Page 1 UEN00084-06 HYDRAULIC EXCAVATOR PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 PC240LC-8 PC240NLC-8 PC210- K50001 PC210LC- K50001 PC210NLC- K50001 SERIAL NUMBERS and up PC230NHD-K50001 PC240LC- K50001 PC240NLC- K50001...
Page 3 UEN00093-06 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 00 Index and foreword Index Organization list of the shop manual....................
Page 4 UEN00093-06 00 Index and foreword Organization list of the shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 5 00 Index and foreword UEN00093-06 Troubleshooting of hydraulic and mechanical system (H-mode) UEN00245-02 Troubleshooting of engine (S-mode) UEN00246-02 Troubleshooting of Auto Grease system UEN00247-00 50 Disassembly and assembly Disassembly and assembly related information UEN00659-00 Engine cooling related UEN00660-00 Power train UEN00661-00 Under carriage and frame UEN00662-00...
Page 6 UEN00093-06 00 Index and foreword Table of contents 00 Index and foreword Index UEN00093-06 Organization list of the shop manual ..................Table of contents........................Foreword and general information UEN00094-00 Foreword and general information ....................Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............
Page 7 00 Index and foreword UEN00093-06 Hydraulic system, Part 2 UEN00100-00 Hydraulic system, Part 2 ......................Control valve..........................CLSS ............................15 Functions and operation by valve.................... 20 Hydraulic system, Part 3 UEN00160-03 Hydraulic system, Part 3 ......................Swing motor..........................Centre swivel joint ........................12 Travel motor..........................
Page 8 UEN00093-06 00 Index and foreword Checking exhaust gas colour....................Adjusting valve clearance ......................Measuring compression pressure.................... 11 Measuring blow-by pressure....................13 Measuring engine oil pressure....................14 Handling fuel system parts ...................... 15 Releasing residual pressure from fuel system................. 15 Measuring fuel pressure ......................16 Measuring fuel return rate and leakage ...................
Page 9 00 Index and foreword UEN00093-06 Failure code [B@BAZK] Eng Oil Level Low ................20 Failure code [B@BCNS] Eng Water Overheat ................ 21 Failure code [B@BCZK] Eng Water Level Low ............... 21 Failure code [B@HANS] Hydr Oil Overheat ................22 Failure code [CA111] EMC Critical Internal Failure ..............22 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............
Page 10 UEN00093-06 00 Index and foreword Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............51 Failure code [DA29KQ] Model Selection Abnormality ............. 58 Troubleshooting by failure code (Display of code), Part 3 UEN00242-01 Failure code [DA2RMC] CAN Discon (Pump Con Detected) ..........Failure code [DAFGMC] GPS Module Error ................
Page 11 00 Index and foreword UEN00093-06 Failure code [DFB4L8] Service Lever 2 Potentio Error ............58 Troubleshooting of electrical system (E-mode) UEN00244-02 Troubleshooting of electrical system (E-mode) ............... Before carrying out troubleshooting of electrical system ............Troubleshooting of electrical system (E-mode) ............... Information in troubleshooting table ..................
Page 12 UEN00093-06 00 Index and foreword H-23 Upper structure does not swing ..................25 H-24 Swing acceleration or swing speed is low............... 27 H-25 Upper structure overruns remarkably when it stops swinging ........28 H-26 Large shock is made when upper structure stops swinging ........... 29 H-27 Large sound is made when upper structure stops swinging ...........
Page 13 00 Index and foreword UEN00093-06 Power train UEN00661-00 Power train ..........................Removal and installation of final drive assembly ..............Disassembly and assembly of final drive assembly ..............Removal and installation of swing motor and swing machinery assembly ......20 Disassembly and assembly of swing motor and swing machinery assembly......22 Removal and installation of swing circle assembly..............
Page 14 00 Index and foreword UEN00093-06 Hydraulic circuit diagram 1/2....................... Hydraulic circuit diagram 2/2....................... Electrical diagrams and drawings UEN00113-04 Electrical diagrams and drawings (for PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303) ........................Electrical circuit diagram (1/5) ....................Electrical circuit diagram (2/5) ....................Electrical circuit diagram (3/5) ....................
Page 15 00 Index and foreword UEN00093-06 PC210, 230, 240-8...
Page 17 UEN00094-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 00 Index and foreword Foreword and general information Foreword and general information ........................
Page 18 Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 19 00 Index and foreword UEN00094-00 When disassembling or assembling, sup- When removing piping, stop the fuel or oil port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips stands before starting work. onto the floor, wipe it up immediately. Fuel Remove all mud and oil from the steps or or oil on the floor can cause you to slip other places used to get on and off the...
Page 20 UEN00094-00 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily.
Page 21 00 Index and foreword UEN00094-00 If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
Page 22 This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC210, 230, 240-8...
Page 23 00 Index and foreword UEN00094-00 Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 24 UEN00094-00 00 Index and foreword Explanation of terms for maintenance standard The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 25 00 Index and foreword UEN00094-00 Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 26 UEN00094-00 00 Index and foreword Handling electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 27 00 Index and foreword UEN00094-00 Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
Page 28 UEN00094-00 00 Index and foreword Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
Page 29 00 Index and foreword UEN00094-00 Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
Page 30 UEN00094-00 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
Page 31 00 Index and foreword UEN00094-00 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
Page 32 UEN00094-00 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Page 33 00 Index and foreword UEN00094-00 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
Page 34 UEN00094-00 00 Index and foreword How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and colour of each electric wire are indicated by sym- bols.
Page 35 00 Index and foreword UEN00094-00 Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
Page 36 UEN00094-00 00 Index and foreword Colour codes table (Table 3) Colour Code Colour of wire Colour Code Colour of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
Page 37 00 Index and foreword UEN00094-00 Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
Page 38 UEN00094-00 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
Page 39 00 Index and foreword UEN00094-00 Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end.
Page 40 UEN00094-00 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
Page 41 00 Index and foreword UEN00094-00 Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
Page 42 UEN00094-00 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
Page 43 00 Index and foreword UEN00094-00 Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size Tightening torque inch...
Page 44 UEN00094-00 00 Index and foreword Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimetres to inches Convert 55 mm into inches.
Page 45 00 Index and foreword UEN00094-00 Millimetres to inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181...
Page 46 UEN00094-00 00 Index and foreword Litres to U.K. Gallons 1 l = 0.21997 U.K.Gal 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379...
Page 47 00 Index and foreword UEN00094-00 kg/cm to lb/in 1 kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 48 UEN00094-00 00 Index and foreword Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi- grade temperature reading or vice versa is to enter the accompanying table in the centre (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the centre column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 49 00 Index and foreword UEN00094-00 PC210, 230, 240-8...
Page 51 UEN00095-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 01 Specification Specification and technical data Specification and technical data............................
Page 52 UEN00095-02 01 Specification Specification and technical data Specification dimension drawings PC210, PC210LC, PC210NLC, PC230NHD-8 Check item Unit PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 A Overall length 9,475 B Overall height 3,000 3,025 C Overall width 2,800 3,080 2,540 D Shoe width E Cab height...
Page 53 01 Specification UEN00095-02 Working range diagram PC210, PC210LC, PC210NLC,PC210NLC-8 Check item Unit PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 A Max. digging reach 9,875 B Max. digging depth 6,620 C Max. digging height 10,000 Max. vertical wall digging 5,980 depth E Max. dumping height 7,110 Min.
Page 54 UEN00095-02 01 Specification Specifications PC210, PC210LC, PC210NLC, PC230NHD-8 Machine model PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 Serial number K50001 and up Bucket mass Operating weight 21,390 22,260 21,830 22,820 Max. digging depth 6,620 Max. vertical wall digging depth 5,980 Max. digging radius 9,875 Max.
Page 55 01 Specification UEN00095-02 Machine model PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 Serial number K50001 and up Model SAA6D107E-1 4-cycle, water-cooled in-line, direct injection with Type turbocharger and air-cooled aftercooler Number of cylinders – bore x stroke 6 – 107 x 124 l {cc} Piston displacement 6.69 {6,690}...
Page 56 UEN00095-02 01 Specification PC240LC, PC240NLC-8 Machine model PC240LC-8 PC240NLC-8 Serial number K50001 and up Bucket capacity 1070 Operating weight 26,290 25,290 Max. digging depth 6,920 Max. vertical wall digging depth 6,010 Max. digging radius 10,180 Max. reach at ground level 10,020 Max.
Page 57 01 Specification UEN00095-02 Machine model PC240LC-8 PC240NLC-8 Serial number K50001 and up Model SAA6D107E-1 4-cycle, water-cooled in-line, direct injection with Type turbocharger and air cooled aftercooler Number of cylinders – bore x stroke 6 – 107 x 124 l {cc} Piston displacement 6.69 {6,690} 125/2,000 (ISO 9249)
Page 58 UEN00095-02 01 Specification Weight table This weight table is prepared for your reference when handling or transporting the components. PC210, PC210LC, PC210NLC, PC230NHD-8 Unit: kg Machine model PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 Serial number K50001 and up Engine assembly • Engine •...
