JEBM000106 STOW IMLAINI OAV IL KOMATSU PC210-5 PC240-5 MACHINE MODEL SERIAL No. PC210,210LC-5KP K20001 and up PC240,240LC,240NLC-5KP K20001 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. C210, 240-SKP mount the Perkins 1006-6T engine. For details of the engine, see the Perkins 1000 Series Engine Shop Manual. Printed in Belgium 00-1 03-95(BO1) ®01 10 20 30 40 CONTENTS No. of page GENERAL ........ccesesceccncecenenentencnsenens 01-1 STRUCTURE AND FUNCTION ............---ee sees 10-1 TESTING AND ADJUSTING ........ sc eee eee eee e eee 20-1 DISASSEMBLY AND ASSEMBLY........5....-.+000 30-1 MAINTENANCE STANDARD..........-..eeeeeeeeeee 40-1 K205P5‘The alfected pages ar the following marks. It Is requested that necassary actions be taken to these pages according to the table below. Indicated by the use of Mark. Indication Action required ° Page to be newly added Add. e Page to be replaced Replace cy Page to be deleted Discard Pages having no mmarks are those previously revised or made additions LIST OF REVISED PAGES Mark Page [ime ol |Mark Pago Time ot |wark Page Time ot |Mark Page Time ol |mark Page Peed + m1 o wor ® 10:29 1059 1086-1 © 2 © 102 10-30 10-60 10.862 © + 0-21 © 103 10-31 10-81 © 1086-3 © + 22 © 104 10-82 10-62 © 1086-4 © + 023 © 105 10-33 10-63 10-87 106 10-38 10-64 10-88 00-3 107 10-35 10-65 10-89 00-4 108 10-36 10-66 10-80 00-5 109 1037 1067 10-91 00-6 10-10 10-38 10-68 10-92 00-7, tot 10-39 10-69 10-93 00-8 10-2 10-40 10-70 10-94 00-9 1043 to-41 10-71 10-95 00-10 10.45 10-42 10-72 10-96 ont 1046 10-43, 10-78, 10-87 ore tar @ 10-46 10-74 10-98 O13 sara © 10-45, 10-75 10-99 ore 10-18 10-46 1076 10-100 ors 10-19 10-47 10-77 to-101 or 1020 10-48 10-78 t0-102 or 10-21 10-50 10-79 10-103 018 10-22 10-51 10-80 10-105 ors 10-23 10-52 10-81 10-106 01-10 10-24 10-59 10-82 10-107 ort 10-25 10-58 10-83 10-108 or-12 10-28 10-56 10-84 10-109 1027 1057 10-85 10-110 1028 1058 10-86 roti K205°5 00-2-1 ®Mark Page pee Mark Page pec Mark Page eosin ‘Mark Page pe et Mark Page nel tone 2028 @] toate eoreaet 20-75 @ 20126 @ 20.175 @ rosin 2030 @ 20.76 © 20127 @ 20176 @ 10-115 2031 @ 2077 @ 20128 @ 20.177 @ nae nes 20-78 @ 20-129 @ 20-178 @ To aot 20-73 o 20131 © 20.173 @ otal et 20-80 20122 @ 20-180 © toto Eocene) 2081 @ 20-194 @ 20181 @ 10-120 moO 2082 20135 @ 20182 © coe ae 2083 @ 20-126 @ 20-196 @ to-122 20-38 © 208 @ 20-137 @ 20-185 @ 10-125 ao 2085 o 20-138 @ 20-186 Aneel et 2088 0 20139 @ 20187 10-195 241 20-88 @ 20.140 @ 20-188 © 10-126 2042 o 2089 © roto 20.190 9 10-127 penne) 2090 @ 20142 @ 20-191 @ 10-128 2044 2092 © 20143 @ 20-192 @ © 10129 © ery Oo 20.93 © 20148 @ 20-193 @ © 104130 © et 20.98 © 20-145 @ 20-194 © 10431 © es 2095 zoe o 20-195 @ 21 @ 2048 2097 © 20147 @ 20-198 20.2 2049 2098 © 20148 @ 20-197 @ 20-3 net 20-99 @ 20149 o 20-198 @ 20-4 2052 @ 20-100 @ 20-150 20-109 205 20:53 @ 20101 @ 20181 @ 20-200 @ 206 2054 @ 20102 @ 20-162 @ 20-201 @ 20-7 205s o 20-103 @ 20-153 @ 20-202 @ 20-8 Eases) 20-105 © 20-154 © 20-203 @ 20-9 2057 o 20-108 © 20-155 @ 20-205 @ 20-10 nes) 20-107 20-186 @ 20-208 @ 20-11 20:59 @ 20-108 @ 20.187 @ 20-207 @ 20-12 20-60 @ 20-109 20-158 @ 20-208 @ 20-13 eat 20110 @ 20-159 @ 20-208 0 20-14 2062 20111 @ 20-161 © 20.210 © 20-15 2069 @ 20.113 @ 20-162 @ 20211 o 2018 @ 2064 @ 2o1e @ 20-163 © 20-212 @ 2018 eat 20115 @ 20165 @ 20213 © 2019 @ 2066 @ 20-116 0 20168 @ 2024 o 2020 2067 o 20118 @ 20-167 20.215 2021 2068 o 2119 o 20-168 20216 @ 2022 @ 2069 oO 20-120 20-169 @ 20.217 @ 2023 @ 2070 @ 20121 @ 20.170 @ 20218 @ 2024 @ st 20122 @ 20171 o 20219 o 2025 @ wor © 20-123 @ 20172 © 20-220 @ 20-26 @ 2073 @ 20124 © 20.173 @ 20221 @ 2027 2074 @ 20128 zoe @ |’ 20-222 @ 0-2-2 K205e5mark Page Time ot Twark Page Time ct Twa Page Time ot Thtark Page Time ot [mark Pago Time of vision revision vision revision revision 20-223 © 30-24 @ 062 30-100 @ 401 © 20-224 © 30-25 @ 3063 30-101 @ 402 0 20-225 @ 3028 © 3064 30-102 @ 409 0 20-226 @ 30.27 2 3065 30-103 @ sos 20227 © 30-28 @) 30-65 @ 30-104 @ 4s 0 20-228 9 2029 @ 2067 @ 30-105 @ 406 0 20-229 @ 30-30 @ 3068 @ 30-108 @ 407 0 20-290 © gost sose 30-107 @ 408 0 202381 o 30-32 © 30-70 @ 30-108 @ 409 0 20-232 @ 3033 © Pe) 30-109 @ 4010 @ 20293 @ 30-34 @ sore @ 20-110 © 4011 0 20204 @ 3035 @ 3073 @ 30111 @ 4012 © 20-235 0 20:98 @ 3078 @ 30-112 @ 40:13 © sosy @ 20-75 @ seta @) 4015 0 30-1 @ 30-98 © 3078 @ sons @ 40-16 0 30-2 @ 3039 © 3077 @ Bons @ 4017 0 so4 @ 3040 2 30-78 @ 30-116 @ 40-18 0 35 goat @ 3079 @ 30417 @ 4019 © 30-6 @ go-42 30-80 @ aoe 4020 0 30-7 @ 3043 @ 3081 son9 4021 © 38 @ 3044 2 so-82 30-120 @ 40-22 © 010 30458 30-83 @ gora1 40.23 © 30-101 @ 30-46 3084 @ sore © 4024 © 30-102 @ 047 3085 30123 @ 40.26 © 30-103 © 3048 @ 30-86 so124 4027 0 son @ 3049 @ 30-87 sors @ 4028 0 sore @ 3050 © 30-88 so-126 4029 0 013 3051) 30-89 30-127 @ 4031 0 ste @ 3052 @ 30-90 © gore @ 40:33 0 3015 @ 3053 @ 30.91 © so-129 @) 4034 © 9016 @ 3054 @ 3092 @ 30-190 @ 4035 30.17 @ 3085 @ 30-93 @ 30.191 @ 4035 8 seo 30-58 30-94 @) gorse @ 4037 © so-19 @ 3057 @ 3095 2 go183 @ 40.99 © 3020 @ 2058 2 30:96 © 30-136 @ 4039 © 3021 2059 @ 3097 30-135 @ 30-22 @ 30-60 @ 30-98 @ 3023 @ s061 2 30-99 @ K2055 00-2-3 ©A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers. the symbols and "A ore used to mark safety pre- cautions inthis manual. The cautions accompanying these symbols should always be followed carefuly I any dangerous sitution arises or may possibly aie, fst concider sofety, ond take the necessary ations to deal with the situation A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual 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 hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, etc. 3.f 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, 4.When carrying out any operation with two ‘or more workers, always agree on the op- erating 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. 6.Decide @ 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 PREPARATIONS FOR WORK 7.Before adding 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 work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places 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. 00-3PRECAUTIONS DURING WORK 11. When removing the oil filer cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents 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 car- rying 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 the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal 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 fies. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil fon 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, use only the mini- mum of gasoline when washing electrical parts. 