get on and off the machine. Al­ways use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to pro­vide safe footing.

SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK

11. When removing the oil filter cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.

12. The water and oil in the circuits are hot when
the engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying
out any work on the oil or water circuits.

13. Before starting work, remove the leads from the
battery . Always remove the lead from the nega­tive (-) terminal first.

14. When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at he correct places.
Use a hoist of crane and operate slowly to pre­vent the component from hitting any other part.
Do not work with any part still raised by the
hoist or crane.

20. When installing high pressure hoses, make
sure that they are not twisted. Damaged tubes
are dangerous, so be extremely careful when
installing tubes for high pressure circuits. Also,
check that connecting parts are correctly in­stalled.

21. When assembling or installing parts, always
use the specified tightening torques. When in­stalling protective parts such as guards. or
parts which vibrate violently or rotate at high
speed, be particulary careful to check that they
are installed correctly .

22. When aligning two holes, never insert your fin­gers or hand. Be careful not to get your fingers
caught in a hole.

23. When messuring hydraulic pressure, check that
the messuring tool is correctly assembled for
taking any measurements.

24. Take care when removing or installing the
tracks of track-type machines. When removing
the track, the track separates suddenly, so
never let anyone stand at either end of the
track.

15. When removing covers which are under inter­nal pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.

16. When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.

17. When removing piping, stop the fuel or oil from
spilling out. If any oil or fuel drops onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to wash
parts. In particular, only use the minimum of
gasoline when washing electrical parts.

19. Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.

• When installing hoses and wires, be sure

that the will not be damaged by contact
with oter parts when the machine is being
operated.

00-7

00-8

FOREWORD GENERAL

FOREWORD

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make
judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity .

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are
further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under­standing of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs , as well as adjustments to be
made at completion of the checks and repairs. Troubleshooting charts correlating "problems" to "Causes"
are also included in this section.

DISASSEMBL Y AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling
eachr component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifiactions contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-9

FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES

Shop manuals are issued as a guide to carrying out
repairs. They are devided as follows:

Chassis volume: Issued for every machine model
Engine model: Issued for each engine series

Electrical volume:
Attachments volume:

These various volumes are designed to avoid dupli­cating the same information. Therefore, to deal with
all repairs for any model, it is necessary that chas­sis, engine , electrical and attachement volumes be
available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to­date information before you start any work.

FILING METHOD

1. See the page number on the bottom of the
page. File the pages in correct order.

2. Following examples show how to read the page
number
Example 1 (Chassis volume:)

10 - 3

Example 2 (Engine Volume:)

1 2 - 5

3. Additional pages: Additional pages are indi­cated by a hyphen (-) and number after the
page number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
10-4-2 12-203-2
10-5 12-204

Added pages

Each issued as one
volume to cover all

}

models

Item number (10. Structure
and Function)
Consecutive page number
for each item

Unit number (1. Engine)
Item number (2. Testing and
Adjusting)
Consecutive page number
for each item

REVISED EDITION MARK

When a manual is revised, an edition mark
(a,b,c,...) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISED
P AGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.

lobmySmetIskrameR

snoituacerpytefaslaicepS

ytefaS

★

noituaC

thgieW

gninethgiT

euqrot

taoC

.cte

retaw,liO

.yticapac

niarD

nehwyrassecenera

.krowehtgnimrofrep

lacinhcetlaicepS

rehtorosnoituacerp

gnivreserprofsnoituacerp

yrassecenerasdradnats

.krowehtgnimrofrepnehw

.smetsysfostrapfothgieW

nehwyrassecennoituaC

ro,eriwgnitsiohgnitceles

sierutsopgnikrownehw

.tce,tnatropmi

laicepseriuqertahtsecalP

gninethgitehtrofnoitnetta

.ylbmessagnirudeuqrot

htiwdetaocebotsecalP

,stnacirbuldnasevisehda

roretaw,lioerehwsecalP

ehtdna,deddaebtsumleuf

retawrolioerehwsecalP

dna,deniardebtsum

.deniardebotytitnauq

00-10

FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the DISASSEM-
BLY AND ASSEMBLY section, every
part weighing 25 kg op mroe is indicated
with the symbol

• If a part cannot be smootlhy removed from the
machine by hoisting, the following checks
should be made:

1) Check for removal of all bolts fastening the

part to the relative parts.