Page 59 01 Specification UEN00095-02 Unit: kg Machine model PC210-8 PC210LC-8 PC210NLC-8 PC230NHD-8 Serial number K50001 and up Boom assembly 1,393 Arm assembly (2.9M) Bucket assembly Boom cylinder assembly 173 x 2 Arm cylinder assembly Bucket cylinder assembly (std) Bucket cylinder assembly (large)
Page 60 UEN00095-02 01 Specification PC240LC, PC240NLC-8 Unit: kg Machine model PC240LC-8 PC240NLC-8 Serial number K50001 and up Engine assembly • Engine • Damper • Hydraulic pump • Diesel Particulate Filter Assembly Radiator and oil cooler assembly Hydraulic tank and filter assembly (Not including hydraulic oil) Fuel tank assembly (Not including fuel) Revolving frame...
Page 61 01 Specification UEN00095-02 Unit: kg Machine model PC240LC-8 PC240NLC-8 Serial number K50001 and up Boom assembly 1,273 Arm assembly (3.0M) Bucket assembly 1,070 Boom cylinder assembly 200 x 2 Arm cylinder assembly Bucket cylinder assembly (std) Bucket cylinder assembly (large) Link (large) assembly Link (small) assembly 22 x 2...
Page 62 Table of fuel, coolant and lubricants a For details of the notes (Notes 1, Note 2...) in the table, see Operation and Maintenance Manual. AMBIENT TEMPERATURE Reservoir Fluid type Recommended komatsu Fluids -30°C 30°C Komatsu EOS0W30 -25°C 40°C Komatsu EOS5W40...
Page 63 01 Specification UEN00095-02 PC210,230, 240-8...
Page 65 UEN00096-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 66 UEN00096-01 10 Structure, function and maintenance standard Engine and cooling system Engine related parts Drive plate Outline Torsion spring A damper assembly is wet type. Stopper pin Oil capacity: 0.65 l Friction plate Muffler Rear engine mount Front engine mount Damper assembly PC210, 230, 240-8...
Page 67 10 Structure, function and maintenance standard UEN00096-01 Radiator, oil cooler, aftercooler and fuel cooler Reservoir tank Specifications Radiator : Aluminium wave type, 4th row Shroud Oil cooler : CF40-1 Radiator cap Aftercooler : Aluminium wave type Radiator inlet hose Fuel cooler : Drawn cup type Radiator outlet hose Radiator Oil cooler...
Page 68 UEN00096-01 10 Structure, function and maintenance standard Diesel Particulate Filter Diesel Particulate Filter PC210, 230, 240-8...
Page 69 10 Structure, function and maintenance standard UEN00096-01 Diesel Particulate Filter - Component Parts Inlet In-Cab Monitor Catalyst Pressure Sensor Filter 10. Hose (sensor) Outlet 11. Temperature Sensor Gasket 12. Tee Ring Clamp 13. Plug Mount PC210, 230, 240-8...
Page 70 UEN00096-01 10 Structure, function and maintenance standard System Description This diesel particulate filter effectively removes particulate matter (soot) from diesel exhaust. The regenera- tion function also removes carbon monoxide (CO) and hydrocarbons. The filter is a ceramic monolith, protected by an insulated stainless steel housing.
Page 71 10 Structure, function and maintenance standard UEN00096-01 PC210, 230, 240-8...
Page 73 UEN00097-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 74 UEN00097-00 10 Structure, function and maintenance standard Power train Power train Idler Center swivel joint Control valve Final drive Travel motor (HMV110ADT-2) Hydraulic pump PC210 / 230 (HPV112 + 112) - PC240 (HPV95 + 95) Engine (SAA6D107E-1) Travel speed solenoid valve Swing brake solenoid valve 10.
Page 75 10 Structure, function and maintenance standard UEN00097-00 PC210, 230, 240-8...
Page 76 UEN00097-00 10 Structure, function and maintenance standard Final drive PC210, 230, 240-8...
Page 77 10 Structure, function and maintenance standard UEN00097-00 Level plug No. 1 planetary gear (No. of teeth: 42) Drain plug No. 1 sun gear (No. of teeth: 10) No. 2 sun gear (No. of teeth: 21) No. 1 planetary carrier Cover No.
Page 78 UEN00097-00 10 Structure, function and maintenance standard Swing machinery PC210-8, PC210LC, 210NLC, PC230NHD-8 PC210, 230, 240-8...
Page 79 10 Structure, function and maintenance standard UEN00097-00 Drain plug Swing pinion (No. of teeth: 13) No. 2 planetary carrier No. 2 planetary gear No. 2 sun gear No. 1 planetary carrier No. 1 planetary gear No. 1 sun gear Swing motor 10.
Page 80 UEN00097-00 10 Structure, function and maintenance standard PC240LC, PC240NLC-8 PC210, 230, 240-8...
Page 81 10 Structure, function and maintenance standard UEN00097-00 Drain plug Swing pinion (No. of teeth: 13) No. 2 planetary gear No. 2 sun gear No. 2 planetary carrier No. 1 planetary carrier No. 1 planetary gear No. 1 sun gear Swing motor 10.
Page 82 UEN00097-00 10 Structure, function and maintenance standard Swing circle PC210, PC210LC, 210NLC, PC230NHD-8 716 ~ 814 Nm 716 ~ 814 Nm (73 ~ 83 Kgm) (73 ~ 83 Kgm) Swing circle inner race (No. of teeth: 96) Specifications Ball Reduction ratio: –96/13 = –7.385 Swing circle outer race Amount of filled grease: 14.6 l (G2-LI) Inner race soft zone “S“...
Page 83 10 Structure, function and maintenance standard UEN00097-00 PC240LC-8, PC240NLC-8 Swing circle inner race (No. of teeth: 92) Specifications Ball Reduction ratio: –92/13 = –7.077 Swing circle outer race Amount of filled grease: 15.8 l (G2-LI) Inner race soft zone “S“ position Outer race soft zone “S“...
Page 85 UEN00098-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 86 Carrier roller ture is not different. Final drive Number of track rollers Track roller Track shoe Model Q'ty (One side) Center guard PC210-8 Front guard PC210LC/NLC-8 PC240LC-8 PC240NLC-8 PC210, 230, 240-8...
Page 87 10 Structure, function and maintenance standard UEN00098-00 Standard shoe Models PC210-8 PC210LC-8 PC210NLC-8 PC240LC-8 PC240NLC-8 Item Shoe width (mm) Link pitch (mm) Q'ty (One side) PC210/240-8 Unit: mm Check item Criteria Remedy Standard size Tolerance Repair limit Vertical width Track frame —...
Page 88 UEN00098-00 10 Structure, function and maintenance standard Idler PC210/240-8 PC210, 230, 240-8...
Page 89 10 Structure, function and maintenance standard UEN00098-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protrusion — Outside diameter of tread Build-up welding Thickness of tread or replace Difference of tread Total width — Width of tread 37.5 —...
Page 90 UEN00098-00 10 Structure, function and maintenance standard Carrier roller PC210/240-8 Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange — Outside diameter of tread Width of tread — Thickness of tread Width of flange — Tolerance Standard Standard...
Page 91 10 Structure, function and maintenance standard UEN00098-00 Track roller PC210/240-8 Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange — Outside diameter of tread Build-up welding Thickness of tread 44.5 38.5 or replace Total width —...
Page 92 UEN00098-00 10 Structure, function and maintenance standard Track shoe PC210/240-8 a P portion shows the link of bushing press fitting end. 1. Triple grouser shoe 2. Road liner 3. Swamp shoe 4. Flat shoe PC210, 230, 240-8...
Page 93 10 Structure, function and maintenance standard UEN00098-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Link pitch 190.3 193.3 Reverse or Standard size Reverse replace Outside diameter of bushing 59.3 54.3 Thickness of bushing metal 10.4 Standard size Repair limit Link height Repair or replace...
Page 94 UEN00098-00 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tightening torque (Nm {kgm}) Retightening angle (deg.) Triple grouser 490 ± 49 a. Regular 120 ± 10 shoe {50 ± 5} link Road liner (Rub- 549 ± 59 Shoe bolt —...
Page 95 10 Structure, function and maintenance standard UEN00098-00 PC210, 230, 240-8...
Page 96 UEN00098-00 10 Structure, function and maintenance standard Triple grouser shoe Swamp shoe Road liner PC210, 230, 240-8...
Page 97 10 Structure, function and maintenance standard UEN00098-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Height Thickness Length of base Length of base Length at tip Build-up welding or replace Length at tip Length at tip Standard size Repair limit Thickness Height...
Page 99 UEN00099-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 100 UEN00099-01 10 Structure, function and maintenance standard Hydraulic system, Part 1 Hydraulic equipment layout drawing Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Hydraulic oil filter R.H. travel motor Swing motor Hydraulic pump Control valve 10. Oil cooler 11. L.H. travel motor 12.
Page 101 10 Structure, function and maintenance standard UEN00099-01 PC210, 230, 240-8...
Page 102 UEN00099-01 10 Structure, function and maintenance standard Hydraulic tank and filter (PC240 shown) Hydraulic tank Oil filler port cap Specifications PC240 PC210 / 230 Filter element Tank capacity 190 L 192 L Strainer Amount of oil inside tank 135 L 137 L Bypass valve Suction strainer...