00-4 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 they will not be damaged by contact with other parts when the ma- chine is being operated, 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful 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 particularly 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 measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD. 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 chapters for each main group of components; these chapters are further divided into the following sections. 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. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each 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 specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as fone volume to cover all models Engine volume: 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 neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers, Get the most up-to-date 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 shows how to read the page number. Example 1 (Chassis volume): 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12-410 l Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) ‘Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated 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 Added pages C13 993.2 10-5 12-204 00-6 REVISED EDITION MARK (DODO When a manual is revised, an edition mark is recorded on the bottom outside corer of the Pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. ‘SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbot | erm Remarks ‘Special safety precautions are A mecassory when performing he vrork Safety Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for | Caution | preserving standards are necessary when performing the work [Weight of parts or systems. AN Caution necessary when (ie) | Weight | selecting hoisting wire, or when working posture is important, ete. fen. | Places that require special a |, Tighten: | attention for the tightening "9 tordue| torque during assembly. Places to be coated with 7s | Coat | adhesives and lubricants etc. Places where cil, water or fuel a [Oil water | must be added, and the [capacity + Places where oil or water must wl | Drain |e drained, and quantity to be drained,HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS DD teavy parts (25 kg or more) must be ified with @ hoist etc. In the Disassembly and Assembly section, every part weigh- ing 26 kg or more is indicated clearly with the symbol - 4, 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made + Check for removal of all bolts fastening the part to the relative parts: + Check for existence of another part causing interference with the part to be removed 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard “2” or “S* twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons! 10 | 10 2 | 14 125 | 16 4 22 16 | 28 18 | 36 20 44 22.4 56 30 10.0 40 18.0 50 | 280 60 | 400 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 maximum strength at the middle portion bi « K 4 00% BSB 3) Do not sling @ heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load B. Sinsing 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 ina dangerous accident. 4)Do not sling a heavy load with ropes forming @ wide hanging angle from the hook. When hoisting @ load with two or more ropes, the force subjected to each rope will increase with the hanging 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° 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.STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly” Thread diameter Width e a ‘of bolt across flat (mm) (mm) |— — kgm| Nm 6 10 1.35+0.15 132414 8 13 3.2403 31.4429 10 7 6740.7 65.768 12 19 115410 112298 14 22 18.0420 17719 16 24 28.543 279+29 18 27 394 383439 20 30 56+6 549+58 22 32 76+8 745+78 24 36 94.5+10 927+98 27 ai 135+15 1320140 30 46 17520 17204190 33 50 22525 2210+240 36 55 280+30 2750+290 39 60 335+35, 3280+340 11 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque, ‘* Nm (newton meter): 1Nm + 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. with Tightening torque across flats (mm) Thread diameter of bolt, (mm) 65.7468 112498 27929 12 00-8STANDARD TIGHTENING TORQUE Use these torques for nut part of flared i ‘Thread diameter | Width across flats, Tightening torque ‘of nut part Of nutpart |; (mm) (mm) kgm ] Nm 14 19 25405 245=49 18 24 5x2 494196 22 27 a=2 785+196 24 32 1423 13732294 30 36 18=3 176.5+294 33 a 205 | 196.1449 36 46 2525 | 245,2=49 42 58 30+5 | 294.2249 COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals re listed below. Nomenclature Komatsu code ‘Applications UTA Used to apply rubber pads, rubber gaskets, and cork plugs. ‘Used to apply resin, rubber, metalicand ee non-metallic parts when 8 fast, strong seal is needed Adhesives we Preventing bolts, nuts and plugs from loosening and leaking ol cS) Used for aluminom surfaces Used to coat plugs (plate shaped, bowl shaped and holes, and ne mating portion of shaft ist Used with gaskets and packings to increase sealing effect Teat-resiatant gasket for precombustion chambers Sealant gasket 16s and exhaust piping tema Used by itself on mounting surfaces on the final give and wansmission cases. (Thickness after ughtoning 0.07 ~ 0.08 mmi ‘Used by itself 10 seal grease filings, tapered screw fitungs and tapered Le Screw Titings in hydraulic eveuts of less than 80 mm in aiameter Lo-6 ‘Silicon base type used in combination with LG-1 and LG-4 Tas a shorter curing te thanUG-6, ands easier ty to pecloft * ‘Antifiction compound ‘0 bearings and taper shafts to facilitate press-fitting and to (Lubricant including ime PAcpet to seeir bta ieet ii co aes ree TG aoe ae eel prevent sticking, burning or rusting. Grease Tpplied to bearings, siding parts and ol seals for lubrication, rust Wirnium greased Cx prevention and facilitation of assembling work Vaseline = Used for protecting battery electrode terminals from corrosion. *LT-2is also called LOCTITE in the shop menuals. 