2) Check for existence of another part caus-

ing interference with the part to be re­moved.

WIRE ROPES

1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to

seporeriW

seportsiwt"S"ro"Z"dradnatS(

gnizinavlagtuohtiw

)mm(retemaidepoR)snot(daolelbawollA

010.1

2.114.1

5.216.1

412.2

618..2

816.3

024.4

4.226.5

030.01

Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a seri­ous accident can result. Hooks have a maximum
strength at the middle portion.

3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound onto the load.

Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook. When hoist­ing a load with two or more ropes, the force sub­jected to each rope will increase with the
nahging angles. The table below shows the
variation of allowable load (kg) when hoisting is
made with two ropes, each of which is allowed
to sling up to 1000 kg vertically , at various hang­ing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make
a 120° hanging angle. On the other hand, two
ropes are subjected to an excessive force as
large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.

040.81

050.82

060.04

the table below:

★ The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.

2) Sling wire ropes from the middle portion of the
hook.

00-11

FOREWROD COA TING MA TERIALS

COA TING MA TERIALS

The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.

Category

Adhesive

Gasket sealant

Rust prevention
lubricant

Molybdenum
disulphide
lubricant

Lithium grease

Calcium grease

Molybdenum
disulphide
grease

Komatsu code

LT -1A

LT -1B

LT-2

LT-3

LT-4

(Loctite 648-50)

LG-1

LG-3

LG-4

LG-5

LG-6

LG-7

-

-

G2-LI

G2-CA

-

Part No.

790-129-9030

790-129-9050

09940-00030

790-129-9060
(Set of adhesive
and hardening
agent)

790-129-9040

79A-129-9110

790-129-9070

790-120-9020

790-129-9080

09940-00011

09920-00150

09940-00051

09940-00040

SYG350LI

SYG-400LI

SYG-400LI-A

SYG-160LI

SYGA-160CNLI

SSG2-400CA
SYG2-350CA

SYG2-400CA-A

SYG2-160CA
SYGA-16NCA

SYG2-400M

Q'ty

150 g

20 g

(x2)

50 g

Adhesive
: 1 kg
Hardening
agent
: 500 g

250 g

50 cc

200 g

1kg

200 g

1 kg

250 g

150 g

60 g

200 g

Various

Various

400 g (10
per case)

Container

Tube

Plastic

container

Plastic

container

Can

Plastic

container

-

Tube

Can

Tube

Plastic

container

Tube

Tube

Can

Tube

Various

Various

Bellows type

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and
cork plugs from coming out

• Used in places requiring an immediately effective, strong
adhesive. Used for plastics (except polyethylene,
polyprpylene, tetrafluoroethylene and vinyl chloride),
rubber, metal, and non-metal.

• Features: resistance to heat, chemicals

• Used for anti-lossening and sealant purposes for bolts
and plugs

• Used as adhesive or sealant for metal, glass, plastic

• Used as sealant for machined holes

• Features: Resistance to heat, chemicals

• Used at joint portions subject to high temperature

• Used as adhesive or sealant for gaskets and packings of
power train case, etc.

• Features: Resistance to heat

• Used as sealant for flange surfaces and bolts at high
temperature locations, used te prevent seizure

• Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe

• Features: Resistance to water, oil

• Used as sealant for flange surface, thread

• Aiso possible to use as sealant for flanges with large
clearance

• Used as sealant for mating surfaces of final drive case,
transmission case.

• Used as sealant for various threads, pipe joints, flanges

• Used as sealant for tapered plugs, elbows, nipples of
hydraulic piping

• Features: Silicon based, resistance to heat, cold

• Used as sealant for flange surface, thread

• Used as sealant for oil pan, final drive case, etc.

• Features: Silicon based, quick hardening type

• Used as sealant fo rflywheel housing, intake manifold, oil
pan, thermostat housing, etc.