Page 103: Hydraulic Pump
10 Structure, function and maintenance standard UEN00099-01 Hydraulic pump PC210 / 230 - Type: HPV112+112 PLSFC PLSRC PD1R PEPPC PENF 34.3 ~ 44.1 Nm (3.5 ~ 4.5 Kgm) PEPC PENR PSIG 11.8 ~ 14.7 Nm (1.2 ~ 1.5 Kgm) SUCTION PD2F PD2R 58.8 ~ 78.4 Nm...
Page 104 UEN00099-01 10 Structure, function and maintenance standard Hydraulic pump PC240 - Type: HPV95+95 PC210, 230, 240-8...
Page 105 10 Structure, function and maintenance standard UEN00099-01 Outline This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve. : Front PC mode selector current : Rear PC mode selector current ISIG : LS set pressure selector current : Front pump delivery port : Rear pump delivery port : Pump pressure input port...
Page 106 UEN00099-01 10 Structure, function and maintenance standard PC210 / 230 58.8 ~ 78.4 Nm 7.8 ~ 13.7 Nm (6 ~ 8 Kgm) (0.8 ~ 1.4 Kgm) 58.8 ~ 78.4 Nm (6 ~ 8 Kgm) 637 ~ 764.4 Nm (65 ~ 78 Kgm) 246.3 ~ 308.7 Nm (25.3 ~ 31.5 Kgm) Front shaft...
Page 107 10 Structure, function and maintenance standard UEN00099-01 PC240 Front shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Valve plate End cap 10. Rear shaft 11. Rear case 12. Servo piston 13. PC valve PC210, 230, 240-8...
Page 108 UEN00099-01 10 Structure, function and maintenance standard PC240 Function Piston (6) carries out relative movement in the The pump converts the engine rotation trans- axial direction inside each cylinder chamber of mitted to is shaft to oil pressure and delivers cylinder block (7).
Page 109 10 Structure, function and maintenance standard UEN00099-01 Operation of pump Cylinder block (7) rotates together with shaft As center line (X) of rocker cam (4) matches (1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between along cylindrical surface (B), so angle (a)
Page 110 UEN00099-01 10 Structure, function and maintenance standard Control of delivery If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b e c o m e s l a r g e r a n d p u m p d e l i v e r y ( Q ) increases.
Page 111 10 Structure, function and maintenance standard UEN00099-01 1. LS valve : Pump port Sleeve PDP : Drain port Piston PLP : LS control pressure output port Spool PLS : LS pressure input port Spring : Pump port Sheet PPL : Control pressure input port Sleeve PSIG : LS mode selector pilot port Plug...
Page 112 UEN00099-01 10 Structure, function and maintenance standard Operation 1) When the control valve is situated at neutral The LS valve is a 3-way selector valve, with Spool (6) is pushed to the right, and port (C) pressure (PLS) (LS pressure) from the outlet and port (D) will be connected.
Page 113 10 Structure, function and maintenance standard UEN00099-01 2) Action for the direction of maximizing the pump delivery When the difference between the main pump If the output pressure of the EPC valve for the pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is w o r d s , L S d iff e r e n t i a l p r e s s u r e ( P L S )
Page 114 UEN00099-01 10 Structure, function and maintenance standard 3) Action for the direction of minimizing the pump delivery When differential pressure PLS) Δ becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo piston (12), pump pressure (PP) pushes spool (6) to the right.
Page 115 10 Structure, function and maintenance standard UEN00099-01 4) When servo piston is balanced Let us take the area receiving the pressure at Force of spring (4) is adjusted in such that the the large diameter end of the piston as (A1), position of the balanced stop of this spool (6) the area receiving the pressure at the small may be determined when (PP) —...
Page 116 UEN00099-01 10 Structure, function and maintenance standard 2. PC valve : Pump port Plug PA2 : Pump pressure pilot port Servo piston assembly PDP : Drain port PM : Mode selector pressure pilot port Spool PPL : Control pressure output port (to LS valve) Retainer Sheet Cover...
Page 117 10 Structure, function and maintenance standard UEN00099-01 Operation 1) When pump controller is normal (1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low Action of PC-EPC valve solenoid (1) a Other pump's pressure denotes the pressure Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller.
Page 118 UEN00099-01 10 Structure, function and maintenance standard Action of spring Load of springs (4) and (6) on the PC valve is Self pressure (PP1) enters port (B) and the determined by the swash plate position. small diameter end of servo piston (9), and As servo piston (9) moves to right, spring (6) is other pump pressure (PP2) enters port (A).
Page 119 10 Structure, function and maintenance standard UEN00099-01 As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are con- nected.
Page 120 UEN00099-01 10 Structure, function and maintenance standard (2) When load on actuator is large and pump discharge pressure is high Outline When servo piston (9) moves to the right, springs (4) and (6) are compressed and push When the load is large and pump discharge back spool (3).
Page 121 10 Structure, function and maintenance standard UEN00099-01 The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q) becomes as shown below. If command voltage (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/ 2, and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves...
Page 122 UEN00099-01 10 Structure, function and maintenance standard 2) As the emergency pump drive switch is turned on due to failure on the pump controller (1) When the main pump is under light load If there is a failure in the pump controller, the Since the pressure on the small diameter end emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in...
Page 123 10 Structure, function and maintenance standard UEN00099-01 (2) When the main pump is under heavy load If the emergency pump drive switch is turned The curve resulting when the emergency pump on in the same way as in above, the command drive switch is ON is situated further to the left current (X) sent to PC-EPC valve solenoid (1) (B) than when the pump controller is normal...
Page 124 UEN00099-01 10 Structure, function and maintenance standard 3. LS (PC)-EPC valve C : To LS (PC) valve P : From self pressure reducing valve T : To tank Connector Coil Body Spring Spool Plunger PC210, 230, 240-8...
Page 125 10 Structure, function and maintenance standard UEN00099-01 Function Operation The EPC valve consists of the proportional 1) When signal current is 0 (coil is solenoid portion and the hydraulic valve por- deenergized) tion. When it receives signal current (i) from the When there is no signal current flowing from controller, it generates the EPC output pres- the controller to coil (2), coil (2) is deenergized.
Page 126 UEN00099-01 10 Structure, function and maintenance standard 2) When signal current is very small 3) When signal current is maximum (coil is energized) (coil is energized) When a very small signal current flows to coil As the signal current flows to coil (2), coil (2) is (2), coil (2) is energized, and a propulsion force energized.
Page 127 10 Structure, function and maintenance standard UEN00099-01 Pilot oil filter For breaker Filter Specifications Case Rated pressure : 6.57 MPa {67 kg/cm Head cover : 16 l/min. Flow rate Relief valve Relief valve cracking pressure : 0.15 MPa {1.5 kg/cm Filter mesh size : 6 μm Filtering area : 450 cm...
Page 129 UEN00100-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 130 UEN00100-00 10 Structure, function and maintenance standard Hydraulic system, Part 2 Control valve Outline This control valve consists of a 6-spool valve (one body composition) and a set of service valve. A merge-divider valve, a back pressure valve and a boom hydraulic drift prevention valve are installed to it.
Page 131 10 Structure, function and maintenance standard UEN00100-00 General view PC210/230-8 PC210, 230, 240-8...
Page 132 UEN00100-00 10 Structure, function and maintenance standard PC240-8 PC210, 230, 240-8...
Page 133 10 Structure, function and maintenance standard UEN00100-00 PC210, 230, 240-8...
Page 134 UEN00100-00 10 Structure, function and maintenance standard Sectional view (1/5) PC210, 230, 240-8...
Page 135 10 Structure, function and maintenance standard UEN00100-00 Pressure compensation valve (Arm out) Pressure compensation valve (R.H. travel reverse) Pressure compensation valve (Right swing) Pressure compensation valve (Boom raise) Pressure compensation valve (L.H. travel reverse) Pressure compensation valve (Bucket dump) Pressure compensation valve (Service 1) Pressure compensation valve (Service 2) Pressure compensation valve (Service 3) 10.
Page 136 UEN00100-00 10 Structure, function and maintenance standard (2/5) PC210, 230, 240-8...
Page 137 10 Structure, function and maintenance standard UEN00100-00 Suction valve (Arm out) Suction valve (R.H. travel reverse) Suction valve (Boom raise) Suction valve (L.H. travel reverse) Safety-suction valve (Bucket dump) Safety-suction valve (Service 1) Safety-suction valve (Service 2) Safety-suction valve (Service 3) 2-stage safety-suction valve (Service) 10.
Page 138 UEN00100-00 10 Structure, function and maintenance standard (3/5) PC210, 230, 240-8...
Page 139 10 Structure, function and maintenance standard UEN00100-00 Unload valve Main relief valve Lift check valve Arm valve LS shuttle valve Quick return valve Pressure compensation valve (IN) Spool Safety-suction valve (IN) Back pressure valve 10. Regeneration circuit check valve 11. Suction valve (OUT) 12.
Page 140 UEN00100-00 10 Structure, function and maintenance standard (4/5) PC210, 230, 240-8...