00-9ELECTRIC WIRE CODE iT 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: SWE indicates a cable having a nominal number § and white coating with black stripe. CLASSIFICATION BY THICKNESS (Copper wire Nominal Cableo.D. | Currentrating number | Number ]Dia. of strands] Cross section| (mm) a) ‘Applicable circuit strands (ren) (mm) —t 088: w (032 088 24 12 Starting, lightina, sianal ete 2 26 | (032 2.09 30 20 Lighting, signal ete. 5 65 032 5.23 46 37 Charging and signal 15 8a 0.45 13.36 70 58 Starting (Glow plug) 40, 85 0.80 4273 14 135 Starting 60 127 (0.80 63.84 136 178 Starting 100 217 080 1091 176 230 Starting CLASSIFICATION BY COLOR AND CODE Create a geet Charging | Ground | Starting Ughting | Instrument ‘Signal Other a 3 = ® Y @ t may [coir] white | Black Bick Red Yelow Green Bue [cose] wr = ow aw we ow ow 2 Color] white@Rea | — | Bick white | Rese whie | vetow ned | Groen whie| Bue & Whe 7 = wy me ve a ® | pov. [£2] Whe artick | — [Bock Yonow | Ross uck | Youow a Back Sie Red for eoge | we e aR mY vs o ‘ Color] white &Biwe | — | Bleck Rea | fea Vetow | Yelow & Green| Green 8 Votow] Biv & Yolow cose] we = = ¥ © ea) or . Covor| white &Green | — =__| Fed Green | Yetow & Bie [Greene Biocd | he & Beco coce[ E E m Ww wo = cor] _— E = Fest.ave [Yeiow#whie] Greens ave | —— 00-10ort GENERAL K205P5, | assembly drawing fications .. Weight table .. . List of lubricant and water o1- 2 on 4 o1- 8 01-12 01-1GENERAL ASSEMBLY DRAWING Pc210-5 PC2t0LC-5 _190__ 80 298 7680 208F0002 ( ): Pe2t0Le-s 01-2 K205P5PC240-5 PC240LC-5 PC240NLC-5 ee ; ; =e Lie 7 ees . co = 2730 | yo at oo 8 : 120805003 9000 = e238 soto 0 TE 208F0s004 (}: PC240LC-5 [i PC240NLC-5 01-3SPE CIFICATIONS PC210, 2101¢-5 Machine Model Serial Numbers PC210-5, 20001 and up PC210LC-5, 20001 and up PERFORMANCE DIMENSIONS Operating Weight - Bucket Capacity Maximum digging depth Vertical wall depth Maximum digging reach Maximum digging reach at ground level Maximum digging height WORKING RANGE Maximum dumping height © Maximum digging force (when using power max) Continued swing speed Swing maximum slope angle Travel speed Gradeability Ground pressure (standard triple-shoe) Overall length (at transportation) Overall width Track width Overall height (at transportation) Height of cab Ground clearance of counterweight Minimum ground clearance Radius of upper structure Minimun swing radius at front end Arm height at minimum swing radius Length of track on ground Track gauge Height of machine hood (kg) (my) (mm) (mm) (mm) (mm) (mm) (mm) (kg) (rpm) (deg.) (kenjh) (deg.) (kg/em?) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) 19,900 09 a 5,405: 9,395 9,205 9,070 6,280 13,700 (14,300), 8 20 Lo:32 Hi:5.5 35 0.46 (600 mm) 9,440 2,780 2,780 3,230 2,860 1,080 440 2,760 3,630 7,680 3,260 2,180 2,260 21,100 13,700 (14,300) 3 20 Lo:3.2 Hi:55 35 0.38 (700 mm) 9,440 3,080 3,080 3,230 2,860 1,080 440 2,760 3,630 7,680 3,640 2,380 2,260 01-4 K205P5k205P5 Machine Model Serial Numbers Engine model Type PC210-5 20001 and up 1006-6T PC210LC-5, 20001 and up 4-cycle, in-line vertical, water cooled, direct injection type diesel engine with turbocharger No. of cylinder - bore x stroke (mm) 6-100x 127 Total displacement (cc) - 985 Flywheel horsepower (HPirpm) "—12572,100 2 Maximum torque (kgrm/epm) 52.1/1,400 2 | High ating speed (om) 2,260 60 Low idling speed (pm) 90025 Minimum fuel consumption ratio _(g/HPh) 49 Starting motor 24V, 5.2kw Alternator 24V, 55A, Battery 12V, 95h x2 Type of radiator core OWK4 WB) Carrier roller (one side) 2 2 & Treckroller {one side) 7 8 S| Track shoe Built-up triple grouser | Built-up triple grouser Type, number Variable displacement piston type x 2 le Gear type x1 2 cxinery umn | Penne: 142 2 Gear type : 50 = 2 Setpressure (kg/em’) Piston type 325 (340), 5 (when using power max.) Gear type: 32 & Z| Tee, eumber - a ‘4spo0l type and 5-spool type 3 8% Control ever operation Hydraulic assist type z | 3, | Travel motor Piston type (with brake valve, parking brake) x 2 = | BS ‘Swing motor Piston type (with safety valve, parking brake) x 1 Hydraulic cylinder Hydraulic tank Hydraulic filter Hydraulic cooler Double acting piston Closed box type Tank return side Air cooled 01-5C240, 240LC, 240NLC-5 Machine Model Serial Numbers PC240-5 PC240LC-5 PC240NLC-5 20001 and up K20001 and up K20001 and up PERFORMANCE DIMENSIONS Operating Weight ita) Bucket Capacity (m3) Maximum digging depth (mm) 3 Vertical wal depth tenn) z i Maximum digging reach (mm) 2 (mm} & _Moximum doing rach tou lm 5 eximum digging height tem = Maximum dumping height tem) ‘Maximum digging force (when using power mex) (kg) Continued swing speed (rpm) Swing maximum slope angle ides.) Travel speed (ken) Gradeability (deg. Ground pressure (standard triple-shoe) _(kg/em*) Overall length (at transportation) (mm) Overall width (mm) Track width (mm) Overall height (at transportation) (mm) Height of cab (mm) Ground clearance of counterweight (mm) Minimum ground clearance (mm) Radius of upper structure (mm) Minimun swing radius at front end (mm) ‘Arm height at minimum swing radius (mm) Length of track on ground ° imm) Track gauge (mm) Height of machine hood (om) 23,000 24,100 23,700 ow 6350 63506350 5,160 5,160 5,160 9,655 9,656 9,655 9,470 9,470 9,470 9,000 9,000 9,000 6235 6,235 6.235 15,700 (6,400) 15,700 (16.400) 15.700 16,400) 13 13 13 175 175 175 Lo: 3.4, His5.5 Lo: 3.4, Hi:5.5 Lo: 3.4, Hi: 5.5 35 35 35 51 600 mn) 042 (700 mmm) 051 (600 mm) 9,780 9780 9,780 2,980 3,280 2,980 2,980 3,280 2,980 3.310 3.310 3310 2,860 2,860 2,860 1.080 1,080 1.080 440 440 440 2,860 2,860 2,860 3970 3970 3970 7,870 7,870 7.870 3.445 3,830 3,640 2,380 2,580 2,380 2,260 2,260 2,260 01-6 K205P5K205P5 ‘Machine Model Serial Numbers PC240-5 PC240LC-5 PC240NLC-5 20001 and up 20001 and up K20001 and up Engine model Type 1006-612 4-cycle, in-line vertical, water cooled, direct injection type diesel engine with turbocharger No. of eylinder - bore x stroke (mm) 6- 100% 127 Total displacement (co) 5,985 Flywheel horsepower (Pip) : 15572,100 Zo Maximum wrque (kgrnirpm) 58.7/1,600 Z High icling speed (rpm) 2,260 = 60 Low idling speed (rpm) 900+ 25 Minimum fuel consumption ratio (giHPh) 150 “Starting motor i 7 26,5200 Alternator 28V, 55A, Battery 12V, 95Ah x2 Type of radiator core - wx - B Carrierrolter ~ onesider] 2 2 2 es BE track roller (one side)] 8 10 9 3S trackshoe Tee je grower _ tle groveer Type, number Variable displacement piston type x2 g Gear type x1 = Delivery (e/min) Piston type: 205 x2 3 Geartype: 50 = 8 setpressure (kg/em) Piston type: 325 (340) # (when using power max.) Geartype: 32 & gy Type, number | spool type and 5-spool type : 3 8% Control lever operation Hydraulic assist type zg 3, Travel motor Piston type (with brake valve, parking brake) x2 = 85 swing motor Piston type (with safety valve, parking brake) x1 Hydraulic cylinder Hydraulic tank Hydraulic filter Hydraulic cooler Double acting piston Closed box type Tank return side Air cooled 01-7WEIGHT TABLE Ay This weight table isa guide for use when transporting or handling components. PC210, 210LC-5 Unit: kg, Machine Mode! Serial Numbers PC210-5 20001 and up PC210LC-5 20001 and up Engine assembly 694 694 + Engine 492 492 + Damper 7 7 + Hydraulic pump 195 195 Radiator and oil cooler assembly 90 90 Hydraulic tank assembly (without hydraulic oil) 198 194 Fuel tank (without fuel) 98 98 7 “Revolving frame —— 11598 “1,598 Operator's cab - 238 238 Operator's seat ai 317 Counterweight a 3,600 | 3,600 © Swing machinery - 258 | 258 “Control valve assembly 7” i ” ‘Swing motor assembly — 50 | 50 “Travel motor assembly 7 aax2 | TT x2 Center swiveljoint 3 a8 ‘Track frame assembly 4399 (8,180 + Track frame 2333 2966 + Swing circle assembly 270 210 + Idler 140x2 140 x2 + Idler cushion 1352 135 x2 + Carrier roller nxe 2x4 + Track roller 37x14 | 37x18 + Final drive 322 x2 | 322 x2 K205P5K205P5 Unit: kg Machine Model PC2105 Poat0Le-s Serial Numbers 20001 and up 20001 and up ‘Track shoe assembly Triple shoe (600mm) 2,620 2,850 Triple shoe (700mm) 2,870 3,120 Wide tripte-shoe (800mm) 3.130 3400 Wide triple-shoe (900mm) 3,380 = Boom assembly 7 1,362 1,362 Arm assembly a 563, 563 - Bucket assembly —_ 7 726 1! 