EEBMOO0505 SOW IM LAINNO AIL KOMATSU PC210, 210LC-ck PC240, 240LC, PC240NLC-ck MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up This shop manual may contain attachments 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-6 mount the S6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual. ©1997 MOMATSU All Rights Reserved Printed in Belgium 02-97‘The affected pages are indicated by the use of the following marks. It is requested that necessary ac- Merk | indication Action required tions be taken to these pages according to the table below. Page to be newly added ane [Page to be replaced | Replace (_ ) [Page tobe deleted | Discard Pages having no marks are those previously revised or made addons. LIST OF REVISED PAGES wa Pace eT wane Page Tl wan rage Th] man Pape 770] wan page Tat © 004 ® 10-13 fo} 10-48 oO 10-82 @ 10-115 © vo uO oO ros} one © 2 021 © 10-45, @ 10-50 oO 10-84 oO wn7 © 0-2-2 ® 10-16 oO 10-51 oO 10-85, oO 10-118 @ © 023 © 10-17 oO 10-52 o 10-86 @Q 18119 @ 00-3 10418 fo} 10-53 ® 10-87 o 10-120 @ vo 0 wo oO wont os io} 1080 oe 0 foi 0 toe ne oe oO wows o7 woe} wor oO wom toe ioe 10880 oe 8 ious 0 009 10-25 oO 10-59 oO 10-93 ® 10-126 OD coro oO oo wo 0 won? oo wor 8 or ios om 0 0012 10-28 @ 10-62 oO 10-96 oO 10-129 00-13 10-29 oO 10-63, @® 10-97 ® 10-130 © 00-14 10-30 oO 10-64 oO 10-98 oO 10-131 @ wos sr | ees 8 mo woe cos be 6 08 8 om ois @ oo sO eer 8 wor wore ne we 3 joi 0 ious sO we 3 wom 0 wore tos ioe} om foie foie1 @ we 8 woe won 0 ions 0 o1ee @ 10-3, oO 10-39 oO 10-72 oO 10-106 = @ 10-1363 @ 104 @ 10-40 fo 10-73 oO 10107 © 10-136-4 @ sO io tom 0 iow ones 10-6 oO 10-42 ® 10-76 OQ 10109 @ 10-1366 @ 10-7 oO 10-43 ® 10-77 ® 10-110 @ 10-138 sO tou on 0 foi 0 owe 0 sO ios om O wore © iouo 10-10 oO 10-46 @O 10-80 ® 10113 © 10-141 fo} 10-12 ® 10-47 Oo 10-61 ® 10-114 @ 10142 @ 00-2-1Mark Page Foreon| Mat Page iugol| Mark Page TM! mark Pago TIMES! wark Page Time of 1143 @ 2019 20-69 2osa8 zo-te tore @ 20-14 20-70 20-128 20-182 co) © 2015 2071 2os27 20-188 (oan © 20-16 zor 20-128 20-108 (10-148) © 2017 20-73 20-120 20-185, 10-149 2018 2074 20-190 20-108 10-180 © 2020 2075 20-31 20-187 10181 2021 2076 20-132 20-188, 1012 © 2022 2078 204138 20-189 10153 © 2023 2079 20134 20-190 10158 2024 2080 20-135 20-101 10-155 2025 2081 20-136 20-192 10-158 2028 2082 20197 20-183 10157 2027 2089 20-138 20-196 10-158 20.28 20-84 20-139 20-195 1189 © 2029 20.85 2-140 zows tote 20-0 20.88 zoe ow wis © 2031 20.87 20-42 20-198 wie 202 20-88 2osa3 20.199 118s © 2003 20-89 2014s tore 20-94 20-00 20-48, 20201 118s © 2095 2001 20-46 20202 1016 © 2036 20-82 2oca7 20208, 10167 © 2087 2093 20-48 20.204 1018 2038 2094 20-49 20.205 10-168 2030 2095 20150 20206, 10170 20.40 2098 20st 20207 171 2041 2007 20153 20.208 1017 20.42 2098 20154 20209 10.173 © 2043 2090 20455, 20210 10178 20.48 20-100 20-156 zo2ti 10175 20.45 20:01 20187 20212 10.178 20.48 zo-102 204158, 20213 10.177 2047 20-108 201859 20216 10.178 20.48 20-104 20-160 20215 10.179 20-49 20-105 zoe 20216 10-180 © 2080 20-108 2oss2 20217 worse 2051 20007 204183, 20-218 118s 2053 20-108 20-68 20219 10-188 20-54 20-100 20-165 20-200 2055 20-110 204186 20-221 2058 2011 20467 20222 201 2087 zone 20-168 20-205 22 20.58 20-113 20-169 2022 208 2059 20-18 2070 20225 204 200 20-16 