Page 141 10 Structure, function and maintenance standard UEN00100-00 Return spring 14. Merge-divider valve (travel junction valve) Merge-divider valve (for LS) 15. Return spring Valve (Sequence valve) 16. LS shuttle valve Spring (Sequence valve) 17. Pressure compensation valve (Forward) Merge-divider valve (Main) 18.
Page 142 UEN00100-00 10 Structure, function and maintenance standard (5/5) Service valve 1 Service valves 2 and 3 LS shuttle valve LS shuttle valve Pressure compensation valve Pressure compensation valve Spool Spool 2-stage safety-suction valve Safety-suction valve Safety-suction valve 10. Unload valve 11.
Page 143 10 Structure, function and maintenance standard UEN00100-00 CLSS Outline of CLSS Features Configuration CLSS stands for Closed center Load Sensing Sys- CLSS is configured with variable capacity pis- tem, which has the following characteristics: ton pumps, control valves, and respective actuators.
Page 144 UEN00100-00 10 Structure, function and maintenance standard Basic principle 1. Pump swash plate angle control The pump swash plate angle (pump delivery) The pump swash plate angle shifts toward the is controlled so that LS differential pressure maximum position if LS differential pressure PLS) (the difference between pump pressure PLS) is lower than the set pressure of the LS Δ...
Page 145 10 Structure, function and maintenance standard UEN00100-00 2. Pressure compensation control A pressure compensation valve is installed to the outlet port side of the control valve to bal- ance the load. When actuators are operated together, the p r e s s u r e d i f f e r e n c e ( P ) b e t w e e n t h e Δ...
Page 146 UEN00100-00 10 Structure, function and maintenance standard 3. System diagram a The illustration shows the actuator (6) in the merge mode with stroke end at the time of relief. Front pump LS circuit Rear pump 10. Tank circuit Main relief valve 11.
Page 147 10 Structure, function and maintenance standard UEN00100-00 PC210, 230, 240-8...
Page 148 UEN00100-00 10 Structure, function and maintenance standard Functions and operation by valve Hydraulic circuit diagram and the name of valves PC210, 230, 240-8...
Page 149 10 Structure, function and maintenance standard UEN00100-00 Arm valve 28. Arm quick return valve R.H. travel valve 29. Self pressure reducing valve Swing valve 30. Travel junction valve Boom valve 31. Back pressure valve L.H. travel valve 32. Cooler check valve Bucket valve 33.
Page 150 UEN00100-00 10 Structure, function and maintenance standard Unload valve 1. When the unload valve is actuating LS circuit Tank circuit Valve Spring Pump circuit Function Operation Drains an oil discharge for the portion of the Pressure of pump circuit (3) is received by the minimum pump swash plate angle while all end of valve (2).
Page 151 10 Structure, function and maintenance standard UEN00100-00 During operation (a work within a scope of dis- 2. Operation of relief valve charge by a minimum swash plate angle), the When the cylinder reaches the stroke end, the discharge pressure for the portion of minimum main relief valve opens.
Page 152 UEN00100-00 10 Structure, function and maintenance standard Introduction of LS pressure Hydraulic pump Main spool Pressure compensation valve Valve Check valve LS circuit LS shuttle valve Function Introduces the upstream pressure (down- stream pressure of the spool meter-in) of pres- sure compensation valve (3) and leads to LS shuttle valve (7) as the LS pressure.
Page 153 10 Structure, function and maintenance standard UEN00100-00 LS bypass valve Hydraulic pump Main spool Pressure compensation valve LS shuttle valve LS bypass valve LS circuit Function Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b). Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres- sure.
Page 154 UEN00100-00 10 Structure, function and maintenance standard Pressure compensation valve 1. During independent operation and under maximum load pressure (If the load pressure is higher than other work equipment during a combined operation) Hydraulic pump Piston Valve Spring Shuttle valve LS shuttle valve Function As principle, port (C) and spring chamber (E)
Page 155 10 Structure, function and maintenance standard UEN00100-00 2. When compensated (If the load pressure is lower than other work equipment during a combined operation) Function The pressure compensation valve closes under LS pressure of port (D), and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
Page 156 UEN00100-00 10 Structure, function and maintenance standard 3. Pressure compensation valve area ratio Function The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2). Area ratio = (A2)/(A1) If area ratio = 1 : The spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure will be divided according to the opening area ratio.
Page 157 10 Structure, function and maintenance standard UEN00100-00 Pressure compensation valve inner shuttle valve 1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B) Hydraulic pump Valve Pressure compensation valve inner shuttle valve Piston Function Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection...
Page 158 UEN00100-00 10 Structure, function and maintenance standard 2. In the case of travel Outline Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensa- tion valve without shuttle valve (3) is adopted. PC210, 230, 240-8...
Page 159 10 Structure, function and maintenance standard UEN00100-00 Boom regeneration circuit 1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.) Hydraulic pump Suction valve Boom spool Check valve Pressure compensation valve LS shuttle valve Safety-suction valve Function Operation Provides the regeneration circuit from the cyl-...
Page 160 UEN00100-00 10 Structure, function and maintenance standard 2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.) Function Check valve (6) provided to regeneration cir- cuit (C) closes to shut off the flow from the cyl- inder bottom to the head.
Page 161 10 Structure, function and maintenance standard UEN00100-00 Arm regeneration circuit 1. If the cylinder head pressure is higher than the bottom pressure Hydraulic pump Suction valve Arm spool Check valve Pressure compensation valve LS shuttle valve Safety-suction valve Function Operation During arm digging, regeneration circuit pro- If the cylinder head pressure is lower than the vided from the cylinder head to the bottom...
Page 162 UEN00100-00 10 Structure, function and maintenance standard 2. If the cylinder head pressure is lower than the bottom pressure Function Check valve (6) provided to regeneration cir- cuit (C) closes to shut off the flow from the cyl- inder bottom to the head. PC210, 230, 240-8...
Page 163 10 Structure, function and maintenance standard UEN00100-00 Merge-divider valve 1. When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are OFF] Main spool LS circuit (bucket side) Spring LS circuit (arm side) LS spool LS circuit (arm side) Spring EPC valve (for main spool) LS circuit (bucket side)
Page 164 UEN00100-00 10 Structure, function and maintenance standard 2. When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are ON] Operation Selector signal (IS1) turns ON, and output pressure from the EPC valve shifts main spool (1) to the left, and ports (E) and (F) are divided. Pressurized oil discharged from the two pumps are sent to respective control valves.
Page 165 10 Structure, function and maintenance standard UEN00100-00 LS select valve Function Operation Prevents high LS pressure from the swinging 1. If pilot pressure (BP) is OFF from entering the LS circuit of work valves Since pilot pressure (BP) is OFF, piston (3) is while the swinging and work equipment are in pressed to the left by spring (2).
Page 166 UEN00100-00 10 Structure, function and maintenance standard Self pressure reducing valve Function Reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, EPC valves, etc. Operation 1. While engine is stopped Poppet (11) is pressed by spring (12) against the seat and port (PR) is not connected to (TS).
Page 167 10 Structure, function and maintenance standard UEN00100-00 2. During neutral and when load pressure 3. When load pressure (P2) is high (P2) is low Load pressure (A2) increases with the opera- a When load pressure (A2) is lower than self tion of digging, etc., and the pump discharge increases accordingly.
Page 168 UEN00100-00 10 Structure, function and maintenance standard 4. When abnormally high pressure is gen- erated If pressure (PR) of self pressure reducing valve becomes abnormally high, ball (16) con- tracts spring (15) and becomes separated from the seat. Allows the pressurized oil to (TS) from port (PR) and lowers pressure (PR).
Page 169 10 Structure, function and maintenance standard UEN00100-00 Travel junction valve 1. When pilot pressure is turned ON Function Operation This valve connects the L.H. and R.H. travel Pilot pressure from the travel junction solenoid circuits via travel junction valve so that the valve contracts spring (1), and travel junction hydraulic oil will be supplied evenly to both spool (2) moves to the left to the stroke end.
Page 170 UEN00100-00 10 Structure, function and maintenance standard 2. When pilot pressure is turned OFF Operation If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the If pilot pressure (PST) from the solenoid valve oil flows through the route between port (PTL), is 0, travel junction spool (2) is pressed by the travel junction spool (2), and port (PTR) so that...
Page 171 10 Structure, function and maintenance standard UEN00100-00 Travel PPC shuttle valve 1. When travel lever is in neutral Function Operation Regulates flow to each cylinder by controlling The oil in stroke regulation signal chamber (a) the stroke of each spool of the boom, arm, and is drained through orifices (5) and (6) of pis- bucket using the pilot pressure of travel PPC tons (3) and (4) in the travel spring case and...
Page 172 UEN00100-00 10 Structure, function and maintenance standard 2. When travelling Operation Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) If the right travel lever is set in the reverse (or to the right.
Page 173 10 Structure, function and maintenance standard UEN00100-00 PC210, 230, 240-8...
Page 174 UEN00100-00 10 Structure, function and maintenance standard Hydraulic drift prevention valve (For the boom and arm) PC210, 230, 240-8...