726 Boom cylinder assembly : 187 x2 187, x2 i Arm cylinder assembly 7 251 i 251 Bucket cylinder assembly - 153 158 Link (large) assembly - 80 7 80 Link (small) assembly 22x2 22x2 Boom pin - 12351012425410620 43+10x2+25+10+20 7 Arm pin 10x2 10x2 Bucket pin 7 "2x2 20x2 Link pin : 18x2 | 18x2 : 01-9PC240, 240LC, 240NLC-5 Unit: kg Machine Model Serial Numbers PC240-5 —-PC240LC-5 PC240NLC-5 20001 and up 20001 and up 20001 and up, Engine assembly + Hydraulic pump Engine Damper 694 694 604 492 492 492 7 7 7 Hydraulic tank assembly (without hydraulic oil) Fuel tank (without fuel) Revolving frame Operator's cab Operator's seat Counterweight 4,300 5,120 5,120 ‘Swing machinery _ _ 258 258 28 Control valve m m m _Swing motor assembly lt so Travel motor assembly 137 x2 137 x2 Center swivel joint 8 a Track frame assembly 5,572 5,180 Track frame 2,850 3,284 2,986 ‘Swing circle 270 270 270 + Idler 140 x2 140 x2 140 x2 Idler cushion 135 x2 135x2 135 x2 Carrier roller 2x4 2x4 2x4 Track roller 37x20 37x20 37x18 Final drive 322 x2 322 x2 322x2 01-10 k205P5K205P5 Unit: kg Machine Model PC2MOLC-S, PCZ40NLC5 Serial Numbers K20001 and up —-—-K20001 andup ——_—K20001 and up Track shoe assembly Triple shoe (600mm) 2,730 2,960 2,850 Triple shoe (700mm) 3,000 3,250 = Wide triple-shoe (A00mm) 3.260 = ~ Boom assembly “1880 1,850 1,850 ‘Arm assembly _ | 680 660 680 Bucket assembly 254 854 _ 254 Boom eylinder assembly 214x2 2142 214x2 "em oylinder assembly | 297 297 Bucket evlinder assembly 182 182 182 Link (large) assembly _ 80 80 Link (small) assembly 2x2 2x2 22x2 51410 2430610432 $1+10x 2430410432 51410 x 2430410432 Boom pin Armpin ~ 10x2 10x2 10x2 Bucket pin 20x2 20x2 20x2 “Link pin - 18x2 “tex2 18x2 01-11LIST OF LUBRICANT AND WATER moe AMBIENT TEMPERATURE CAPACITY (£) RESERVOIR PLUTO) 14 3208068 DC Cae Roc Specified | Refill imo DEE a ene ee |} 0 | 200 nae cle = PROT SAE UW Eee TL SAE EWA ‘Swing machinery case Engine oil Eee ae Final drive case (each) 16 76 Tn DTSAE TOW. eae Hydraulic system SAE1OWSO 230 170 7 SAE TEW-40 Carrier roller (1 pigcs) ! | 0.19 - 0.23]0.19 - 0.21 Track roller (1 piece) | Gear oil = FT SAE 140 SD 0.23 - 0.25)0.23 - 0.25 Idler (1 piece) T (0.07 - 0.08|0.07 - 0.08 Fuel tank Diesel fuel = L L 1 310 - ‘ASTM D975 No.2 Cooling system Water ‘Add antifreeze 255 = ASTM D975 No. 1 NOTE: (1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric. change oil in the oil pan every periodic main- temperature of lower than O°C, be sure to tenance hours described in this manual. use engine oil of SAE1OW, SAE10W-30 and Change oil according to the following table if SAE15W-40 even though an atmospheric fuel sulphur contect is above 0.5% temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. Change interval of oil in Fuel sulphur contect engine oil pan 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 01-12 K205P510 STRUCTURE AND FUNCTION k205P5 Engine related parts and engine mount .. Radiator and oil cooler ... Fuel tank and piping Power train Final drive... Swing circle Swing machinery Track frame Idler and recoil spring Track roller, carrier roller Track shoe ... Hydraulic piping Hydraulic circuit diagram Hydraulic tank ... Hydraulic pump. Control valve ‘Swing motor .. Center swivel joint .. Travel motor. Valve control PPC valve : — Accumulator, safety lock valve Solenoid valve assembly Shuttle valve Boom holding valve Hydraulic cylinder. Work equipment Electrical wiring diagram .. Electrical circuit diagram . Engine control system... PEMC system EMACC... OthersENGINE RELATED PARTS AND ENGINE MOUNT 10-2 pgeene Damper Air cleaner Muffler . Engine . Front engine mount . Rear engine mount (! it u Section 8 - 8 Section C—C Section D — D F4205°5003, K205P5K205P5 RADIATOR AND OIL COOLER Fx 205°5004 Radiator inlet hose ‘SPECIFICATIONS Fan Radiator: CWX-4 Radiator Oil cooler: SF-3 Oil cooler Oil cooler inlet hose Oil cooler outlet hose Radiator outlet hose ‘Sub-tankFUEL TANK AND PIPING |. Drain valve Fuel tank Filler cap (with lock device) Fitter Sight gauge Fuel level sensor |. Sedimenter Nogeene 10-4 K205P5K205P5 POWER TRAIN —t 00001 A 7 Kb 1.Idler 2. Center swivel joint 3. Control valve assembly 4. Final drive 5. Travel motor 6. Engine 206F05008 7. Hydraulic pump 8. Swing brake solenoid valve 9. Travel speed solenoid valve 10. Swing motor 11. Swing machinery 12. Swing circle 10-5FINAL DRIVE 208F05008 10-6 1. Oillevel plug 2. Drain plug 3.No. 1 sun gear (18 teeth) 4.No. 2 sun gear (12 teeth) 5. No. 2 planetary carrier 6.Cover 7.No. 1 planetary carrier 8. Sprocket 9. Floating seal 10. Travel motor 11. Hub 12. No.1 planet gear (31 teeth) 13. Ring gear (81 teeth) 14, No. 2 planet gear (34 teeth) SPECIFICATIONS Reduction ratio: 81 +12) 81 +18), ,_ ~ (GSA )PaS8) +1 = = 41.625 K205P5K205P5 SWING CIRCLE ere Section B—B Section A~A aa 205605010 ‘Swing circle outer race ‘SPECIFICATIONS Ball bearing Reduction ratio: a = 7.333 ‘Swing circle inner race (110 teeth) Grease volume: 21% (G2-LI) Inner race soft zone “s Outer race soft zone “ 10-7SWING MACHINERY oy m r — 7 14 sa | 7” = c 18 — ie Section A—A 10-8 1. Swing pinion (15 teeth) 2.Cover 3.Cage 4. Planetary carrier 5. Ring gear (63 teeth) 6. Bearing holder 7. Drive gear (15 teeth) 8. Swing motor 9. Bearing holder 10. Breather 11. Oillevel gauge 12. Cover 13. Driven gear (76 teeth) 14. Planetary gear (24 teeth) 15. Sun gear (15 teeth) 16. Drain plug SPECIFICATIONS Reduction ao: 784(0318) = 26.347 Section B-B Section CC -208F05011 K205P5K205P5 TRACK FARME eexoraene Idler Track frame Cartier roller Final drive Track roller Track Center guard Recoil spring Front guard Fx 20sP5006 Depending on the model, the dimensions and number of track rollers is different, but the basic structure is the same. (The diagram shows PC210) + Number of track rollers PC210: 7 (each side) PC210 LC: 9 (each side) PC240: 8 (each side) PC240LC: 10 (each side) PC240NLC: 9 (each side) 10-9IDLER AND RECOIL SPRING SS eesoosens 10-10 F«205°5007| Idler Support Lubricating plug. Spring Seal Cylinder Plunger Lubricator Bushing Idler shaft Floating seal K205P5,k205P5 TRACK ROLLER Collar Floating seal Track roller Lubricating plug Bushing Shaft ~ oeeeNe CARRIER ROLLER Fxz0sP5008 Shaft Collar Floating seal 1. Carrier roller Bearing Cover Lubricating plug Fx205°5009 10-11TRACK SHOE Link Shoe Regular pin Regular bushing . Regular dust seal Master bushing Master dust seal . Master pin Shoe nut Shoe bolt