Komatsu PC210-6K, PC210LC-6K, PC240LC-6K & PC240NLC-6K Excavator Shop Manual – 2000s (P/N EEBM001801)

This Komatsu shop manual (P/N EEBM001801) covers PC210-6K, PC210LC-6K, PC240LC-6K, and PC240NLC-6K excavators, serial K32001 and up. It contains chassis repair and diagnostic procedures; engine-specific details referenced in the text require the separate 102 Service Engine Shop Manual, which is not included.

PDF Search, Bookmarks, and Diagram Detail

Finding text and reading circuits: Text search is available through the main sections, but some tables and foldout diagrams have no searchable text. Embedded bookmarks lead to chapters and many individual components; the legacy MAIN MENU bookmark points to a separate HTML file. Small wiring codes and connector-pin labels require zooming.

The download contains one printable, English-language 665-page PDF, including 22 preliminary pages, foldout diagrams, divider and blank pages, the manual-revision form, and the closing memo page.

CLSS Diagnostics and Component Repair

The following selected topics outline the workshop coverage rather than reproduce the full contents. Other sections address the overload warning device and boom hose-burst protection valve.

• Engine checks and adjustment: Valve-clearance adjustment, compression and blow-by testing, fuel injection timing, governor motor lever-stroke adjustment, and engine oil-pressure measurement.

• Hydraulic fault isolation: PC and LS valve pressure tests, servo-piston input-pressure checks, hydraulic drift diagnosis, cylinder and motor leakage measurements, and air bleeding.

• Control-valve service: Step-by-step disassembly and assembly procedures for the six-spool control valve, pump merge-divider valve, main relief valve, and PPC valves.

• Swing and final drives: Step-by-step disassembly and assembly of the center swivel joint, swing machinery, and final drive, alongside swing and travel motor diagnostics.

• Undercarriage and cylinders: Recoil spring, idler, track roller, carrier roller, and hydraulic-cylinder service, plus track-shoe replacement and tension adjustment.

• Electrical troubleshooting: Wiring diagrams, service-code charts, S-NET communication checks, connector identification, and circuit tests for the governor, pump controller, and machine monitor.

Written for service-workshop personnel, this manual assumes access to hydraulic test equipment, electrical measuring tools, and suitable lifting equipment.

Pump Control and Attachment Hydraulics

The structure-and-function chapters explain the variable-capacity swash plate piston pumps and the Closed Center Load Sensing System (CLSS). They show how PC and LS control, pressure compensation, and pump merge-divider operation regulate flow during independent and combined movements.

Sectional drawings show six-, seven-, eight-, and nine-spool control-valve configurations. The detailed main-control-valve teardown procedure applies to the six-spool version. Attachment flow-controller adjustment is covered for machines equipped with that system.

The Hydraulic Piping Drawing and Hydraulic Circuit Diagram for System support circuit tracing. Pressure-test procedures and troubleshooting charts help distinguish pump-control, valve, and pump faults before a repair is selected.

Engine Setup and Cooling-System Work

Engine-related sections cover installed-component access, governor motor replacement, and radiator/oil-cooler removal and installation. Separate cylinder-head access procedures distinguish the PC210 and PC240 arrangements, including the PC240 aftercooler.

The testing chapter supplies the injection-timing and governor-linkage adjustment procedures used during engine setup. Moving the disconnected governor motor lever abruptly can generate electricity and damage the governor controller.

Final Drives, Rollers, and Cylinder Assemblies

Travel-motor material explains parking-brake and counterbalance-valve operation and provides leakage tests and inspection standards. The final-drive and swing-machinery chapters contain the internal teardown and reassembly procedures.

Roller service includes floating-seal installation and leakage checks. Hydraulic-cylinder procedures address piston-rod assemblies, packings, wear rings, and cylinder-head bushings. The center swivel instructions warn that careless shaft installation can damage its seals and O-rings.

Electrical Tests and Workshop References

The electrical circuit diagrams for E Mode and C/F Mode accompany fault charts for engine control, pump control, and input signals. Connector mounting-location drawings and pin-number tables connect those checks to the machine wiring.

Standard bolt-torque charts and component-specific maintenance standards provide assembly data, clearances, and wear limits. Tool references include final-drive floating-seal installer 791-545-1510, while fabrication sketches support locally made service tools. These references help a shop plan equipment needs for in-house work.

Examples of Tank Relief and PPC Switch Specifications

The hydraulic-tank pressure valve has a documented relief cracking pressure of 16.7 ± 3.9 kPa. This specification concerns tank pressure, rather than the high-pressure working circuits.

For the PPC hydraulic switches, actuation (ON) pressure is 0.49 ± 0.1 MPa and reset (OFF) pressure is 0.29 ± 0.05 MPa. These thresholds relate to detecting control-lever operation.

Always depressurize hydraulic circuits and verify equipment stability before applying the specifications listed in this document or performing any repair.