Page 175 10 Structure, function and maintenance standard UEN00100-00 To work equipment cylinder PCY: For pressure pickup port and equalizer circuit From PPC valve To tank From control valve Pilot spool Spool (1st stage spool) Spring (2nd stage spool) Safety valve Check valve Spring Unit: mm Check item...
Page 176 UEN00100-00 10 Structure, function and maintenance standard Function Prevents the pressurized oil from reversing from the work equipment cylinder and the latter from a sudden drop if the piping bursts between the control valve and the work equip- ment cylinder. Operation When the work equipment lever is in neutral When the piping is free of burst...
Page 177 10 Structure, function and maintenance standard UEN00100-00 When pressurized oil flows from the main valve to the cylinder When the piping is free of burst Pressurized oil led to chamber (a) from the control valve becomes higher than the com- bined force of pressure from work equipment cylinder circuit chamber (b) and spring (6).
Page 178 UEN00100-00 10 Structure, function and maintenance standard When returning pressurized oil to the main valve from the work equipment cylinder When the piping is free of burst If the piping is bursted Holding pressure of the work equipment cylin- If piping (A) bursts between the control valve der is led to chamber (b) and check valve (5) and the work equipment cylinder.
Page 179 10 Structure, function and maintenance standard UEN00100-00 Quick return valve 1. When arm OUT Function If the pressure of chamber (b) drops lower than When arm OUT, large volume of oil returns that of port (A), pressure receiving force of the from the cylinder bottom.
Page 180 UEN00100-00 10 Structure, function and maintenance standard 2. When the arm is in neutral Operation Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/cm The pressurized oil that has flowed and been drained through orifice (a) in valve (2) is closed by pilot piston (1).
Page 181 10 Structure, function and maintenance standard UEN00100-00 Lift check valve Function 2. While engine is running Output pressure (PR) of the self pressure This valve applies back pressure to the drain reducing valve is applied via the control valve circuit to prevent generation of negative pres- to spring chamber (c) of back pressure valve sure on each actuator (motors, cylinders, etc.).
Page 182 UEN00100-00 10 Structure, function and maintenance standard Main relief valve Spring Poppet Function Set pressure of the relief valve is in two stages. When power is needed, pilot pressure (P) is turned ON and the set pressure becomes higher. Operation The set pressure of relief valve is determined by spring (1) installed load.
Page 183 10 Structure, function and maintenance standard UEN00100-00 2-stage safety-suction valve [Installed to port (B) of the service valve] Spring Piston Spring Holder Function 1. If pilot pressure is OFF (high-pressure Enables to provide the safety valve set pres- setting) sure in two stages, and make the low-pressure setting smaller.
Page 184 UEN00100-00 10 Structure, function and maintenance standard 2. If pilot pressure is ON (low-pressure setting) If the pilot pressure (P) is ON, the pilot pres- sure is led to section (A) via passage (B). Piston (2) works on the pressure-receiving bore portion [(d2) —...
Page 185 10 Structure, function and maintenance standard UEN00100-00 PC210, 230, 240-8...
Page 187 UEN00160-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 188 UEN00160-03 10 Structure, function and maintenance standard Attachment circuit selector valve......................54 Quick coupler control valve - For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and PC240 K50001~K50303 ............................56 Function.............................. 59 Hydraulic cylinder ..........................60 PC210, 230, 240-8...
Page 189 10 Structure, function and maintenance standard UEN00160-03 Hydraulic system, Part 3 Swing motor Type: KMF125ABE-6 From swing brake solenoid valve Specifications MA: From control valve Models MB: From control valve PC210 / 230-8K PC240-8K Item From control valve Type KMF125ABE-6 To tank Reverse prevention valve Theoretical displacement...
Page 190 UEN00160-03 10 Structure, function and maintenance standard PC210, 230, 240-8...
Page 191 10 Structure, function and maintenance standard UEN00160-03 Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston 10. Cylinder block 11. Valve plate 12. Centre shaft 13. Centre spring 14. Check valve 15. Check valve spring 16. Shuttle valve 17.
Page 192 UEN00160-03 10 Structure, function and maintenance standard Swing holding brake 1. When solenoid valve is deenergized 2. When solenoid valve is energized Operation Operation As the swing holding brake is deenergized, the As the swing brake solenoid valve is ener- pressurized oil from the self pressure reducing gized, the valve is switched.
Page 193 10 Structure, function and maintenance standard UEN00160-03 Relief valve portion Outline 2 When swing is stopped The relief valve portion consists of check When the swing control lever is returned to valves (2) and (3), shuttle valves (4) and (5), neutral, the supply of pressurized oil from the and relief valve (1).
Page 194 UEN00160-03 10 Structure, function and maintenance standard Reverse prevention valve PC210, 230, 240-8...
Page 195 10 Structure, function and maintenance standard UEN00160-03 MA: From control valve MB: From control valve T1: To tank T2: To tank Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side) Explanatory drawing of effects PC210, 230, 240-8...
Page 196 UEN00160-03 10 Structure, function and maintenance standard Function 2. When motor is stopped temporarily This valve reduces the swing back generation The motor rotation is reversed by the closing in the swing body by the inertia of the swing pressure generated at port (MB). (1st time: body, the backlash and rigidity of the machin- reverse rotation) ery system, and the compression of the...
Page 197 10 Structure, function and maintenance standard UEN00160-03 PC210, 230, 240-8...
Page 198 UEN00160-03 10 Structure, function and maintenance standard Centre swivel joint PC210, 230, 240-8...
Page 199 10 Structure, function and maintenance standard UEN00160-03 Cover Slipper seal Body O-ring Shaft : To L.H. travel motor port (PB) : From control valve port (A5) : To L.H. travel motor port (PA) : From control valve port (B5) : To R.H. travel motor port (PA) : From control valve port (A2) : To R.H.
Page 200 UEN00160-03 10 Structure, function and maintenance standard PC210, 230, 240-8...
Page 201: Specifications
10 Structure, function and maintenance standard UEN00160-03 Travel motor Type: HMV110ADT-3 : Brake release pressure port Specifications MA : MA pressure detection port Models MB : MB pressure detection port PC210-8K PC230 / 240-8K Item : From travel speed solenoid valve Type HMV110ADT-3 : From control valve...
Page 202 UEN00160-03 10 Structure, function and maintenance standard PC210, 230, 240-8...
Page 203 10 Structure, function and maintenance standard UEN00160-03 Regulator piston Spring Regulator valve Spring Motor case Suction safety valve spring Suction safety valve Check valve Check valve spring 10. Output shaft 11. Rocker cam 12. Retainer guide 13. Pin 14. Piston 15.
Page 204 UEN00160-03 10 Structure, function and maintenance standard Operation of motor 1) At slow speed (motor swash plate angle at maximum) As the solenoid valve is deenergized, the pilot The combined force of the piston propulsion pressurized oil from the self pressure reducing forces works as the moment of inclining rocker valve does not flow to port (P).
Page 205 10 Structure, function and maintenance standard UEN00160-03 2) At high speed (motor swash plate angle at minimum) As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P). Regulator valve (9) is pushed to the left. The pressurized oil from the control valve passes through passage (d) in regulator valve (9) and enters regulator piston (15).
Page 206 UEN00160-03 10 Structure, function and maintenance standard Operation of parking brake 1) When starting travel As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (19), opening the parking brake circuit. The pressurized oil is conducted to chamber (e) of brake piston (12) and compresses spring (11), pushing piston (12) toward left.
Page 207 10 Structure, function and maintenance standard UEN00160-03 2) When travel is stopped As the travel lever is placed in neutral, counter- balance valve spool (19) returns to the neutral position and closing the parking brake circuit. The pressurized oil in chamber (e) of brake piston (12) passes through orifice (f) of brake piston (12) and is drained to the motor case.
Page 208 UEN00160-03 10 Structure, function and maintenance standard Brake valve Operation when pressurized oil is supplied The brake valve consists of suction safety Operating the travel lever conducts the pressu- valve (18A) and counterbalance valve (18). rized oil from the control valve to port (PA). Functions and operations of respective compo- The pressurized oil push-opens suction safety nents shall conform to the following.
Page 209 10 Structure, function and maintenance standard UEN00160-03 Port (MB) and port (PB) are connected, open- Operation of brake during travelling downhill ing the motor outlet port side and starting the If indication of the machine runaway is sensed motor rotating. while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure.
Page 210 UEN00160-03 10 Structure, function and maintenance standard 2) Safety valve When the pressure rises above the set pressure of the suction safety valve, poppet (1) opens. The pressurized oil passes through notch (A1) Function of spool (19) into chamber (MA) of the circuit at As long as the machine travel is stopped (or it the opposite side.
Page 211 10 Structure, function and maintenance standard UEN00160-03 The pump pressure rises, providing a large tractional force to the valve. PC210, 230, 240-8...
Page 212 UEN00160-03 10 Structure, function and maintenance standard PPC valve Work equipment and swing PPC valve : From self pressure reducing valve P1 : L.H. PPC: Arm out/R.H. PPC: Boom lower P2 : L.H. PPC: Arm in/R.H. PPC: Boom raise P3 : L.H. PPC: Swing left/R.H PPC: Bucket curl P4 : L.H.