BSeomrnogsuna 10-12 2055010 Standard shoe specifications PC210 600 mm triple-shoe Link pitch: 190 mm Number of shoe: 90 PC210LC 700 mm triple-shoe Link pitch: 190 mm Number of shoe: 98 PC240 600 mm triple-shoe Link pitch: 190 mm Number of shoe: 94 PC240LC 700 mm triple-shoe Link pitch: 190 mm Number of shoe: 102 PC240NLC 600 mm triple-shoe Link pitch: 190 mm Number of shoe: 98 K205P5K205P5, SELECTION OF TRACK SHOE ‘© Select the most suitable track shoe from the following table PC210 PC210LC PC240 PC240 LC PC240 NLC Specification Cee Specification Cate” Specification Cate” Specification, C2Ne Specification oe 600mm Joomm gg _-— 600mm = gy 700mm ge 600mm ag triple shoe triple shoe triple shoe tripleshoe B.C triple shoe 700mm 600mm 700mm 600mm triple shoe tripleshoe A tripleshoe 8 tripleshoe A = 800mm 800mm soomm triple shoe c triple shoe c triple shoe c ~ ~ ~ 7 goomm _ _ _ _ _ _ _ triple shoe Category Cate- Us Precautions when using orl ise 9 | 7 Rocky ground, | normal ver soi Travel in Lo when traveling on rough ground with obstacles such as large boulders and fallen trees, Cannot be used on rough ground where there are large . roe obstacles such as boulders and fallen trees, B eTtined | @ Travelin Hi speed only on flat ground, and when itis j Seftlen | impossible to avoid traveling over obstacles, | | lower the travel speed to approx. half of Lo. speed. | Ts Use only for ground where “A” and "B” sink and Extremely short | ® c ground | (swampy ground) | * D | Pavedsurface | 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. The shoe are flat, so they have low gradeability. * Categories “B” and their use. are wide shoe, so there are restrictions on their use. Therefore, before using, check the restrictions and con- sider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in + When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be @ 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. 10-13K205P5, HYDRAULIC PIPING |. Bucket cylinder . Arm cylinder . Boom cylinder . Swing motor 5. R.H. travel motor . Control valve . Oil cooler Arm, swing shuttle valve |. Boom, bucket, travel shuttle valve . Hydraulic pump . Accumulator . LH. travel motor Hydraulic filter . Solenoid valve assembly . LH. PPC valve . Safety lock valve Travel PPC valve . Boom holding valve . RH. PPC valve Center swivel joint F«205°5011 10-15,HYDRAULIC CIRCUIT DIAGRAM Irene: ates 0-120) (Pez, giao 90 120; sag0zy Feat metar P0210 96.6/1608 elev core santo po airs! | Homan ; ts + BH | Sag 10-1620572 - 21557 HYDRAULIC 10-17 K205P5 2085PC210-5K Serial No: K21558 and up i HYDRAULIC CIRCUIT DIAGRAM gas0zxHYDRAULIC TANK Bypass valve Filter element Bypass filter Filter check valve Filler cap Lift check valve Sight gauge . Strainer Hydraulic tank . Filter case |. Hydraulic oil level sensor 1 2 3. 4, 5. 6 7, 8. 9. 0. 1 10-18 1 2 — c Ae a fa ||| 3 section a= A - } + Section C—C pe § 4 of Section DD zoe ‘SPECIFICATIONS Tank capacity: 240 ¢ Oil amount: 150 Pressure valve Relief set presssure: 0.17 + 0.007 kg/cm? Suction set pressure: 0 - 0.046 kg/cm? Bypass valve set pressure: 1.05 + 0.2 kg/em? Filter check valve set pressure: 1.82 + 0.2 kg/em* Lift check valve set pressure: 4.2 kg/cm? K205P5k205P5 HYDRAULIC PUMP \ 4 ' \ | | smd et: Jet sensor output pressure Pt IN port Jet Sensor output pressure Pd IN port Jet sensor output pressure Pt IN port Jet sensor output pressure Pd IN port CO cancel pressure Psor IN port CO cancel pressure PsoF IN port spaoge OPNOMAONE 205F05017 Front servo valve Front CO *NC valve Rear CO + NC valve Rear servo valve TVC valve Charging pump Rear main pump Front main pump 10-191. reeaoge FRONT MAIN PUMP AND Front main pump discharge Prt port Front main pump discharge Pr2port Suction PS port Servo valve output pressure Pers port Charging pump pressure Pct port Front main pump output pressure Pat port 10-20 REAR MAIN PUMP (HPV090 +090) ; 205F05018 Servo valve output pressure Pc1A port Servo valve output pressure Pcza port Front main pump output pressure PP1 port Rear main pump output pressure Pez port Charging pump pressure Pcz port Servo valve output pressure Pez port k205P5K205P5 123 4 5 6 7 8 9 10 1 12 13 14 15 18 17 1. Front drive shaft 2. Front cradle 3. Front pump case 4. Front rocker cam 5. Front piston 6. Front cylinder 7. Front valve plate 8. Frontend cap 9. Impeller 10. Coupling 11. Rear end cap 12. Rear valve plate 13, Rear cylinder 14, Rear piston 15. Rear rocker cam 16. Rear pump case 17. Rear cradle 18. Rear drive shaft 19. Servo piston 18 Section CC 20805019 10-212. SERVO VALVE * The drawing shows the servo valve for front main pump Section C~C i 1 4] ° ] © | ] St A Gs) Le @s/ 93) Section D0 Section E-E Section FF Section 6-6 Servo actuator port Servo actuator port Servo actuator port NC valve output pressure Pi pick-up port Servo valve drain Pdr OUT port Rear main pump output pressure Pa2 IN port Front main pump output pressure Pat IN port e@>eaoge 10-22 208F05020 hh. CO*NC valve drain Par IN port i. CONC valve output pressure Pi IN port i. Charging pump pressure Ppo OUT port k. Rear main pump output pressure Pe2 OUT port |. Front main pump output pressure Ppt OUT port K205P5k205P5 Section A—A 20sr0so21 1. Lock nut 8.Pin 18. Guide spool 2.Cover 9. Control piston 16. Spring 3.Plug 10. Lock nut 17.Plug 4. Spring 11. Plug 18. Cover 5. Body 12.Lock nut 19. Lock nut 6. Spring 13. Cover 7.Arm 14. Sleeve FUNCTION a Discharge volumes Q1 and G2 of main pumps) : Prt and PP2 are controlled individually by 3 their own servo valve. — | The relationship between pump discharge vo- > | lume Q and input signal Pi sent to the servo valve is as shown in the graph on the 3 right. Q changes in proportion to Pi. 2 & (ecitew) ee CO*NC valve output pressure Pecn {kg/em*) 208F05022 10-23OPERATION 1) Operation for increasing pump be h scharges (rocker cam angle changes to the large) sent from port b to chamber ¢. 