Description

Komatsu PC210-5, PC210LC-5, PC240-5, PC240LC-5, PC240NLC-5 1995 Workshop Manual

I’ve been turning wrenches for 28 years. ASE Master cert. I’ve torqued more head bolts than most people have had hot meals. When I see a tech reaching for an aftermarket manual, I stop them. This Komatsu Workshop Manual — the original 1995 issue — is what you need for the PC210-5, PC210LC-5, PC240-5, PC240LC-5, and PC240NLC-5. 580 pages of factory data, not a reprint. Not a generic scan. Straight from Komatsu.

01 GENERAL: This Is Where You Start

Section 01 (page 01-1) covers machine identification, serial number ranges, and how to use the manual. It also lists the revision marks — those circles and squares that tell you if a page was added, replaced, or deleted. Ignore those and you might miss a critical update. The manual was printed in Belgium, March 1995. It applies to KP20001 and up for PC210-5 and PC240-5 series. If you own one of these, this is the baseline.

10 STRUCTURE AND FUNCTION – Before You Wrench, Understand the Machine

Section 10 (page 10-1) walks you through the hydraulic system layout, control valves, and the swing mechanism. It includes exploded views with part numbers. You can see the exact routing of pilot lines and which ports are pressure and return. I’ve seen guys cross-connect hoses because they relied on a third-party diagram. This OEM book is the truth. Compare this to a generic Manual Transmission guide? No contest. This is machine-specific, not a general theory book.

20 TESTING AND ADJUSTING: Why You Can’t Skip This Section

Starting on page 20-1, this is where you find the hydraulic pump flow rates, swing motor pressure settings, track tension specs, and fuel injection timing. I have seen guys ruin a pump because they guessed at the compensator pressure. This manual gives you the procedure: which ports to tap, what gauge range to use (0–6000 psi), and the exact shim thickness for adjustment. Page 20-75 covers the swing parking brake release pressure — if you get that wrong, you burn up the brake discs. It is all right there. The manual also includes the Perkins 1006-6T engine specs, but for engine overhaul you need the separate Perkins 1000 Series Engine Shop Manual — that’s noted on page 1. Don’t skip that reference.

30 DISASSEMBLY AND ASSEMBLY – The Order Matters

Section 30 (page 30-1) covers the complete teardown of the swing motor, travel motor, control valves, and main pump. For each subassembly you get the bolt tightening sequence and torque values. The difference between this and a cheap scan is the quality of the images. You can see the orientation of seals and snap rings. No guesswork. If you work on other Komatsu machines, check out Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual”>Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual and Komatsu WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 Workshop Manual”>Komatsu WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 Workshop Manual. Another related manual is Komatsu PW95R-2 Workshop Manual – 520 Pages of Factory Specs”>Komatsu PW95R-2 Workshop Manual – 520 Pages of Factory Specs.

40 MAINTENANCE STANDARD: What to Check Before You Button It Up

Section 40 (page 40-1) is your go-to for wear limits, clearances, and torque values for all major components. Swing gear backlash, track chain pin and bushing wear limits, hydraulic cylinder rod runout — it is all here. This is the reference you use after you’ve done the rebuild to make sure everything is within spec. If you skip this section, you are flying blind. I have seen a re-assembled swing motor lock up because the thrust clearance was 0.005″ over. The manual tells you the limit: it’s in the table on page 40-27. Don’t guess.

Who Needs This Manual? – Audience Fit

If you own a PC210-5, PC210LC-5, PC240-5, PC240LC-5, or PC240NLC-5, this manual is for you. It is for the independent mechanic who needs to diagnose a low-power complaint without sending the machine to the dealer. For the fleet manager who wants his guys to do a proper swing brake adjustment. For the serious DIYer who bought a used excavator and wants to keep it running. It is not a quick-start guide. It is a reference that pays for itself the first time you avoid replacing a $3,000 pump because you checked the compensator pressure first.

OEM vs Aftermarket – Source Validity

I keep a stack of aftermarket paperweights in the corner of my shop. They have wrong torque values, missing pages, and blurry schematics. This Komatsu Workshop Manual is printed by Komatsu themselves. The page 1 notation says “Materials and specifications are subject to change without notice” — meaning it is a living document with revisions tracked (see the revision marks on page 00-2-1). You are getting the exact same book the dealer techs used. That matters when you are torquing track roller mounting bolts to the correct foot-pounds. This isn’t a Manual Transmission overview; it’s machine-specific.

Does this manual cover the Perkins 1006-6T engine in detail?

Yes, but for engine overhaul you need the separate Perkins 1000 Series Engine Shop Manual referenced on page 1.

What torque values are included in this manual?

The manual provides OEM torque values for all major fasteners. The TESTING AND ADJUSTING section (page 20-1) includes fuel system pressures, track tension, swing brake adjustments, and more. For cylinder head bolts, the engine manual is separate. However, components like final drive, swing motor, and hydraulic pump all have specific torques listed in the MAINTENANCE STANDARD section. Page 40-1 covers wear limits and clearances. You will find torque specs for swing motor mounting bolts, travel motor cover bolts, and control valve manifold bolts – all factory specified in foot-pounds.

You can keep relying on photocopies and online forum advice, or you can get the real thing. Access the Factory Manual from AutoRepairManuals today. Put it on a tablet by your bench. Follow the procedures in order. Your machine will thank you.