zor 20205, 205 2081 20-116 zoare * 227 © 206 2062 20118 20.173 20208 207 20-63 2-119 2oara 20220 ns @ 2064 20-120 2075 2021 209 2065, 20-121 20.176 20282 20-10 20-66 20-122 zea? 20283 zon 2067 20-123 20-78 20235, 202 2068 20-124 20-180 20236 00-2-2Mark Page [ircon| Mark Page (yrgcl| Mark Page T¢Ol Mak Page TIME! wark Page Timeot 202007 3027 30-82 oO 20-298 3028 30-89 ow 0 20-299 2029 20-04 21 O 20-240 30.90 20-85 «2 © 20281 3031 20-86 42 ® 20242 m0 2087 4022 20.248 90.33 30-88 4023 2024 3034 2089 4024 20245 w025 20-90 4025 20.246 3096 2001 4028 20247 3037 30-92 4027 20248 2098 2009 4028 20-240 2099 3084 doz 20-250 2040 30-95 40:30 20251 aot 20-06 4031 20-252 9042 3097 4032 20-259 3043 30-08 4033 20254 20-44 20-09 404 20255 2045 230-100 4035 ® 20.256 2046 30-101 40-96 20-257 30-47 30-102 40-37 @ 20258 2048 20103 4038 20.250 209 so-108 402 «@ 20-260 20-50 30108 faa) 20261 2st 20-106 40st 20-262 20-82 3007 20263 3053 30-108 3054 20-109 90-55 30-110 4 30-56 sont 02 2057 sone 203 2058 oo-119 204 2089 0-114 205. 3060 0-115 206 2061 0-116 27 2062 30-117 8 2009 209 20-64 20-10 3065 404 won 20-86 402 w0-12 2067 403 20-19 20-68 404 woe 20-89 405 18 30-70 406 2047 oo-72 407 20418 90-73 408 a9 2074 09 3020 30-75 40-10 2021 2076 wont 2022 2077 40-12 3023 3078 40-19 3028 2079 404 2025 30-80 40-18 3026 3081 4018 00-2-3a)20506 10 STRUCTURE AND FUNCTION Engine related parts nn 10-2 Radiator « oil cooler « aftercooler wo 10-3. Powertrain nnn eee 0) Final dfive sesnmnnnnnnnnnnnnnnnnn 102 5) Swing circle 10 6 Swing machindery smn W028 Track frame recoil spring 10- 9 Hydraulic piping drawing sno W001 Hydraulic circuit diagram 10- 12 Hydraulic tank. 10-14 Hydraulic PUMP wnnnnnnmnnnnnnnne 10° 15 Control valve... 40- 38 ciss 10- 47 SWING MOF ensmnmnesennnnnnnnnsnnn 10° 92 Center swivel joint so snes 10> 96 Travel motor... 40-105 Work equipment « swing PPC valve 10-108 Travel PPC valve se 0-110 Service PPC valve osnnneesnnnee WANG Safety lock valve 10-117 PPC accumulator 10-117 PPC shuttle « travel junction Valve nnn 10-118, EPC * solenoid ValVE wnrnnnnnnnennnnnees 10425, Hydraulic cylinder 10-130 Additional ft for breaker 10-131 Overload warning device svnnnees 10-432 Hose burst protection valve snnnees 10-136, 2nd Boom Holding valve sow 10-136-3 Work equipment... 10-136-6 Electrical control system 10-138 Electrical wiring diagram 10-143 Engine control SySteM w.rnnnnnnnnnnne 10-149) Electronic control system 10-154 Machine monitor system on 10179, 10-1STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS Be cc ce 1. Drive plate OUTLINE . Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.752 2 3 4, Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount }0. Front engine mount 10-2 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE pooe Port T (to tank) Port Pi (from boom LOWER PPC valve) Port Cy (to boom cylinder bottom) Port V (from boom control valve) osena 2ND BOOM HOLDING VALVE . Safety-suction valve Pilot spring . Pilot spool Poppet spring Poppet 10-136-3STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE Operation 1) 2) At boom EXTEND When the second boom is extended, the main pressure from the control valve pushes poppet (6) up in the direction of the arrow. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom adjust cylinder. f Seat FF een a Tren # exten OF Premen, Boom pedal at NEUTRAL When the second boom is raised and the control lever is returned to NEUTRAL, the cir- cuit for the holding pressure at the bottom end of the boom adjust cylinder is closed by poppet (6) and at the same time, the oil flowing into poppet (5) through orfice a of poppet (5) is closed by pilot spool (3). Asa result, the second boom is held in position. concros econo Contras valve 10-136-4 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 3) Atboom RETRACT When teh second boom is retracted, the pilot pressure from the PPC valve pushes pilot spool (3) and the pressurised oil in chamber b inside the poppet is drained, ‘When the pressure at port Cy rises because of the pressurised oil from the bottem end of the adjust cylinder, the difference in pressure bet- ween the oil surrounding the lower end of pop- pet (5) and the oil in chamber b allows the pop- pet tot rise allowing to flow from port Cy to port V which then flows to the control valve. If anny abnormal pressure is generated in the circuit at the bottom end of the boom adjust cylinder, safaty valve (1) is actuated contro! Seas! secona 10-136-5 ®STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 208608129 Arm Bucket cylinder . Arm cylinder Boom Boom cylinder Bucket Parons 10-136-6EEBM000502 DIOP 1M WANINAOANILy KOMATSU PC210,210LC-6k PC240 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up + This shop manual may contain attachments 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-6 mount the $6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU All Rights Reserved. Printed in Belgium 10-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION weve 10-1 TESTING AND ADJUSTING... DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD..............c:ss:scssessesssssssesesseeneeees 40-1 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list oe Indication eeecae below. © | Page to be newly added | Add # | Page 0 be replaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time LIST OF REVISED PAGES. Mork Pages Revo” Tarark Pages ReViiON | ntark Pages PESO | ear Pages FEB | Mark Pages Revlon © 00-1 @ 10-23 @ 10-64 @® 10-105 @ © 10-143 @® 00. 2 wa oO 10-65 1-106 O | + wm @ © 00-21 @ 10-25 @ 10-66 10-107 @ (10-146) @ © 00-22 @ 10-26 @ 10-67 © 10-108 @ (10-147) @ © 0-23 @ 10-27 @ 10-68 @D 10-109 @® (10-148) @ 00- 3 10-28 @ 10-69 D 10-110 OD 10-149 © 00- 4 10-29 OD 10-70 @ 0-111 @ 10-150 O 00- 5 10-30 @ 0-71 @ 10-112, @ 10-151 © 00. 6 031 wn @ 10.113 © 1182 00-7 10-32 oO 10-73 OD 10-114 D 10-153 @ 00-8 033 074 @ 10-115 10-154 00-8 1038 @ 0-76 018 10-185 00-10 1035 077 0117 10-155 © 00-11 1036 10-78 OD 10-118 OD 10-157 @ 00-12 10-38 10-79 OD 10-119 10-158 @ 00-13 1033 10-80 OD 10-120 OD 10-159 © oo-t4 1040 wer o w121 10-160 00-15 10-41 ® 10-82 © 10-122, D 10-161 @® 00-16 02 © wes © 10-123 toi 00-17 10-43 10-84 © 10-124 OD 10-168 OD +01 @ wu 085 © 0-125 @ tose 02 O 45 wo8 0-126 10185 03 @ 1048 © wa 0127 @ 10-188 04 O 47 we @ 10-128 10.167 05 © 1048 © 10-89 OD 10-129 OD 10-168 10-6 fo} 10-49 @ 10-90 © 10-130 © 10-169 OD 07 © |e 00 © war © | o wim @ 0.170 08 @ 1031 © we © | o wim @ win 10-9 oO 10-52 @ 10-93 © © 10133 @ 10-172, 10-10 @ 10-63 ® 10-94 ® o 10134 @ 10-173 wn @ 1054 @ ws © | o 15 @ wim 