Page 213 10 Structure, function and maintenance standard UEN00160-03 Spool Joint Metering spring Plate Centring spring Retainer Piston 10. Body Disc 11. Filter Nut (for lever connection) Table 1 (PC210 #K50001- K52292, PC230 #K50001- K50200, PC240 #K50001- K50595) Unit: mm Check item Criteria Remedy Standard size...
Page 214 UEN00160-03 10 Structure, function and maintenance standard Table 2 (PC210 #K52293 - Up, PC230 #K50201- Up, PC240 #K50596 - Up) Unit: mm Check item Criteria Remedy Standard size Repair limit Centring spring Free length x Installation Installation Installation Free length (for ports P3 and P4 Outside diameter length...
Page 215 10 Structure, function and maintenance standard UEN00160-03 3. During fine control 4. At full stroke (When control lever is returned) Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). When disc (5) starts to be returned, spool (1) is Fine control hole (f) is shut off from drain pushed up by the force of centring spring (3) chamber (D), and is interconnected to pump...
Page 216 UEN00160-03 10 Structure, function and maintenance standard Travel PPC valve From self pressure reducing valve P1: L.H. reverse P2: L.H. forward P3: R.H. reverse P4: R.H. forward P5: Travel signal P6: Steering signal To tank PC210, 230, 240-8...
Page 217 10 Structure, function and maintenance standard UEN00160-03 PC210, 230, 240-8...
Page 218 UEN00160-03 10 Structure, function and maintenance standard Plate Body Piston Collar Centring spring Metering spring Valve Damper Steering signal spool 10. Steering signal spool spring Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installation Installation Installation Free length Centring spring...
Page 219 10 Structure, function and maintenance standard UEN00160-03 1. Pressure reducing valve function The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pres- Operation sure chamber (PP)] does not change until retainer (9) contacts spool (1).
Page 220 UEN00160-03 10 Structure, function and maintenance standard Therefore, the pilot pressure oil from the self 3) During fine control (When control lever is returned) pressure reducing valve passes through fine When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from is pushed up by the force of centring spring (3) port (P1) to push the control valve spool.
Page 221 10 Structure, function and maintenance standard UEN00160-03 Operation 1) When in neutral No output is made from respective output ports [from port (P1) to (P4)], travel signal [port (P5)] and steering signal [port (P6)]. PC210, 230, 240-8...
Page 222 UEN00160-03 10 Structure, function and maintenance standard 2) During straight travel a The Illustration shows the circuit for travelling straight forward. When operating L.H. motor forward [port (P2) output] and R.H. motor forward [port (P4) out- put], pressure of both L.H. spring chamber (k) and R.H.
Page 223 10 Structure, function and maintenance standard UEN00160-03 3) When steered or pivot-turned a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation. If the operation quantities of both levers are dif- Port (P4) pressure of the L.H. or R.H. PPC ferent from each other as in the steering opera- valves, whichever having a higher output pres- tion (if the difference of the pilot pressure...
Page 224 UEN00160-03 10 Structure, function and maintenance standard 4) When counter-rotated a The illustration shows the circuit for travelling left reverse and right forward. When operating L.H. motor reverse [port (P1) output] and R.H. motor forward [port (P4) out- put], pressure of the R.H. spring chamber (l) only rises high.
Page 225 10 Structure, function and maintenance standard UEN00160-03 Service PPC valve (with EPC valve) a For the details of operation, see the paragraph of “Work equipment swing PPC valve.” PC210, 230, 240-8...
Page 226 UEN00160-03 10 Structure, function and maintenance standard From self pressure reducing valve P1: To service valve P2: To service valve To tank Spool Piston Lever Plate Retainer Block Body EPC valve Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installation Installation...
Page 227 10 Structure, function and maintenance standard UEN00160-03 1. EPC valve C: To control valve Spool From self pressure reducing valve Push pin To hydraulic tank Coil Plunger Body Connector Plug Unit: mm Check item Criteria Remedy Standard size Repair limit If damaged or Installation Installation...
Page 228 UEN00160-03 10 Structure, function and maintenance standard Function Operation The EPC valve consists of the proportional 1) When signal current is 0 solenoid portion and the hydraulic valve por- (coil is deenergized) tion. When it receives signal current (i) from the When there is no signal current flowing from pump controller, it generates the EPC output the controller to coil (14), coil (14) is deener-...
Page 229 10 Structure, function and maintenance standard UEN00160-03 2) When signal current is very small 3) When signal current is maximum (coil is energized) (coil is energized) When a very small signal current flows to coil As the signal current flows to coil (5), coil (5) is (5), coil (5) is energized, and a propulsion force energized.
Page 230 UEN00160-03 10 Structure, function and maintenance standard Service PPC valve a For the details of operation, see the paragraph of “Work equipment swing PPC valve.“ PC210, 230, 240-8...
Page 231 10 Structure, function and maintenance standard UEN00160-03 From self pressure reducing valve P1: To service valve P2: To service valve To tank Spool Piston Lever Plate Retainer Body Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installation Installation Installation...
Page 232 UEN00160-03 10 Structure, function and maintenance standard Valve control PC210, 230, 240-8...
Page 233 10 Structure, function and maintenance standard UEN00160-03 Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment control lever Solenoid block Accumulator 10. Control valve 11. Hydraulic pump 12. Junction box 13.
Page 234 UEN00160-03 10 Structure, function and maintenance standard ATT EPC Valve Assembly For :PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up). 4-P1 PC210, 230, 240-8...
Page 235 10 Structure, function and maintenance standard UEN00160-03 Att EPC Valve Assembly 1A. 1 ATT EPC (LH) 1B. 1 ATT EPC (RH) 1C. 2 ATT EPC (LH) OPT. 1D. 2 ATT EPC (RH) OPT. Block Shuttle Valve A Shuttle Valve B Connector 5A.
Page 236 UEN00160-03 10 Structure, function and maintenance standard Solenoid valve PPC lock, travel junction, ATT selector, travel speed, swing brake, and 2-stage relief solenoid valves PC210, 230, 240-8...
Page 237 10 Structure, function and maintenance standard UEN00160-03 PPC lock solenoid valve When solenoid is turned on 2-stage relief solenoid valve As the signal current flows from the controller Swing brake solenoid valve to solenoid (9), solenoid (9) is energized. Travel speed solenoid valve Accordingly, spool (10) is pushed to the right.
Page 238 UEN00160-03 10 Structure, function and maintenance standard PPC Accumulator Gas plug Shell Poppet Holder Bladder Oil port Specifications Gas capacity: 300 cc (for PPC) PC210, 230, 240-8...
Page 239 10 Structure, function and maintenance standard UEN00160-03 Return oil filter For breaker Drain plug Specifications Filter Rated pressure: 6.9 MPa {70 kg/cm Case Flow rate: /min Head cover Relief valve cracking pressure: Relief valve 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm Filter mesh size: 6 μ...
Page 240 UEN00160-03 10 Structure, function and maintenance standard Attachment circuit selector valve ACC: To accumulator ATT: To attachment From attachment selector solenoid valve To hydraulic tank To hydraulic tank To control valve Spool Spring Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installation...
Page 241 10 Structure, function and maintenance standard UEN00160-03 2. When breaker is installed Function When a breaker is installed, the return oil from Pilot pressure from the attachment circuit the breaker does not pass through the main selector solenoid valve contracts spring (2), valve, but returns directly to the hydraulic tank.
Page 242 UEN00160-03 10 Structure, function and maintenance standard Quick coupler control valve - For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and PC240 K50001~K50303 the quick coupler cylinder is reached the pressure at the cylinder will be the set Pressure regulating valve pressure of the regulating valve(1).
Page 243 10 Structure, function and maintenance standard UEN00160-03 Schematic P Supply pressure from main valve To tank B Supply to quick coupler - lock and hold direction B1 Pressure checking port for B line B2 Spare A Supply to quick coupler - unlock direction PC210, 230, 240-8...
Page 244 UEN00160-03 10 Structure, function and maintenance standard Quick coupler control valve - For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) the quick coupler cylinder is reached the Pressure regulating valve pressure at the cylinder will be the set Lock nut pressure of the regulating valve(1).
Page 245 10 Structure, function and maintenance standard UEN00160-03 Schematic Main Valve Main Pump 24V Power Relay for Quick Coupler Quick Coupler LH Lever Switch 24V Power Quick Coupler Console Switch 24V Power Monitor Panel Pressure (BUZZER) Switch Pump Controller Unlock Press the quick coupler console switch, the P Supply pressure from main valve lamp on the switch will illuminate and a warn- To tank...
Page 246 UEN00160-03 10 Structure, function and maintenance standard Hydraulic cylinder PC210-8K, PC210LC, PC210NLC,PC230NHD-8K Boom cylinder Arm cylinder Bucket cylinder PC210, 230, 240-8...
Page 247 10 Structure, function and maintenance standard UEN00160-03 Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Cylinder size clearance limit Shaft Hole –0.036 +0.222 0.083 – Boom 0.412 –0.090 +0.047 0.312 –0.036 +0.222 0.083 – Clearance between pis- 0.412 Replace bushing –0.090 +0.047...