• Used as lubricant for sliding parts (to prevent squeaking)

• Used to prevent seizure or scuffing of the thread when
presss fitting or shrink fitting

• Used as lubricant for linkage, bearings, etc.

• General purpose type

• Used for normal temperature, light load bearing at places
in contact with water or steam

• Used for places with heavy load

00-12

FOREWORD ST ANDARD TIGHTENING TORQUE

ST ANDARD TIGHTENING TORQUE

ST ANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section
of DISASSEMBLY AND ASSEMBLY.

1 Kgm = 9.806 Nm

retemaiddaerhT

tlobfo

mmmmmgkmN

60153.1±51.02.31±4.1

8312.3±3.04.13±9.2

01717.6±7.07.56±8.6

21915.11±0.1211±8.9

41220.81±0.2771±91

61425.82±3972±92
817293±4383±93
020365±6945±85
222367±8547±87

42635.49±01729±89
7214531±510231±041
0364571±020271±091
3305522±520122±042
6355082±030572±092

htdiW

stalfssorca

9306533±520823±043

★This torque table does not apply to the bolts with nylon packaging or other nonferrous metal wash-

ers are to be used, or which require tightening to otherwise specified torque.

00-13

FOREWORD ST ANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

retemiaddaerhT

tlobfo

mmmmmgkmN

01417.6±7.07.56±8.6

21715.11±1211±8.9

61225.82±3972±92

TIGHTENING TORQUE FOR FLRED NUTS

Use these torques for flared part of nut.

retemiaddaerhT

tlobfo

mmmmmgkmN

htdiW

stalfssorca

htdiW

stalfssorca

euqrotgninethgiT

euqrotgninethgiT

41915.2±5.05.42±9.4
81425±294±6.91
22728±25.87±6.91
422341±33.731±4.92
036381±35.671±4.92
331402±51.691±94
636452±52.542±94
245503±52.492±94

00-14

FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This
wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominale number 5 and white coating with black stripe.

CLASSIFICA TION BY THICKNESS

lanimoN

rebmun

forebmuN

sdnarts

fo.aiD

)mm(sdnarts

noitcesssorC

)2mm(

elbaC

)mm(.D.O

tnerruC

)A(gnitar

58.01123.088.04.221.ctelangis,gnithgil,gnitratS

26223.090.21.302.ctelangis,gnithgiL

55623.032.56.473langisdnagnigrah

514854.063.310.795)gulpwolG(gnitratS

045808.037.244.11531gnitratS

0672108.048.366.31871gnitratS

00171208.01.9016.71032gnitratS

CLASSIFICATION BY COLOR AND CODE

stiucriC

eriwreppoC

-roirP

yti

1

2

3

4

5

6

-salC
noitacifis

-irP

yrail

edoCWBB R Y G L

yram

roloCetihWkcalBkcalBdeRwolleYneerGeulB

edoCRW-WBWRRYWGWL

roloCdeR&etihW- etihW&kcalBetihW&deRdeR&wolleYetihW&neerGetihW&eulB

edoCBW-YBBRBYRGRL

roloCkcalB&etihW- wolleY&kcalBkcalB&deRkcalB&wolleYdeR&neerGdeR&eulB

edoCLW-RBYRGYYGYL

-ixuA
roloCeulB&etihW-deR&kcalBwolleY&deRneerG&wolleYwolleY&neerGwolleY&eulB

edoCGW-- GRLYBGBBL

roloCneerG&etihW-- neerG&deReulB&wolleYkcalB&neerGkcalB&eulB

edoC--- LRWYLG-

roloC--- eulB&deRetihW&wolleYeulB&neerG-

gnigrahCdnuorGgnitratSgnithgiLtnemurtsnIlangiSrehtO

tiucricelbacilppA

00-15

FOREWORD CONVERSION T ABLE

CONVERSION T ABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE

• Method of using the Conversion Table to convert from millimeters to inches

1. Convert 55 mm to inches
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line

from A.

(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down

from B.