02 O 055 © wos © | o 16 @ 10.175 0-14 O 1056 10-97 © © 10-1361 @ 10-176 OD 10-15 oO 10-57 @ 10-98 © o 10-1362 @ 10-177 © 10.18 1058 wo © | o w1363 @ 104178 10-17 oO 10-59 fo} 10-100 ® 10-138 @ 10-179 ® 0-18 OD 10-60 @ 10-101 © 10-139 @ 10-180 © 10-19 oO 10-61 @ 10-102 @® 10-140 @ 10-181 © 10-20 ®Q 10-62 ® 10-103 @ 10-141 O 10-182 O 10-22, 10-63 @ 10-104 10-142, 10-183 00-2-1Mark Pages FOC” | mark Pages REWsiOn | mark ages Fevition | rar Pages ROMSIO" | mare Pages Revision 10-184 20- 64 20-110 20-167 20-225 10-185 © 20- 85 20.111 20-168 20-226 10-188 O 20- 56 20-112 20-169 20-227 20- 87 20-113 20-170 20.228 20-1 20- 58 20-114 204171 20-229 20. 2 20. 59 20-115 20-172 20.231 20-3 20- 60 20-116 20-173 20-232 20- 4 20- 61 20-118 20-174 20-233 20-5 20- 62 20-19 20-175 20-238 20- 6 20- 63 20-120 20-176 20-236 20-7 20-64 @ 204121 20-17 20-237 20- 8 20-65 20-122 20-178 20-238 20- 9 20-66 20-123 20-180 20-239 20- 10 20-67 @ 20-124 20-181 20-240 20-11 20- 68 20-125 20-182 20-241 20- 12 20- 69 20-126 20-183 20-242 20.13 20: 70 20-127 20-184 20-243 20. 14 20-71 20-128 20-185 20-244 20-15 20-72 20-129 20-186 20-245, 20-16 20-73 20-130 20-187 20-246 20-17 20-74 20-131 20-188 20.287 20-18 20-75 20-132 20-189 20-248 20-19 20-76 20-133 20-190 20-249 20- 20 20-77 20-134 20-191 20-280 20-21 20-78 20-135 20-192 20-251 20- 22 20-79 20-136 20-193 20.252 20- 23 20- 80 20-137 20-194 20.253 20- 24 20- a2 20-138 20-195 20.254 20- 28 20- €8 20-138 20-196 20.255 20- 26 20- 84 20-140 20-197 20-256 20-27 20- 86 20-141 20-198 20-257 20- 28 20- 86 20-142 20-199 20-258 20- 29 20- 87 20-143 20-201 20-259 20- 30 20- 88 20-144 20-202 20-260 20- 32 20- 89 20-145 20-203 20.261 20- 33 20- 90 20-48 20-204 20-262 20- 34 20-91 20-47 20-205 20-263 20-35 20- 92 20-48 20-208 20- 36 20- 93 20-149 20-208, 304 20-37 20- 94 20-150 20-209 30-2 20-38, 20- 95 20-151 20-210 30-3 20-39 20- 96 20-153 20211 30-4 20- 40 20. 97 20-154 20-212 30-5 20-41 20- 98 20-155 20-213 30-6 20-42 20- 99 20-156 20-214 30-7 20- 43 20-100 20-157 20-215 30 8 20- 44 20-101 20-158 20-216 30-9 20- 45 20-102 20-159 20.217 30-10 20- 46 20-103 20-160 20.218 30-11 20-47 20-104 20-161 20219 30-12 20- 48 20-108 20-162 20-220 30-13 20- 49 20-108 20-163 20-221 30-14 20- 60 20-107 20-164 20-222 30-16 20- 51 20-108 20185, 20-223 30-17 20. 53 20-109 20-168 20-224 30-18 00-2-2 2050620506 Mark Pages Revlon | hark Pages ROMO | ark Pages FEMSOM | ark pages REVIOM | mark Pages Reiton 30-19 30-75 OD 40-12 30-20 30-76 40-13 30-21 30-7 40-14 30-22 30- 78 40-15 30-23 30-79 40-17 oO 30-24 30- 80 40-18 30-25 30- 81 40-19 30-26 30- 82 40-20 @ 30-27 30- 83 40-21 30-28 30- 84 40-22 30-29 30- 85, 40-23 30-20 30. 86 40.24 30-31 30- 87 40-25 30-32 30- 88 40.28 30-33 30- 89 4027 30-34 30- 90 40-28 30-35 30-91 40-29 30-36 30: 92 40-30 20.37 30. 99 aoa 30-38 30- 94 40-32 30-39 30- 95, 40-34 30-40 30- 96 40-35 30-41 30- 97 40-36 30-42 30- 98 40.37 30-43 30- 99 40-38 30-44 30-100 40-39 30-45 30-101 40-40 30-46 30-102 40-41 30-47 30-103 3048 30-104 3049 30-108 30-50 30-106 30-51 30-107 30-52 30-108 30-53 30-109 30-54 30-110 30-55 30.117 30-56 30-112 30-57 30-113 30-58 30118 30-59 30-115, 30-60 30-116 30-61 30-117 30-62 30-63 4 30-64 40- 2 30-65 40- 3 30-668 wo 4 30-67 40- 5 30-68 00. 