Page 248 UEN00160-03 10 Structure, function and maintenance standard PC240LC-8K and PC240NLC-8K Boom cylinder Arm cylinder Bucket cylinder PC210, 230, 240-8...
Page 249 10 Structure, function and maintenance standard UEN00160-03 Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Cylinder size clearance limit Shaft Hole –0.036 +0.222 0.083 – Boom 0.437 –0.090 +0.047 0.312 Clearance between pis- –0.036 +0.257 0.083 – Replace bushing 0.447 ton rod and bushing –0.090...
Page 251 UEN00101-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 252 UEN00101-00 10 Structure, function and maintenance standard Work equipment Dimensions of components PC210, 230, 240-8...
Page 253 10 Structure, function and maintenance standard UEN00101-00 PC210, PC210LC, 210NLC, 230NHD-8 Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Clearance between pin con- size clearance limit Shaft Hole necting boom and revolving –0.036 +0.135 0.110 – frame and bushing –0.071 +0.074 0.206...
Page 254 UEN00101-00 10 Structure, function and maintenance standard Dimension of arm PC210, 230, 240-8...
Page 255 10 Structure, function and maintenance standard UEN00101-00 Unit: mm PC210, 210LC, 210NLC, 230NHD-8 PC240LC, 240NLC-8 Standard size Tolerance Standard size Tolerance 2.9M Arm 3.0M Arm +0.1 +0.1 φ80 φ80 +0.0 +0.1 +1.5 +1.5 109.3 109.3 +0.0 +0.1 –0.5 –0.5 305.5 305.5 –0.5 –0.5...
Page 256 UEN00101-00 10 Structure, function and maintenance standard Dimension of bucket PC210, 230, 240-8...
Page 257 10 Structure, function and maintenance standard UEN00101-00 Unit: mm PC210, 210LC, 210NLC, 230NHD-8 PC240LC, 240NLC-8 Standard size Tolerance Standard size Tolerance 457.6 ±0.5 442.4 ±0.5 ±0.5 59.2 ±0.5 92° 45’ — 97° 37’ — 458.1 — 446.3 — 1,477.3 — 1,540.5 —...
Page 259 UEN00102-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 260 UEN00102-00 10 Structure, function and maintenance standard Cab and its attachments Air conditioner piping Air conditioner unit A : Fresh air Hot water pickup piping B : Recirculated air Air conditioner compressor C: Hot air/cold air Refrigerant piping Condenser Hot water return piping Duct PC210, 230, 240-8...
Page 261 10 Structure, function and maintenance standard UEN00102-00 PC210, 230, 240-8...
Page 263 UEN00103-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 10 Structure, function and...
Page 264: Electrical System
UEN00103-03 10 Structure, function and maintenance standard Electrical system Engine control Operation of system Starting engine When the starting switch is turned to the START position, the starting signal flows to the starting motor. Then, the starting motor turns to start the engine.
Page 265 10 Structure, function and maintenance standard UEN00103-03 Component Fuel control dial Knob Ball Dial Potentiometer Spring Connector PC210, 230, 240-8...
Page 266 UEN00103-03 10 Structure, function and maintenance standard Function The fuel control dial is installed under the machine monitor. Turning knob (1) rotates the shaft of potentiom- eter (5). The rotation of the shaft changes the resist- ance of the variable resistor in potentiometer (5), sending any throttle signal to the engine controller.
Page 267 10 Structure, function and maintenance standard UEN00103-03 Engine controller CN-CE01 CN-CE01 Input/ Title Pin No. Signal name Pin No. Signal name output panel Electric power supply for lift pump NC(*) Electric power supply for IMA NC(*) Atmosphere sensor NC(*) NC(*) NC(*) NC(*) Engine brake drive...
Page 268 UEN00103-03 10 Structure, function and maintenance standard CN-CE01 CN-CE02 Title Input/ Pin No. Signal name Pin No. Signal name panel output NC(*) NC(*) NC(*) NC(*) 5V electric power supply for sensor Fuel control dial (+5V) Fuel control dial (–) NC(*) NC(*) NC(*) NC(*)
Page 269 10 Structure, function and maintenance standard UEN00103-03 Coolant temperature sensor Sensor O-ring Connector Oil pressure switch Connector Sensor O-ring PC210, 230, 240-8...
Page 270 UEN00103-03 10 Structure, function and maintenance standard Rotation sensor Connector Sensor O-ring Boost pressure and temperature sensor Connector Sensor O-ring PC210, 230, 240-8...
Page 271 10 Structure, function and maintenance standard UEN00103-03 WIF (water-in-fuel detection) sensor Connector Tube Sensor O-ring Engine oil level sensor Connector Bracket Float Switch PC210, 230, 240-8...
Page 272 UEN00103-03 10 Structure, function and maintenance standard Electrical control system Machine control system diagram (FOR PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303) PC210, 230, 240-8...
Page 273 10 Structure, function and maintenance standard UEN00103-03 PC210, 230, 240-8...
Page 274 UEN00103-03 10 Structure, function and maintenance standard Machine control system diagram (FOR PC210 K51095 and up, PC230K50114 and up, and PC240 K50304 and up.) PC210, 230, 240-8...
Page 275 10 Structure, function and maintenance standard UEN00103-03 PC210, 230, 240-8...
Page 276 UEN00103-03 10 Structure, function and maintenance standard 1. Engine and pump composite control function PC210, 230, 240-8...
Page 277 10 Structure, function and maintenance standard UEN00103-03 Function Control method in each mode P mode, E mode, and ATT mode This function allows the operator to select engine torque (T) and pump absorption torque Matching point: d e p e n d i n g o n t h e w o r k c o n t e n ts o f t h e Models machine.
Page 278 UEN00103-03 10 Structure, function and maintenance standard B mode and L mode Mode Partial output point Models PC210/230-8 Mode 80.9 kW/1,780 rpm {108 HP/1,780 rpm} 73.6 kW/1,800 rpm {99 HP/1,800 rpm} Models PC240-8 Mode 103 kW/1,750 rpm {138 HP/1,750 rpm} 80.9 kW/1,870 rpm {108 HP/1,870 rpm} In B or L mode, engine output is controlled to a...
Page 279 10 Structure, function and maintenance standard UEN00103-03 Function to control when emergency pump drive switch is turned on Even if any abnormality occurs in the controller or sensor, setting emergency pump drive switch (1) to the “ON” position activates the machine with an absorption torque approxi- mately equivalent to that in E mode.
Page 280 UEN00103-03 10 Structure, function and maintenance standard 2. Pump and valve control function Function The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc. PC210, 230, 240-8...
Page 281 10 Structure, function and maintenance standard UEN00103-03 LS control function 2-stage relief function Depending on the operation condition of the The relief pressure in the normal work is 34.8 actuator, this function changes the pressure MPa {355 kg/cm }. If the 2-stage relief function output from the LS-EPC valve to LS valve to is turned on, however, the relief pressure rises change the change point (LS set differential...
Page 282 UEN00103-03 10 Structure, function and maintenance standard 3. Power maximizing function Function These settings are automatically reset after 8.5 seconds when the switch is pressed. The power maximizing function allows the operator to increases power for a certain time by operating the left knob switch. This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock).
Page 283 10 Structure, function and maintenance standard UEN00103-03 4. Auto-deceleration function Function The auto-deceleration function automatically reduces the engine speed to its medium speed range when the all control levers are set in NEUTRAL while waiting for a dump truck or work to reduce the fuel consumption and noise.
Page 284 UEN00103-03 10 Structure, function and maintenance standard 5. Auto-warm-up and overheat prevention function Function engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts. The overheat prevention function reduces the pump load when coolant or hydraulic oil tem- perature is too high during operation to protect the engine from overheating.
Page 285 10 Structure, function and maintenance standard UEN00103-03 Auto-warm-up function After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All of following conditions) Operated Coolant temperature: Below 30°C Engine speed: 1,200 rpm Engine speed: Max.
Page 286 UEN00103-03 10 Structure, function and maintenance standard 6. Swing control function Function The swing lock and swing holding brake function are provided as a swing control function. PC210, 230, 240-8...
Page 287 10 Structure, function and maintenance standard UEN00103-03 Swing lock and swing holding brake func- Quick hydraulic oil warm-up function when tion swing lock switch is turned on The swing lock function (manual) is used to If swing lock switch (2) is turned on, the pump lock machine from swinging at any position.
Page 288 UEN00103-03 10 Structure, function and maintenance standard 7. Travel control function Function The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or allowing operator to change travel speed automatically or manually.
Page 289 10 Structure, function and maintenance standard UEN00103-03 Function to control pump during travel For details, see Engine and pump composite control function. Travel speed change function Manual change with travel speed selector switch Switching the travel speed selector switch from Lo to Mi and Hi causes the pump controller to control the pump capacity and motor capacity at each gear speed as shown below,...
Page 290 UEN00103-03 10 Structure, function and maintenance standard 8. Attachment flow control circuit selector function (if equipped) (For PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303.) Function Working mode Attachment operation This function is available only with the attach- Single-acting ment specification. The function acts as follows according to the flow command and working mode from the monitor.