(3) Take the point where the two lines cross as C. This pint C gives the value when converting from

millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550 mm into inches.
(1) The nuber 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the orginal value. This gives 550 mm = 21.65 inches.

B

Millimeters to inches 1 mm = 0.03937 in

0123456789

00 930.0970.0811.0751.0791.0632.0672.0513.0453.0

01493.0334.0274.0215.0155.0195.0036.0966.0907.0847.0

02787.0728.0668.0609.0549.0489.0420.1360.1201.1241.1

03181.1022.1062.1992.1933.1873.1714.1754.1694.1635.1

04575.1416.1456.1396.1237.1277.1118.1058.1098.1929.1

C

A

05969.1800.2740.2780.2621.2561.2502.2442.2382.2323.2

06263.2204.2144.2084.2025.2955.2895.2836.2776.2717.2

07657.2597.2583.2478.2319.2359.2299.2230.3170.3011.3

08051.3981.3822.3862.3703.3643.3683.3524.3564.3405.3

09345.3385.3226.3166.3107.3047.3087.3918.3858.3898.3

00-16

FOREWORD CONVERSION TABLE

Millimeters to Inches

1 mm = 0.03937 in

0123456789

00930.0970.0811.0751.0791.0632.0672.0513.0453.0

01493.0334.0274.0215.0155.0195.0036.0966.0907.0847.0

02787.0728.0668.0609.0549.0489.0420.1360.1201.1241.1

03181.1022.1062.1992.1933.1873.1714.1754.1694.1635.1

04575.1416.1456.1396.1237.1277.1118.1058.1098.1929.1

05969.1800.2740.2780.2621.2561.2502.2442.2382.2323.2

06263.2204.2144.2084.2025.2955.2895.2836.2776.2217.2

07657.2597.2538.2478.2319.2359.2299.2230.3170.3011.3

08051.3981.3822.3862.370.33643.3683.3524.3564.3405.3

09345.3385.3226.3166.3107.3047.3087.3918.3858.3898.3

Kilogram to Pound

1kg = 2.2046 lb

0123456789

0002.214.416.628.820.1132.3134.5146.7148.91

0150.2252.4264.6266.8268.0370.3372.5384.7386.9398.14

0290.4403.6405.8417.0519.1521.5523.7535.9537.1639.36

0341.6643.8655.0757.2769.4761.7773.9775.1887.3889.58

0481.8893.0995.2908.4900.7912.9914.10126.30128.50130.801

0532.01144.21146.41158.61150.91152.12164.32166.53178.72170.031

0682.23184.43196.63198.83101.14103.34115.54117.74119.94121.251

0723.45135.65137.85149.06141.36153.56155.76167.96169.17171.471

0873.67175.87187.08189.28191.58193.78106.98108.19110.49112.691

0924.89126.00230.20230.50242.70244.90246.11258.31250.61262.812

00-17

FOREWORD CONVERSION TABLE

Litre to U.S. Gallon

1l = 0.2642 U.S. Gal

0123456789

00462.0825.0397.0750.1123.1585.1948.1311.2873.2

01246.2609.2071.3434.3896.3369.3722.4194.4557.4910.5

02382.5845.5218.5670.60433.6406.6968.6331.7793.7166.7

03529.7981.8454.8817.8289.8642.9015.9477.9930.01303.01

04765.01138.01590.11953.11426.11888.11251.21614.21086.21449.21

05902.31374.31737.31100.41562.41925.41597.41850.51223.51685.51

06058.51511.61973.61346.61709.61171.71534.71007.71469.71822.81

07294.81657.81020.91582.91945.91318.91770.02143.02506.02078.02

08431.12893.12266.12629.12091.22554.22917.22389.22742.32115.32

09577.32040.42403.42865.42238.42690.52163.52526.52988.52351.62

Litre to U.K. Gallon

1l = 0.21997 U.K. Gal

0123456789

00022.0044.0066.0088.0001.1023.1045.1067.1089.1

01002.2024.2046.2068.2080.3003.302.53047.3059.3971.4

02993.4916.4938.4950.5972.5994.5917.5939.5951.69736