6 30-69 @ 40- 7 30-70 40- 8 30-72 “0 9 30-73 oO 40- 10 30-74 @ 40-11 00-2-3k20506 10 STRUCTURE AND FUNCTION Engine related parts Radiator « oll cooler + aftercooler. 3 Power train .. 4 Final drive .. 5 Swing CifCle «von 6 Swing machinery 10-7 Track frame + recoil spring... 10-8 Track shoe Hydraulic piping drawing .. Hydraulic circuit diagram .. Hydraulic tank. Hydraulic pump Control valve .. CLSS.... Swing motor... Center swivel joint Travel motor Valve control... Work equipment « swing PPC valve .. Travel PPC valve Service PPC valve ... Safety lock valve .... PPC accumulator... PPC shuttle + travel junction valve EPC + solenoid valve Hydraulic cylinder Additional filter for breaker... Overload warning device .. Hose burst protection valve . Work equipment: Electrical control system Electrical wiring diagram Engine control system Electronic control system .. Machine monitor system 10-1 ®STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS 20506 on 88 ce DD |. Drive plate OUTLINE Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.758 . Friction plate . Damper assembly . Air cleaner . Intake connector Muffler . Rear engine mount . Front engine mount Seerogsens 10-2k20506 STRUCTURE AND FUNCTION 2). Pressure compensation ciss A valve (pressure compensation valve) is installed to the outlet port side of the control valve to balance the load. When there is compound operation of the actuators, this valve acts to make pressure difference AP constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening $1 and $2 of each valve. Load oe Actuator Load w g ft oe R [Pressure Pressure ese et »| TS Lf le ” WU um LT 202F06081 10-49 ©STRUCTURE AND FUNCTION OPERATION FOR EACH FUNCTION OF CLSS Hydraulic cirouit diagram for system fee 10-50 2050620506 STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER ADDITIONAL FILTER FOR BREAKER * FOR MACHINE EQUIPPED WITH BREAKER 20505096 1. Head cover SPECIFICATIONS 2. Element Rated pressure : 6.86 MPa (70 kg/cm?) 3. Case Flow :107¢/min 4. Drain plug Relief valve cracking pressure: 0.34 + 0.049 MPa 5. Valve (3.5 £ 0.5 kg/om’) 6. Spring Filter mesh size: 6 um 7. Spring set plug Filtering area: 3160 em? 10-131 ®‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 1 OUTLINE Buzzer Oil pressure switch / /- Boom control 7 “ / 800m eylindor aaa ae FUNCTION + This device is installed to warn the operator when the machine is close to tipping over when it lifts an excessive weight while be- ing used as a crane. STRUCTURE + When an excessive weight is lifted, the oil pressure goes up at the bottom side of the boom cylinders. When this happens, the pressure switch senses the rising pressure, turns the pressure switch on, and lights the monitor lamp to warm the operator. When the monitor lamp lights, immediately lower the weight to the ground or bring the arm closer in to the operator to prevent the ma- chine from tipping over. 10-132 OVERLOAD WARNING DEVICE FO20E346C20506 STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE Control panel Overload warning pilot lamp (Monitor, 10-133STRUCTURE AND FUNCTION OPERATION + Hose (2) directs the oil pressure from the bottom side of the boom cylinders to pressure switch (3). When the boom is in the lowest position + When boom (5) is in the lowest po: tion, lever (4) takes position A in Fig. 1 and the