6). é = mF = J b Pi a Ne NC valve i CO valve TVe vave i 4 Pc 2osr05023A © Charging pump pressure Pe is sent to port. @ The movement of guide spool (15) closes : port a and port d, and connects port d with Signal pressure Pi from the NC valve is drain chamber e. As a result, servo piston chamber f is also connected to chamber e e As signal pressure Pi rises, the pressure in ‘through port g and port d. chamber C pushes control piston (9) to At the same time, port a and port h are the left in the direction of the arrow. The connected, and the flow passes through piston stops in a position where it is port i to servo piston chamber j to push balanced with the force of springs (4) and servo piston (20) to the left in the direction of the arrow. The rocker cam angle of the At the same time, arm (7) uses servo piston ‘main piston pump becomes larger, and the (20) as a fulcrum, moves to the left in the pump discharge volume increases. @ Because of the movement of servo piston same way as control piston (9), and while fluctuating, moves guide spool (15) to the left. 10-24 (20), arm (7) rotates clockwise around pin (8), moves guide spool (15) to the right, and closes port a, port d, and port h, so the discharge volume increases only by an amount corresponding to signal pressure Pi, K205P5k205P5, 2) Operation for decreasing pump discharges (rocker cam angle changes to the small) 1 e oh NC valve cOvalve © When signal pressure Pi drops, control piston (9) moves to the right in the direction of the arrow to a point where the hydraulic pressure of chamber ¢ is in balance with the force of springs (4) and (6) At the same time, arm (7) uses servo piston (20) as a fulcrum, moves to the right in the same way as control piston (9), and while fluctuating, moves guide spool (15) to the right. @ The movement of guide spool (15) closes port a and port h, and connects port h with drain chamber e. As a result, servo piston chamber j is also connected to chamber e through port i and port h. | \I TC valve 2osF05024A, At the same time, port a and port d are connected, and the flow passes through port g to servo piston chamber f to push servo piston (20) to the right in the direction of the arrow. The rocker cam angle of the main piston pump becomes smaller, and the pump discharge volume decreases. Because of the movement of servo piston (20), arm (7) rotates counterclockwise around pin (8), moves guide spool (15) to the left, and closes port a, port d, and port hh, so the discharge volume decreases only by an amount corresponding to signal pressure Pi. 10-253. TVC VALVE Do Section C—C Charging pump pressure Ppo IN port b. Front main pump output pressure Pes IN Port . Rear main pump output pressure Pr IN port 4. TVC valve drain Par OUT port e. TVC valve output pressure Ptz OUT port 10-26 Section B-B [oe Section D-D PONS SectionE-£ Section F—F Spring Spool Piston Piston 20505025 Sleeve Piston Body Solenoid exon K205P5,K205P5 FUNCTION AND OPERATION 1). When command current from pump controller is small (when pump controller is normal) Pil Servo valve | Servo piston pecans TI increase Discharge came eS Pry Mi FUNCTION @ When the pump controller is normal, the main pump discharge volume can be controlled as desired over a wide range according to the command current from the pump controller to carry out the power mode function. @ When the pump controller is abnormal hydraulic sensing is carried out to contro! the main pump discharge volume according to the load (pump discharge pressure) to carry out the constant torque control function (prolix function.) + For details, see PEMC SYSTEM. TVC valve Pump icontroller| OFF: TVC prolix switch 205050264, Resistor OPERATION © Because of the command current sent from ‘the controller, solenoid push pin (9) moves, and piston (2) also moves. It stops at 2 point where the sum of the force of spring (1) and the force of push pin (9) and the force of TVC output pressure Ptz acting on piston (3) is in balance. When this happens, ‘the command current is small, so piston (2) balances at the bottom. As a result, port a and port b are almost completely open, and almost all the pressurized oil from the charging pump is ‘output as TVC output pressure Ptz. Be- cause of this, the pump discharge volume is maximum. , 10-272) When command current from pump controller is large (when pump controller is normal) nc | co vaive | valve LL] ‘Servo valve = | Servopiston | | Decrease = increase Discharge aes (Control valve Per MR > ¢ Because of the command current sent from the controller. solenoid push pin (9) moves, and the piston (2) also moves. It stops at the point where it is balanced with the force of spring (1). When this happens, the com- mand current is large, so piston (2) is bal- anced at the top. As a result, the flow of oil sent from the charging pump is throttled at port a and port b, and the area of the open- ing at port b and port ¢ (drain port) becomes larger. Because of this, TVC valve output pressure Ptz drops and the pump discharge volume is reduced. 10-28 [Pump controller Resistor o TVC valve TVC prolix switch 208Fos0274 K205P5,k205P5 3) Main pump under light load (pump controller abnormal and TVC prolix switch ON) Tc valve dy A KK Ti 1 = TT SU len | 2 | ie Po Pine co Pr valve | valve +, Pe Pry Seroveve | r Pra, 4 Servo piston Pets | | 6 Decrease [,] —= increase I Discharge Capea efSHRETa | Evalve valve | | Ld Pri Pr2| Pc IPum ump ME _/ yt feontroter | \ x LY ma TVC prolix switch Resistor aosroszea © Main pump discharge pressures Pet and Pr2 are low, so spool (2) is pushed down by spring (1). As a result, charging pump discharge pressure Pe and TVC valve out- put pressure Ptz are equal When this happens, TVC valve output pressure Ptz is maximum and the main pump discharge volume is also maximum. 10-294) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON) TVC valve | ne | co valve | valve Servo valve Servo piston Decrease =— [Jin Discharge Tanirar valve Control valve Per Pomp |controtier on! M TVC prolix switch Resistor 205050298, © When main pump discharge pressure Ppt (or Pr2) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow at port a and port b is throttled by the notch in the spool, and the area of the opening at port b and port ¢ (drain Port) becomes larger. Because of this, TVC valve output pressure Ptz drops and the main pump discharge volume is reduced. 10-30 k205P5,K205P5 rs orga 4. CO + NC VALVE Charging pump pressure PRO OUT port Main pump output pressure Ppt (Pp2) OUT port ‘Main pump output presure Pr2 (Pp1) OUT port TVC valve output pressure Pt2 IN port TVC valve drain Pdr port CO cancel pressure Pef (Per) IN port TVC valve output pressure Ptz F-R connection port Jet sensor output pressure Pd IN port Jet sensor output pressure Pt IN port * The diagram shows the CONC valve for the front pump. Section AA 205605030 CO VALVE NC VALVE 1. Plug 7. Plug 2. Piston 8 Sleeve 3. Spring 9. Piston 4. Spool 10. Spool 5. Piston 11. Spring 6.Plug 12. Plug * (- ): Forrear servo valve 10-31FUNCTION AND OPERATION OF CO VALVE 1) When main pump discharge pressure is below relief pressure Servo valve Servo piston se] inerease Discharge FUNCTION '@ If the load increases during operation, and the main pump discharge pressure in- creases, when it becomes nearly the relief pressure, the CO valve carries out the cut- off function to reduce the discharge ‘amount of the pump and reduce the relief loss. @ At the same time, the pilot pressure of the CO function cancel solenoid valve also has the function of canceling the cut-off. @ The CO vaive is controlled by balancing the spring with the sum of main pump dis- charge pressure Pp and CO valve output pressure Peo. 10-32 ° eee 205F0s018 OPERATION © Spool (4) is pushed down by spring (3). As a result, port a and port b are com- pletely open, and TVC valve output pres- sure Peo are equal. Because of this, CO valve otput pressure Pco becomes maximum, and the dis~ charge volume of the main pump is also maximum. K205P5K205P5, 2) When the main pump discharge pressure is higher than the main relief pressure CO cancel solenoid valve ql. NC vaive | Servovalve | Servo piston | Decrease —— Tncrease Discharge (Convoll,, {Control valve 3/"valve r w © When main pump discharge pressure PP comes close to the relief pressure owing to an increase in the load, piston (5) is pushed by main pump discharge pressure Pe and at the same time piston (6) is pushed by CO valve output pressure Peo. When the force of spring (3) is overcome by the pressing force of the pistons, spool (4) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening areas of port b and port ¢ (drain port) are made larger. ‘With angle reduced by the operation of the servo valve, the main pump discharge is reduced. 