03995.6918.6930.7952.7974.7969.7919.7931.8953.8975.8

04997.8910.9932.9954.9976.9998.9911.01933.01955.01877.01

05899.01182.11834.11856.11878.11890.21813.21825.21857.21879.21

06891.31814.31836.31858.31870.41892.41815.41837.41859.41871.51

00-18

07893.51816.51838.51850.61872.61894.61817.61839.61851.71873.71

08895.71818.71730.81752.81774.81796.81719.81731.91753.91775.91

09797.91710.02732.02754.02776.02798.02711.12733.12755.12777.12

FOREWORD CONVERSION TABLE

kgm to ft. lb

1 kgm = 7.233 ft. lb

0123456789

002.75.417.129.822.634.346.059.751.56

013.276.978.680.493.1015.8017.5110.3212.0314.731

027.4419.1511.9514.6616.3718.0811.8813.5915.2028.902

030.7122.4225.1327.8329.5422.3524.0626.7629.4721.282

043.9826.6928.3030.1133.8135.5237.2330.0432.7434.453

057.1639.8631.6734.3836.0938.7931.5043.2145.9148.624

060.4342.1445.8447.5549.2642.0744.7746.4848.1941.994

073.6055.3158.0250.8252.5355.2457.9459.6552.4654.175

086.8759.5851.3953.0066.7068.4160.2263.9265.6367.346

090.1562.8564.5667.2769.9761.7864.4966.1078.8071.617

0013.3275.0378.7370.5472.2575.9577.6679.3772.1874.887

0116.5979.2081.0183.7186.4288.1380.9383.6485.3587.068

0210.8682.5784.2887.9889.6981.4094.1196.8198.5291.339

0313.0495.7498.4590.2692.9695.6797.3899.0992.8994.5001

0416.21019.91011.72013.43015.14018.84010.65012.36015.07017.7701

0519.48012.29014.99016.60119.31111.12113.82116.53118.24110.0511

0613.75115.46117.17110.97112.68114.39117.00219.70211.51214.2221

0716.92118.63211.44213.15215.85218.56210.37211.08215.78217.4921

0819.10312.90314.61316.32319.03311.83313.54216.25318.95310.7631

0913.47315.18317.88310.69312.30414.01417.71419.42411.23414.9341

00-19

FOREWORD CONVERSION TABLE

kg/cm2 to lb/in

2

1 kg/cm2 = 14.2233 lb/in

0123456789

002.414.827.249.651.173.586.998.3110.821

012.2415.6517.0719.4811.9914.3126.7228.1420.6522.072

025.4827.8929.2131.7234.1436.5538.9630.4833.8935.214

037.6249.0441.5544.9646.3848.7940.2153.6255.0457.455

049.8652.3854.7956.1168.5261.0463.4565.8667.2869.696

052.1174.5276.9378.3571.8673.2875.6977.0180.5282.938

064.3586.7688.1881.6983.0195.4297.8390.3592.7694.189

076.599010142018301350176011801590190114211
088311251166111811591190213221732125216621
090821492190313231733115315631083149318041

2

0012241734115415641974139418051225163510551
0115651975139517061126163610561466187613961
0217071127153719471467187712971608112815381
0319481368177812981609102914391949136917791
0411991500202024302840226027702190250129112

0514312841226126712091250229122332274222622
0616722092240328132333274321632573298324042
0718142234264420642574298423052815223526452
0810652475298523062716113626462066247628862
0912072717213725472957237728872208261820382

0025482958237827882109261920392449285923792
0127892100351030303440385032703680310135113
0229213341385132713681300234123922334237523

00-20

0321723682300334133823334337533174458339933
0424143824324436543074358439943315372532453

FOREWORD CONVERSION TABLE

Temperature

Fahrenheit-Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahren­heit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