pressure to activate its switch (closed and open) becomes 60 kg/cm*. . When the boom is in the highest position + When the boom is in the highest posi tion, lever (4) takes position B in Fig. 1 and the pressure to activate the switch becomes 360 kg/cm, When the boom is in an arbitrary position + When the boom is in a position any- where between the lowest and the high- est points, the operating pressure of switch (3) will be somewhere between 60 kg/cm? and 360 kg/cm’, based on the boom position: For instance, when the boom is in a cer- tain position between the lowest and the highest points, lever (4) takes a position which corresponds to that boom posi tion. OVERLOAD WARNING DEVICE If lever (4) is in the position to make the operating pressure of the pressure switch 10 kg/cm? (which is the same pressure as the bottom side of the boom cylin- der), the pressure switch will turn on when excessive weight is lifted by the boom and the oil pressure of the bot- tom of the boom cylinders exceeds 150 kgfor. When the machine is performing any kind of operation other than lifting loads, fasten the pressure switch lever (4) with the bolt (6) to prolong the life at the pressure switch. k2050620506 ‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 3. ADJUSTING PRESSURE OF THE OIL PRESSURE SWITCH + Screw D: Pressure range adjustment screw To make an adjustment so that the oil pressure switch acts normally when checking the operation of the overload warn- ing device. Turning to the left makes the pressure range wider. + Screw E: Zero point adjustment screw Turning to the right one com- plete turn raises the pressure by 57 kg/cm’. Each complete turn to the left lowers the pressure by 57 kg/ cm? a 1. Body AiWren an adjustments required, contact 2, Bouldon tube your Komatsu distributor and have 3. Eocontie make the adjustment. 4, Microswitch 5. é 1 Lever and roller Adjustment screw (E) Adjustment screw (D) 0206361 10-135 ©STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) HOSE BURST PROTECTION VALVE (BOOM) High pressure from 1) @D contrel valve w'por At signal ipod —_ Overond cation signal yp YZ, TEA < ‘ ao Ly vy 3 1. Body 2. Spool 3. Relief valve 4, Check valve pone 210-1008 FUNCTION This valve prevents sudden uncontrolled lowering of the boom, when lifting, due to the burst of a hose in the boom cylinder line. In such a condition this valve will hold the load until operator lowers the boom in a controlled way using the normal wrist control. 10-136 2050620506 STRUCTURE AND FUNCTION When hose burst occurs (Operation to lower safety) The sudden loss of pressure at port V will cause check valve (4) to re-seat and so the valve is locked. + The boom can be lowered in a controlled way by operating the wrist control in the normal way. HOSE BURST PROTECTION VALVE (BOOM) V port Ec To tank cylinder [| Be0m control |L_L contot ever i 10-136-1 ®STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) OPERATION BOOM RAISE During boom raising the pilot signal from wrist control operates control valve spool to direct high pressure oil to port V of hose burst valve. + This pressure lifts check valve (4) from seat & high pressure oil flows in the bottom of the cylinder raising the boom. V port ED To tank aon Boom control L\ control lever BOOM LOWER