205F050528, 10-333) When cut-off function is canceled by CO cancel solenoid valve mT PiyNC —— | | servovave | Lo = L_ Decrease Uj Tncrease Discharge Conwor} a valve. @ When the CO cancel solenoid valve is switched, pilot pressure is taken to port Pso and piston (2) is pushed down. As a result, the setting of spring (3) be- comes larger, so even when main pump. discharge pressure Pp rises and reaches the relief pressure, spool (4) is not actuat- ed and CO valve output pressure Peo re- mains at the maximum. 10-34, 205F050308, k205P5k205P5 FUNCTION AND OPERATION OF NC VALVE 1) Control valve at neutral det sensor NC valve Servo valve | Ler | Servo piston | L_ Decrease—— Tnorease FUNCTION ‘@ The NC valve controls the main pump dis- charge volume according to the amount of operation of the control valve spool, and carries out the function of controlling the oil flow to reduce the neutral loss and fine con- trol loss, ‘© The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and NC valve output pressure Pi with the sum of the force of NC vaive spring (12) and jet sensor output pressure Pd The jet sensor detects the flow of return oil passing through the control vaive and re- turing to the tank, and takes it as NC valve Pt and Pd. 205050248 OPERATION ‘© The differential pressure (Pt — Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (10) becomes greater than the sum of the force of spring (12) and jet sensor output pressure Pd acting on the lower end of spool (11) As a result, spool (11) is pushed downward, causing a restriction of the oil flow between port ¢ and port b and in turn opening port b and port a (drain port) Output pressure Pi of the NC valve is then re- duced to the minimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servo valve. 10-352) When the control valve is operated Control valve Servo valve Servo piston | | Decrease [J Increase 205050354, ‘© With the jet sensor differential pressure (Pt — Pé) reduced according to the operation of the control valve, spool (11) is pushed upward, fully opening port c and port b. Thus, the NC valve output pressure in- creases. Together with the increase in the main pump swash plate angle through the servo valve operation, the main pump dis- charge is also increased. That is to say, the pump discharge increases as the stroke of the lever increases. 10-36 k205P5K205P5 PERNA Relief valve Body Cover Drive gear Driven gear Filter 5. CHARGING PUMP Discharge 20805036 SPECIFICATIONS Theoretical delivery: 25 cc/rev Operating pressure: 32kg/cm? 10-37,CONTROL VALVE sasozy 208F05037 10-38K205P5 yoseaoge nexeserenraposgrr Travel shuttle valve 4-spool valve (Built-in straight-travel valve, arm throttle valve) 5-spool valve (Built swing priority valve) 3 port (From arm PPC valve) PL port (From rear main pump) PR port (From front main pump) BSL port (To bucket cylinder bottom side) B2L port (To boom cylinder head side) B1L port (To LH. travel motor PB port) 5 port (From swing PPC shuttle valve) 4 port (From boom bucket PPC shuttle valve) P6 port (To work equipment oil pressure switch) AL port (To LH. travel motor PA port) ‘A2L port (To boom cylinder bottom side) ‘ABL port (To bucke cylinder head side) PAAL port (From arm PPC valve) P3AL port (From bucket PPC valve) P2AL port (From boom PPC valve) P1AL port (From LH. travel PPC valve) PRL port (From 2-stage relief solenoid valve) PRR port (From 2-stage relief solenoid valve) PAAR port (From swing PPC valve) PAR port (Service) PAAR port (From arm PPC valve) PSAR port (From RH. travel PPC valve) ABR port (Service) AiR port (To swing motor MA port) B1R port (To swing motor port MB) B3R port (Service) B4R port (To arm cylinder bottom side) BSR port (To RH. travel motor PA port) T port (To tank) ASR port (To R.H. travel motor PB port) Aak port (To arm cylinder head side) Pt port (To rear NC valve) Pat port (To rear NC valve) PtR port (To front NC valve) Pak port (To front NC valve) PBL port (From LH. travel PPC valve) P2BL port (From boom PPC valve) P3BL port (From bucket PPC valve) Ts port (To tank) PSBR port (From R.H. travel PPC valve) P4BR port (From arm PPC valve) P3BR port (Service) ABR port (From swing PPC valve) OUTLINE ‘@ This control valve consists of @ 4-spool valve and a 5-spool valve. In addition, it also has a travel shuttle valve. It has @ built-in straight-travel valve, arm throttle valve and swing priority valve. © The 4-spool valve and 5-spool valve are connected by bolts to form one unit. The oil flow merges inside the valve, so the valve is compact and provides excellent ease of maintenance. 10-391. Spool return spring 2. Spool (LH. travel) 3. Spool (Boom-Lo} 4. Spool (Bucket) 5. Spool (Arm-Hi) 10-40 Section A—A Section B-B 6. Jet sensor orifice 7. Jet sensor relief valve 8. Main relief valve 9. Spool (Straight-travel) 10. Spool (Arm throttle valve) 205F05038 K205P5k205P5 TD Section D-D 205F 050098 1. Spool return spring 6. Spool (RH, travel) 2. Spool (Swing) 7. Jet sensor relief valve 3. Spool (Boom-Hi) 8 Jet sensor orifice 4. Spool (Service) 9. Main relief valve (5-spool) 5. Spool (Arm-Lo} 10. Spool (Swing priority) 10-41Section E-E Section’G—G 1. Check valve 2. Check valve spring 3. Spool (LH. travel) 4. Spool (Straight-travel) 5. Spool (Swing priority) 6. Spool (Swing) 10-42 Section F—F Section H—H 205F05040 7. Suction valve 8. Spool (Boom-Lo) 9. Check valve 10. Spool (Boom-Hi) 11. Safety-suction valve. k205P5K205P5 Section J—J Section K—K Section L—L 208F05041 1. Safety-suction valve 6. Check valve 2. Spool (Bucket) 7. Spool (Arm-Lo) 8. Safety-suction valve 9. Check valve 10. Spool (RH. travel) 3. Spool (Arm throttle) 4. Spool (Service) 5. Spool (Arm-Hi) 10-43‘TRAVEL SHUTTLE VALVE i fo 7 eG 1 2 304 / rye zat q loo | gloA tells en a. Pe port (Work equipment + swing switch) b. Pa port (From boom + bucket shuttle valve) ae Ps port (From swing shuttle valve) P3 port (From arm shuttle valve) fe. Paaport (To arm throttle valve) 10-44 Psa port (To swing priority valve) Pr port (To tank) Poport (To straight-travel valve) P1 port (From LH. travel control valve) i. P2port (From LH. travel control valve) 207F05028 Cover Spool return spring Body Spool K205P5K205P5 TRAVEL SHUTTLE VALVE FUNCTIONS ‘@ The travel shuttle valve is installed to the top of the 4-spool valve control valve. It takes the PPC valve pressures from the left travel, work equipment, and swing, and sends pilot pressure to the straight-travel valve when the travel and work equipment or swing are operated at the same time. OPERATION Travel lever at “FORWARD” (other levers at NEUTRAL”) ‘© Pilot pressure oil flows to P1 port from the left travel circuit and pushes the spool to the right. Therefore, ports P3, P4, PS and PO are con- nected through the groove in the spool, and are also connected to the straight-travel valve. However, there is no flow of pilot pressure oil from the shuttle valves of the PPC valves, so the straight-travel valve is not actuated. (When operating in “REVERSE”, pressure oil is sent to port P2, and pushes the spool to the left) During simultaneous operation @ When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from the left travel circuit to port P1 and pushes the spool to the right. © At the same time, when the arm is operated, pilot pressure oil flows to port P3 from the shuttle valve of the arm PPC valve. This passes through the groove in the spoo! ‘and port PO, and then flows to the straight-travel valve. © The pilot pressure oil from the shuttle valve of the swing PPC valve flows port P5— port PO—=straight-travel valve, and the pilot pressure oil from the shuttle valve of the boom and bucket PPC valves flows port P4— port PO— straight-travel valve. 6 db To straight-| | FORwARS Stout vovalesee | FromLM. travel From LM. travel REVERSE creuit, Toauto- ¢o Ee) Toarm deceleration Ps] [throttle valve et SS to owing Pea H Peg prionty valve To swing mechanical Pm pressure switch rake ol From shuttle valve From shuttle ‘of atmPPC valve valve of boom From shuttle : Ducket PPC. valve of swing valve PPC valve 205F2032-2 ed t + FromLH. travel To straight FORWARD circuit travel valve | an va tae FromLH, travel REVERSE circuit tow “ Secesosen Pe um Siprecure = cite ave one Re (Ee eee [Peal [Psa priority valve | To swing es U =, mechanical t mg pprEsiaal From shuttle vahe of From shutle ores itch SemPeake heat From shut vie ot ‘boom, bucket swing PPC valve PPC valve 208F2033-2 10-45STRAIGHT-TRAVEL VALVE FUNCTION © While operating the swing, boom, arm, or bucket when traveling, the pressure oil flowing to the RH. and LH. travel circuit branches into the swing, boom, arm, or bucket circuit. Since the supply of pressure oil in a branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting ina turn © When the straight-travel valve is switched over to establish continuity between the RH. and LH. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the RH. and LH. travel motors so that they rotate at the same speed. OPERATION When traveling only © Since no pilot hydraulic oil flows from the shuttle valve in the PPC valve, no hydraulic oil flows from the travel shuttle valve to the straight-travel valve. © Therefore, the circuit between port PR (RH. travel circuit) and port PLILH. travel circuit) remains closed and both circuits remain independent. While operating the swing, boom, arm, or bucket when traveling © Spool (1) of the straight-travel valve is pushed to the right by the pilot pressure from the travel shuttle valve. © Port PR and port PL then become connect- ed to each other and an equal amount of pressure oil is supplied to the RH. and LH travel motors, allowing both motors to rotate at the same speed. The machine trav- els thus in a straight line. 10-46 mM RH wvella | Bucket 205F05042 208F05083, k205P5K205P5 SWING PRIORITY VALVE FUNCTION © When operating the swing and arm at the same time, most of the oil flows to the arm, which has less load. The flow of oil to the ‘swing circuit is reduced so the arm speed is. faster than the swing speed. This makes combined operations difficult. @ To prevent this, the swing priority valve is switched to restrict the flow of pressure oil to the arm-Lo control valve. This restricts the arm speed and makes it easier to operate the arm and swing at the same time. OPERATION When swing is at neutral @ No pilot pressure oil flows from the travel shuttle valve, so the swing priority valve is not switched. Because of this, the pressure oil from the front main pump passes through port Pr and all the oil flows to the arm-Lo control valve. When swing is operated ‘© When the swing is operated, spool (1) of the swing priority valve is pushed to the left by the pilot pressure from the travel shuttle valve, Because of this, the pressurized oil flowing from front main pump — port Pr to the arm-Lo control valve is throttled, and the arm speed is controlled, so the simultaneous operation performance is improved. 2osF0s0s4 ‘Arm-Lo 1 —F7 Pa | avel shatt) valve ME 205F0S085, 10-47,ARM THROTTLE VALVE FUNCTION © When the arm contro! lever and boom control lever are operated at the same time, most of the pressure oil flows to the arm circuit, where the load is less. The amount of oil flowing to the boom circuit drops, so the arm speed is faster than boom speed. This makes combined operations difficult. (particularly when using “ARM OUT” and “BOOM RAISE" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier. OPERATION When arm is operated independently © The pilot pressure does not flow from the travel shuttle valve, so the arm throttle valve is not actuated and the pressure oil from the rear pump passes through port Pt and all flows to the arm Hi control valve. ‘Simulataneous operation © When the arm is operated together with the boom or bucket, the pilot pressure from the travel shuttle valve pushes spool (1) of the arm throttle valve to the left. When this hap- ens, the flow of pressure oil from the rear Pump to the arm Hi control valve is throttled, and the arm speed is controlled to improve the ease of simultaneous operation. 10-48 The arm is actuated by the merged oil flow from two pumps, and the bucket is ‘actuated by the flow from one pump. For this reason, when the arm and bucket are operated together, the flow of oil to the arm circuit is greater, so the arm moves much faster than the bucket. This makes combined operations difficult. (Particularly when using “ARM OUT” and “BUCKET CURL" at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control vaive is restricted. This regulates the ‘arm speed and makes combined operations easier. a ==_Ie al 7 Pi E | = aT = M © sosrosoes 208F05047 k205P5,