4.04-04-0.04-7.11-118.158.7648.4112.72188.711

2.73-53-0.13-1.11-216.353.8746.6118.72286.971

4.43-03-0.22-6.01-314.559.8844.8113.82384.181

7.13-52-0.31-0.01-412.754.9942.0219.82482.381

9.82-02-0.4-4.9-510.950.01050.2214.92580.581

3.82-91-2.2-9.8-618.066.01158.3210.03688.681

8.72-81-4.0-3.8-716.261.11256.5216.03786.881

2.72-71-4.18.7-814.467.11354.7211.13884.091

7.62-61-2.32.7-912.662.21452.9217.13982.291

1.62-51-0.57.6-020.868.21550.1312.23090.491

6.52-41-8.61.6-128.963.31658.2318.23198.591

0.52-31-6.86.5-226.179.31756.4313.33296.791

4.42-21-4.010.5-324.374.41854.6319.33304.991

9.32-11-2.214.4-424.370.51952.8314.43492.102

3.32-01-0.419.3-522.576.51060.0410.53590.302

8.22-9-8.513.3-620.771.61168.1416.53698.402

2.22-8-6.718.2-728.877.61266.3411.63796.602

7.12-7-4.912.2-826.082.71364.5417.63894.802

1.12-6-2.127.1-924.288.71462.7412.73992.012

6.02-5-0.321.1-030.683.81560.9418.730010.212

0.02-4-8.426.0-138.789.81668.0516.045010.122

4.91-3-6.620236.984.91766.2513.340110.032

9.81-2-4.826.0334.190.02864.4511.645110.932

3.81-1-2.031.1432.396.02962.6519.840210.842

8.71-00.237.1530.591.12070.8517.155210.752

2.71-18.332.2638.697.12178.9514.450310.662

7.61-26.538.2736.892.22276.1612.755310.572

1.61-34.733.3834.0018.22374.3610.060410.482

6.51-42.939.3932.2013.32472.5617.265410.392

0.51-50.144.4040.4019.32570.7616.560510.203

4.41-68.240.5148.5014.42678.8613.865510.113

9.31-76.446.5246.7010.52776.0711.170610.023

3.31-84.641.6344.9016.52874.2719.375610.923

8.21-92.847.6442.1111.62972.4717.670710.833

2.21-010.052.7540.3117.62080.6714.975710.743

00-21

FOREWORD MEMORANDA

MEMORANDA

00-22

STRUCTURE AND FUNCTION

10 STRUCTURE AND FUNCTION

ENGINE RELATED PARTS ..................................................................................................................... 10-6

RADIATOR • OIL COOLER...................................................................................................................... 10-7

POWER TRAIN........................................................................................................................................ 10-8

FINAL DRIVE ........................................................................................................................................... 10-9

PC210, PC 240

SWING CIRCLE....................................................................................................................................... 10-10

SWING MACHINERY .............................................................................................................................. 10-11

PC210LC, PC240LC

TRACK FRAME • RECOIL SPRING ........................................................................................................ 10-12

TRACK SHOE.......................................................................................................................................... 10-13

HYDRAULIC PIPING DRAWING............................................................................................................. 10-14

HYDRAULIC CIRCUIT DIAGRAM ...................................................................................................... 10-15 a/b

HYDRAULIC T ANK.................................................................................................................................. 10-16

HYDRAULIC PUMP ................................................................................................................................. 10-17

Basic pump ....................................................................................................................................... 10-17

Outline ....................................................................................................................................... 10-17

Function ..................................................................................................................................... 10-20

Structure .................................................................................................................................... 10-20

Operation ................................................................................................................................... 10-21

LS and PC valve ............................................................................................................................... 10-24

Function ..................................................................................................................................... 10-25

Operation ................................................................................................................................... 10-26

CONTROL VALVE.................................................................................................................................... 10-36

Outline............................................................................................................................................... 10-36

9-spool valve (standard + 3 service valves)...................................................................................... 10-37

Main structure ............................................................................................................................ 10-38

6-spool valve..................................................................................................................................... 10-41

7-spool valve..................................................................................................................................... 10-42

8-spool valve..................................................................................................................................... 10-43

10-1

STRUCTURE AND FUNCTION

SAFETY-SUCTION VALVE FOR SERVICE VALVE................................................................................. 10-44

SELF-REDUCING PRESSURE VALVE................................................................................................... 10-45