During boom lowering the pilot signal re- == verses the front through the control valve spool. High pressure oil flows to the head side of the cylinder. Oil in the bottom side of the cylinder flows through the port Cy of the valve but cannot flow past the check valve. The pilot signal also opens the spool (2) of the hose burst valve and allows oil to flow back to tank. Tpont ep To tank p | 10-136-2 20506k20506 STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT easeNe 2osroei2a Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket 10-136-3 ®EEBM000501 EOP IMUAINTO ANIL KOMATSU PC210,210LC-6k PC240, 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K K30001 and up This shop manual may contain attachments 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-6 mount the S6D102L-1 en; PC240, 240LC-6 mount the SA6D102L-1 1 For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU Al Rights Reserved Printed in Belgium 05-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION.. 10-1 TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY . MAINTENANCE STANDARD................04 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions ‘must be taken to these pages according to thelist below. Mark Indication ‘Action required © | Page to be newly added add © | Page tobe reptaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time. 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Track frame + recoil spring Track shoe : Hydraulic piping drawing .. Hydraulic circuit diagram Hydraulic tank. Hydraulic pump Control valve 2 3 4 5 6 7 8 9 n 2 4 6 38 a7 cis... ‘Swing motor... 0- 92 Center swivel j -10- 95 Travel motor 10- 96 Valve control... ‘Work equipment + swing PPC valve ... Travel PPC valve Service PPC valve Safety lock valve PPC accumulator PPC shuttle « travel junction valve EPC - solenoid valve... Hydraulic cylinder Additional filter for breaker... Overload warning device Work equipment. Electrical wiring diagram Electrical control system ... Engine control system Electronic control system Machine monitor system.. 10-105 10-106 1. 10-110 10-114 10-117 10-117 10-118 . 10-125 10-130 10-131 10-132 10-136 - 10-138, 10-145 10-149 - 10-154 10-179STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS BB cc DD 1. Drive plate OUTLINE 2. Torsion spring + The damper assembly is a wet type. 3. Stopper pin Oil capacity: 0.75¢ 4. Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount 10. Front engine mount 10-2 2050620506 STRUCTURE AND FUNCTION RADIATOR «+ OIL COOLER + 1 2 3 4 PEN OMReNe AFTERCOOLER 5 6 Reservoir tank il cooler Radiator Fan Radiator inlet hose Radiator outlet hose Radiator cap Net Shroud RADIATOR - COOLER + AFTERCOOLER SPECIFICATIONS Radiator: CWX-4 Oil cooler: SF-3 10-3STRUCTURE AND FUNCTION POWER TRAIN POWER TRAIN 1. Idler 2. Center swivel joint 3. Control valve 4, Final drive 5. Travel motor 6. Hydraulic pump 10-4 ® 7. Engine 8, Travel speed solenoid vaive ‘9. Swing brake solenoid valve 10. Swing motor 11. Swing machinery 12. Swing circle 20506k20506 STRUCTURE AND FUNCTION FINAL DRIVE 3 rT) Fr] 12 FINAL DRIVE |. Level plug . Drain plug . No. 2 sun gear (No. of teeth: 12) . No. 1 sun gear (No. of teeth: 21) . No. 1 platetary carrier . Cover . No. 2 planetary carrier . Sprocket . Floating seal ). Travel motor |. Hub . No. 2 planetary gear (No. of teeth: 36) . Ring gear (No. of teeth: 84) . No. 1 planetary gear (No. of teeth: 31) ‘SPECIFICATIONS. Reduction ratio: — CE) x CS) + 1 = 39.000 20sca06012 10-5STRUCTURE AND FUNCTION SWING CIRCLE 1. Swing circle inner race (No. of teeth: 110) 2. Ball 3. Swing circle outer race a. Inner race soft zone position b. Outer race soft zone S position 10-6 2oscaosor SPECIFICATIONS Reduction ratio: 110 . 