Komatsu Excavator PC210-6K PC210LC-6K PC240-6K PC240LC-6K PC240NLC-6K service & repair manual

Description Komatsu Excavator PC210-6K PC210LC-6K PC240-6K PC240LC-6K PC240NLC-6K service & repair manual

Komatsu Hydraulic Excavator PC210-6K, PC210LC-6K, PC240-6K, PC240LC-6K, PC240NLC-6K pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
K30001 and up
K32001 and up

Technical data, specifications, testing, troubleshooting, maintenance, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
STRUCTURE AND FUNCTION
ENGINE RELATED PARTS
RADIATOR OIL COOLER
POWER TRAIN
FINAL DRIVE
SWING CIRCLE
SWING MACHINERY
TRACK FRAME RECOIL SPRING
TRACK SHOE
HYDRAULIC PIPING DRAWING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
HYDRAULIC PUMP
Basic pump
LS and PC valve
CONTROL VALVE
9-spool valve (standard + 3 service valves)
Main structure
6-spool valve
7-spool valve
8-spool valve
SELF-REDUCING PRESSURE VALVE
CLSS
Outline of CLSS
Basic Principle
Operation for each function and valve
Hydraulic circuit diagram for system
Unload valve
Main relief valve (2-stage type)
Introduction of LS pressure
LS bypass valve
Pressure compensation valve
Shuttle valve inside pressure compensation valve
Variable type pressure compensation valve (for service valve)
Boom regeneration circuit
Arm regeneration circuit
Pump merge-divider valve
LS select valve
Spool stroke modulation
Timing valve
2-stage safety valve (installed to boom cylinder head)
Operation of CLSS system as a whole
When all work equipment is at neutral
Pump flow divided, one side actuated, other side neutral
Pump flow merged, arm OUT, standard mode relief (cut-off control)
Pump flow divided, bucket DUMP, power max. relief
Pump flow merged, boom RAISE
Pump flow merged, swing operated independently
Pump flow divided, travel operated independently
Pump flow merged, compound operation
SWING MOTOR
BASIC MOTOR
Swing lock valve
CENTER SWIVEL JOINT
TRAVEL MOTOR
Operation of motor
Operation of parking brake
Operation of brake valve
VALVE CONTROL
WORK EQUIPMENT SWING PPC VALVE
TRAVEL PPC VALVE
SERVICE PPC VALVE
SAFETY LOCK VALVE
PPC ACCUMULATOR
STRAIGHT
EPC SOLENOID VALVE
OVERLOAD WARNING DEVICE  
HOSE BURST PROTECTION VALVE (boom)
WORK EQUIPMENT
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM  
Operation of system
Components of system
Fuel control dial
Governor motor
Engine throttle pump controller
ELECTRONIC CONTROL SYSTEM
Control function
Total system diagram
Pump and engine mutual control function
Function
Control method in each mode
Pump control function when travelling
Control function when pump prolix switch is ON
Pump and valve control function
Power maximizing, slow-down function
Auto-deceleration function
Automatic warming-up and engine overheat prevention function
Swing control function
Travel control function
Components of system
Engine speed sensor
PPC oil pressure switch
Pump pressure sensor
PC Prolix resistor
MACHINE MONITOR SYSTEM
Monitor panel
Monitor display
Content of display
Oil maintenance function
Function and operation
Setting change interval
Display timing, content
Elapsed time reset
Demo mode
Switches
Switch actuation table
SENSORS
Coolant level sensor
Engine oil level sensor
Hydraulic oil sensor
Engine oil pressure sensor
Coolant temperature sensor
Fuel level sensor
Air cleaner clogging sensor

TESTING AND ADJUSTING
STANDARD VALUE TABLE
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURE ENGINE OIL PRESSURE
TESTING AND ADJUSTING FAN BELT TENSION
MEASURING SPEED SENSOR
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE AND LS DIFFERENTIAL PRESSURE)
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
Pressure switch piping diagram
ADJUSTING WORK EQUIPMENT SWING PPC VALVE
ADJUSTMENT OF FLOW FLOW CONTROL SYSTEM
Graph of PPC Pressure Against HCU Circuit Oil Flow
TESTING TRAVEL DEVIATION
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURE OIL LEAKAGE
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING AND ADJUSTING TRACK SHOE TENSION
BLEEDING AIR
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Points to remember when handling electric equipment
Points to remember when troubleshooting electric circuits
Points to remember when handling hydraulic equipment
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
SERVICE CODE TABLE
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)
TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF
ENGINE THROTTLE PUMP CONTROLLER SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
JUDGEMENT TABLE FOR ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM

DISASSEMBLY AND ASSEMBLY
When removing or installing unit assemblies
General precautions
Listing of special tools
PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions when carrying out removal work
Precautions when carrying out installation work
Precautions when completing the operations
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR
ALTERNATOR
FUEL INJECTION PUMP
WATER PUMP
NOZZLE HOLDER
TURBOCHARGER
THERMOSTAT
GOVERNOR MOTOR
CYLINDER HEAD ASSEMBLY
RADIATOR HYDRAULIC OIL COOLER
ENGINE, MAIN PUMP
DAMPER
FUEL TANK
CENTER SWIVEL JOINT
FINAL DRIVE
SPROCKET
SWING MOTOR
SWING MACHINERY
REVOLVING FRAME
SWING CIRCLE
IDLER RECOIL SPRING
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
HYDRAULIC TANK
MAIN PUMP
MAIN PUMP INPUT SHAFT OIL SEAL
CONTROL VALVE
PUMP MERGE-DIVIDER VALVE
MAIN RELIEF VALVE
PC VALVE
LS VALVE
PC, LS-EPC VALVE
SOLENOID VALVE
WORK EQUIPMENT - SWING PPC VALVE
TRAVEL PPC VALVE
BOOM CYLINDER
BUCKET CYLINDER
HYDRAULIC CYLINDER
WORK EQUIPMENT
BUCKET
ARM
BUCKET-ARM
BOOM
OPERATORS CAB
COUNTERWEIGHT
ENGINE THROTTLE - PUMP CONTROLLER
MONITOR

MAINTENANCE STANDARD
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
TRACK FRAME RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC PUMP
CONTROL VALVE
VARIABLE PRESSURE COMPENSATION VALVE
SAFETY-SUCTION VALVE FOR SERVICE VALVE
SELF-REDUCING PRESSURE VALVE
SWING MOTOR
TRAVEL MOTOR
TRAVEL PPC VALVE
WORK EQUIPMENT SWING PPC VALVE
EPC SOLENOID VALVE
CENTER SWIVEL JOINT
HYDRAULIC CYLINDER
Boom cylinder
Arm cylinder
Bucket cylinder
WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT
Arm portion

Engine S6D102L-1, S6D102E-1, SA6D102L-1, SA6D102E-1 workshop service manual