Function ............................................................................................................................................ 10-47

Operation .......................................................................................................................................... 10-47

CLSS ................................................................................................................................................... 10-50

Outline of CLSS ................................................................................................................................ 10-50

Features..................................................................................................................................... 10-50

Structure .................................................................................................................................... 10-50

Basic Principle ........................................................................................................................... 10-51

Operation for each function and valve .............................................................................................. 10-53

Hydraulic circuit diagram for system.......................................................................................... 10-53

Unload valve .............................................................................................................................. 10-56

Main relief valve (2-stage type).................................................................................................. 10-57

Introduction of LS pressure........................................................................................................ 10-59

LS bypass valve......................................................................................................................... 10-60

Pressure compensation valve.................................................................................................... 10-61

Shuttle valve inside pressure compensation valve .................................................................... 10-64

Variable type pressure compensation valve (for service valve) ................................................. 10-65

Boom regeneration circuit.......................................................................................................... 10-67

Arm regeneration circuit............................................................................................................. 10-69

Pump merge-divider valve ......................................................................................................... 10-70

LS select valve........................................................................................................................... 10-72

Spool stroke modulation ............................................................................................................ 10-73

Timing valve............................................................................................................................... 10-74

2-stage safety valve (installed to boom cylinder head).............................................................. 10-75

Operation of CLSS system as a whole ............................................................................................. 10-76

When all work equipment is at neutral....................................................................................... 10-76

Pump flow divided, one side actuated, other side neutral ......................................................... 10-78

Pump flow merged, arm OUT, standard mode relief (cut-off control) ........................................ 10-80

Pump flow divided, bucket DUMP, power max. relief ................................................................ 10-82

Pump flow merged, boom RAISE .............................................................................................. 10-84

Pump flow merged, swing operated independently ................................................................... 10-86

Pump flow divided, travel operated independently .................................................................... 10-88

Pump flow merged, compound operation .................................................................................. 10-90

SWING MOTOR....................................................................................................................................... 10-92

BASIC MOTOR................................................................................................................................. 10-92

Swing lock valve ............................................................................................................................... 10-94

Operation ................................................................................................................................... 10-94

CENTER SWIVEL JOINT ........................................................................................................................ 10-95

TRAVEL MOTOR ..................................................................................................................................... 10-96

Operation of motor..................................................................................................................... 10-98

Operation of parking brake ........................................................................................................ 10-100

Operation of brake valve............................................................................................................ 10-101

VALVE CONTROL ................................................................................................................................... 10-105

WORK EQUIPMENT • SWING PPC VALVE............................................................................................ 10-106

Operation .......................................................................................................................................... 10-108

TRAVEL PPC VALVE ............................................................................................................................... 10-110

Operation .......................................................................................................................................... 10-112

10-2

STRUCTURE AND FUNCTION

SERVICE PPC VALVE............................................................................................................................. 10-114

Operation .......................................................................................................................................... 10-112

SAFETY LOCK VALVE ........................................................................................................................... 10-118

PPC ACCUMULA TOR ............................................................................................................................. 10-118

STRAIGHT-TRAVEL SYSTEM................................................................................................................. 10-119

Function ............................................................................................................................................ 10-119

EPC SOLENOID VALVE .......................................................................................................................... 10-120

Operation .......................................................................................................................................... 10-121

OVERLOAD WARNING DEVICE ............................................................................................................ 10-122

Outline............................................................................................................................................... 10-122

Operation .......................................................................................................................................... 10-123

HOSE BURST PROTECTION VALVE (boom)......................................................................................... 10-124

Function ............................................................................................................................................ 10-124

Operation .......................................................................................................................................... 10-125

WORK EQUIPMENT................................................................................................................................ 10-127

ELECTRICAL WIRING DIAGRAM........................................................................................................... 10-128

ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................... 10-130

ENGINE CONTROL SYSTEM ................................................................................................................. 10-131

Function ............................................................................................................................................ 10-131

Operation of system.......................................................................................................................... 10-132

Components of system ..................................................................................................................... 10-133