7.333 Amount of grease: 21¢ (G2-LI) SWING CIRCLE k2050620506 STRUCTURE AND FUNCTION SWING MACHINERY " 12 13 }—4 15 16 7 20sFosooe ‘SWING MACHINERY 1. Swing pinion (No. of teeth: 15) 2. Cover 3. Case 4. No, 2 of planetary carrier 5. No. 2 sun gear (No. of teeth: 15) 6. No. 2 ring gear (No. of teeth: 72) 7. Case 8. No. 1 ring gear (No. of teeth: 72) 9. No. 1 sun gear (No. of teeth: 21) 10. Swing motor I level gauge 12. Cover 13. No. 1 planetary gear (No. of teeth: 25) 14, No. 1 planetary carrier 15. Coupling 16. No. 2 planetary gear (No. of teeth: 28) 17. Drain plug SPECIFICATIONS Reduction ratio: 21472 ,, 15472 21 15 5.686 10-7‘STRUCTURE AND FUNCTION TRACK FRAME - RECOIL SPRING ‘* The diagram shows the PC210-6K. ‘TRACK FRAME + RECOIL SPRING Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard PON OMPONS 10-8 ® 205cA06015| The dimensions and number of track rollers may differ according to the model, but the. basic structure is the same. No. of track rollers Model PC210-6K PC210LC-6K PC240-6K PC240LC-6K PC240NLC-6K No. of rollers (each side) 7 9 8 10 9 2050620506 STRUCTURE AND FUNCTION ‘TRACK SHOE TRACK SHOE ‘STANDARD SHOE Item Model! pczi0-6k_| PC2t0LC-6k | PC240-6K_| PC240LC-6K |PC240NLC-6K Shoe width (triple shoe) | 600mm | 700mm | 600mm | 700mm | 600mm Link pitch 190 mm 1gomm_ | 190mm | 190mm | 190mm No. of rollers (each side) 45 49 47 51 49 ‘SELECTION OF TRACK SHOE + Select the most suitable track shoe from the following table. PCHIO-GK POZTOLC-OK PozaoeK PCROLESK PORONLC-OK Mots! [Epeareaton] SES [Seciteton, GBR [Specticnion] GE [Soectcwion] SE% [Soectenion] SH standord | su" [ a | Oem | a | Same | | mm | a | RP Tw Option mam [ 8 | Mme |e | am | oe | Ome | Aw | Om | 8 Option me | c | Mmm | c = — | mr [ ic | Mme [ic ‘Option a = = = — | ar |e Option — [-- - e a e - Option =| = J-|] = [-7 - [-[ - [- Option -~| - [-[ = [-[T - [-T = [=STRUCTURE AND FUNCTION TRACK SHOE Precautions when using Travel in Lo speed when traveling on rough ground obstacles such as large boulders and fallen trees. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when i impossible to avoid traveling obstacles, lower the travel speed to approx. half of Lo speed. Category Use ‘a | Rocky ground, normal river soil B | Normal soil, soft land | Extremely soft ground {swampy ground) Use only for ground where “A" and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. * Categories “B" and “C” are wide shoes, so there are restrictions on their use. There- fore, before using, check the restrictions and consider carefully the conditions of use be- fore recommending a suitable shoe width. * When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. Ifa wider shoe than necessary is used, there if ;cessary, give the customer guidance in their use. 10-10 will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems. 20506