Fuel control dial ......................................................................................................................... 10-133

Governor motor.......................................................................................................................... 10-134

Engine throttle • pump controller ............................................................................................... 10-135

ELECTRONIC CONTROL SYSTEM........................................................................................................ 10-137

Control function................................................................................................................................. 10-137

Total system diagram........................................................................................................................ 10-138

Pump and engine mutual control function......................................................................................... 10-139

Function ..................................................................................................................................... 10-140

Control method in each mode.................................................................................................... 10-141

Pump control function when travelling ....................................................................................... 10-143

Control function when pump prolix switch is ON ....................................................................... 10-143

Pump and valve control function....................................................................................................... 10-144

Function ..................................................................................................................................... 10-145

Power maximizing • Swift slow-down function .................................................................................. 10-147

Function ..................................................................................................................................... 10-147

Auto-deceleration function ................................................................................................................ 10-148

Function ..................................................................................................................................... 10-149

Operation ................................................................................................................................... 10-149

Automatic warming-up and engine overheat prevention function ..................................................... 10-150

Function ..................................................................................................................................... 10-150

Swing control function....................................................................................................................... 10-152

Function ..................................................................................................................................... 10-153

Travel control function....................................................................................................................... 10-154

Function ..................................................................................................................................... 10-155

10-3

STRUCTURE AND FUNCTION

Active mode function......................................................................................................................... 10-156

Function ..................................................................................................................................... 10-156

Components of system ..................................................................................................................... 10-159

Engine speed sensor ................................................................................................................. 10-159

PPC oil pressure switch............................................................................................................. 10-159

Pump pressure sensor............................................................................................................... 10-160

PC Prolix resistor ....................................................................................................................... 10-161

MACHINE MONITOR SYSTEM............................................................................................................... 10-162

Function ............................................................................................................................................ 10-163

Monitor panel .................................................................................................................................... 10-163

Outline ....................................................................................................................................... 10-163

Monitor display.................................................................................................................................. 10-164

Content of display ............................................................................................................................. 10-165

Oil maintenance function .................................................................................................................. 10-166

Function and operation .............................................................................................................. 10-166

Setting change interval .............................................................................................................. 10-166

Display timing, content............................................................................................................... 10-167

Elapsed time reset ..................................................................................................................... 10-167

Demo mode ............................................................................................................................... 10-167

Switches............................................................................................................................................ 10-168

Switch actuation table................................................................................................................ 10-168

HOW TO SET TELEPHONE NUMBER ................................................................................................... 10-169

SENSORS................................................................................................................................................ 10-170

Coolant level sensor .................................................................................................................. 10-170

Engine oil level sensor............................................................................................................... 10-171

Hydraulic oil sensor ................................................................................................................... 10-171

Engine oil pressure sensor ........................................................................................................ 10-171

Coolant temperature sensor ...................................................................................................... 10-172

Fuel level sensor........................................................................................................................ 10-172

Air cleaner clogging sensor ....................................................................................................... 10-172

10-4

MEMORANDA

STRUCTURE AND FUNCTIONMEMORANDA

10-5

STRUCTURE AND FUNCTION ENGINE RELATED PARTS

ENGINE RELATED PARTS

6

9

SECTION A-A

SECTION B-B SECTION C-C SECTION D-D SECTION E-E

1. Drive plate

2. Torsion spring

3. Stopper pin

4. Friction plate

5. Damper assembly

6. Air cleaner

7. Intake connector

8. Muffler

9. Rear engine mount

10. Front engine mount

10-6

SPECIFICATIONS

The damper assembly is a wet type
Oil capacity: 0.75 l.

STRUCTURE AND FUNCTIONRADIATOR • OIL COOLER

RADIATOR • OIL COOLER

3

2

1

Z

4

98

6

5

7

1. Reservoir tank

2. Oil cooler

3. Radiator

4. Fan

5. Radiator cap

6. Radiator outlet hose

7. Guard

8. Radiator inlet hose

9. Shroud

SPECIFICATIONS

Radiator: CWX-4
Oil cooler: SF-3

Z

10-7