Page 291 10 Structure, function and maintenance standard UEN00103-03 1st Attachment flow control circuit selector function (if equipped)(For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) Function produced (N.B. max flow preset by moni- tor panel function). The function acts as follows according to the flow and working mode command from the monitor.
Page 292 UEN00103-03 10 Structure, function and maintenance standard 2nd Attachment flow control circuit selector function (if equipped)(For PC210 K51095 and up, PC230 K50114 and up and PC240 K50303 and up.) Function This function is available only with the 2nd attachment specification. The function acts as follows according to the flow command when the following working mode is selected:...
Page 293 10 Structure, function and maintenance standard UEN00103-03 9. System component parts PPC oil pressure switch Plug Switch Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm Resetting (OFF) pressure: 0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm Function The junction block has 2 PPC oil pressure switches.
Page 294 UEN00103-03 10 Structure, function and maintenance standard Oil pressure sensor Sensor Connector Function The junction block has 6 PPC oil pressure sen- sor. This sensor detects the operating condition of each actuator by the PPC pressure and trans- mit it to the pump controller. Operation The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure...
Page 295 10 Structure, function and maintenance standard UEN00103-03 Pump pressure sensor Sensor Connector Operation The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below. PC210, 230, 240-8...
Page 296 UEN00103-03 10 Structure, function and maintenance standard Quick coupler low pressure warning switch Switch Wire Cover Connector Specification ±5 bar (rising) Switching pressure 25 Function The quick coupler circuit has one pressure switch. This sensor detects the circuit pressure, if the pressure falls below the switch set pressure a buzzer is sounded in the operator cab to warn the operator.
Page 297 10 Structure, function and maintenance standard UEN00103-03 Auto Grease pressure switch Switch Wire Cover Connector Specification Switching pressure 150 bar Function The auto grease circuit has one pressure switch. PC210, 230, 240-8...
Page 298 UEN00103-03 10 Structure, function and maintenance standard Monitor system The monitor system notifies the operator of machine status. It monitors the condition of the machine with the sensors mounted on various parts of the machine, processes and immedi- ately displays the obtained information on the panel.
Page 299 10 Structure, function and maintenance standard UEN00103-03 Machine monitor Outline The machine monitor has the functions to dis- play various items and the functions to select modes and electric parts. The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
Page 300 UEN00103-03 10 Structure, function and maintenance standard Input and output signals CN-CM03 Input/ Pin No. Signal name CN-CM01 output Input/ RS232C CD for communica- Pin No. Signal name Input output tion terminal Battery power (+24V con- RS232C RXD for communica- Input Input stantly)
Page 301 10 Structure, function and maintenance standard UEN00103-03 CN-CM05 Input/ Pin No. Signal name output Electric power supply for cam- Output Camera NTSC signal input 1 Input Camera NTSC signal input 2 Input Camera NTSC signal input 3 Input Electric power supply GND for —...
Page 302 UEN00103-03 10 Structure, function and maintenance standard PC210, 230, 240-8...
Page 303 10 Structure, function and maintenance standard UEN00103-03 Monitor control, display portion PC210, 230, 240-8...
Page 304 UEN00103-03 10 Structure, function and maintenance standard Hydraulic oil temperature monitor Hydraulic oil temperature gauge Engine coolant temperature monitor Engine coolant temperature gauge KOMTRAX message monitor Air conditioner monitor Wiper monitor Swing lock monitor Engine pre-heating monitor/power maximizing monitor 10. Time/service meter 11.
Page 305 10 Structure, function and maintenance standard UEN00103-03 Monitor items and display Symbol Display item Display method Swing holding brake Swing lock switch Display of symbol release switch Swing lock Flashes Flashes Preheater operates at low temperature and Automatic preheating symbol keeps lighting up for up to about 30 seconds and then goes off after engine starts.
Page 306 UEN00103-03 10 Structure, function and maintenance standard The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to disconnection of CAN. Temperature or vol- Gauge Range Indicator Buzzer sound Engine coolant tem- perature (°C) White Hydraulic oil tempera-...
Page 307 10 Structure, function and maintenance standard UEN00103-03 Checks before starting (all symbols light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are displayed.
Page 308 UEN00103-03 10 Structure, function and maintenance standard Display Symbol Display item Display range Display method category Green: Displays state of message KOMTRAX There is unread message. (for only machine equipped message Blue: with KOMTRAX). There is unreturned message. Air conditioner/ Displays operating condition.
Page 309 10 Structure, function and maintenance standard UEN00103-03 Switches Buzzer cancel switch Auto-deceleration switch Auto-deceleration switch The auto-deceleration switch toggles the auto- Guidance icon deceleration function on and off. When the working Function switch mode is switched, it is automatically set to ON. Working mode selector switch When it is set to ON, the auto-deceleration monitor Travel speed selector switch...
Page 310 UEN00103-03 10 Structure, function and maintenance standard Symbol Switch Item Function Enter Enters selected/set item. Return Returns to previous screen. Select camera screen Selects camera screen. Select service meter/clock Selects service meter and clock alternately. Select maintenance screen Selects maintenance screen. Select user mode screen Selects user mode screen.
Page 311 10 Structure, function and maintenance standard UEN00103-03 Working mode selector switch Travel speed selector switch Pressing working mode selector switch (5) switches Each time you press the travel speed selector among working modes. switch, the travel speed setting switches as shown Check the working mode on the working mode below.
Page 312 UEN00103-03 10 Structure, function and maintenance standard Camera screen display function 9a : Specifies airflow 9b : Specifies temperature For an optional-camera-equipped machine, 9c : AUTO pressing the F3 on the normal screen switches 9d : A/C to the camera image. 9e : Switches among air blowing modes For a machine with no camera equipped, the 9f : Switches between inside air and outside air...
Page 313 10 Structure, function and maintenance standard UEN00103-03 F6, or no operation for 5 sec.: Returns to the cam- era screen. Even when the camera screen is displayed, the working mode selector switch, travel speed selector switch, auto-deceleration switch, buzzer cancel switch, wiper switch, and win- dow washer switch are enabled.
Page 314 UEN00103-03 10 Structure, function and maintenance standard Service meter/time selector function Pressing F4 on the normal screen when the service meter is displayed in the top centre of the screen switches the display to the time, and doing so when the time is displayed switches the display to the service meter.
Page 315 10 Structure, function and maintenance standard UEN00103-03 Maintenance function Pressing F5 on the normal screen switches to the maintenance screen. F5 : Cancels the reset to return to the maintenance table screen. F6 : Resets the remaining time to return to the nor- mal screen.
Page 316 UEN00103-03 10 Structure, function and maintenance standard You can lock the maintenance time by a pass- word to prevent it from carelessly being reset. The default password is “000000”. Enabling the password lock on an attachment- equipped machine locks the breaker/attach- ment setting screen at the same time.
Page 317 10 Structure, function and maintenance standard UEN00103-03 User mode Breaker/attachment 1 setting Pressing F6 on the normal screen enters the For an attachment-equipped machine, this user mode, switching to the user menu screen. menu allows you to adjust a flow rate in B In user mode, you can specify items relating to mode and ATT mode.
Page 318 UEN00103-03 10 Structure, function and maintenance standard Changing breaker mode setting Selecting B on the breaker/attachment setting screen switches to the breaker setting screen. On this screen, select the breaker setting selection screen or breaker flow rate setting screen. F3 : Selects (highlights) an item one down. F4 : Selects (highlights) an item one up.
Page 319 10 Structure, function and maintenance standard UEN00103-03 Breaker setting selection screen. On the flow rate level setting screen, On this screen, you can allocate one of change the set flow rate. two set flow rates as a flow rate in breaker mode.
Page 320 UEN00103-03 10 Structure, function and maintenance standard The ATT symbol is displayed before items specified to attachment mode. (A) In case of machine with two attachment lines, this symbol is displayed to show 1 attachment setting mode. F3 : Selects (highlights) an item one down. F3 : Selects (highlights) an item one down.
Page 321 10 Structure, function and maintenance standard UEN00103-03 a The defaults of both flow rates are 40 l/ Attachment 2 Setting (For PC210 K51095 and min. up, PC230 K50114 and up and PC240 K50304 and up) Note - If installing 2nd attachment line as a field kit ask the distributor to change monitor setting to allow 2 attachments (as shown below).
Page 322 UEN00103-03 10 Structure, function and maintenance standard On the flow rate level setting screen, change the set flow rate. F3 : Decreases the flow rate. F4 : Increases the flow rate. F5 : Returns to the flow rate setting screen without changing the flow rate.
Page 323 10 Structure, function and maintenance standard UEN00103-03 Message display For a KOMTRAX-equipped machine, you can view notification from the sales representative. When there is a message, the message moni- tor appears on the upper left of the normal screen. The lighting green monitor indicates that there are messages to be read.
Page 324 UEN00103-03 10 Structure, function and maintenance standard Clock adjustment For a camera-equipped machine, the bright- ness, contrast, and illuminance of the camera Selecting the Clock adjustment from the user screen are also adjustable. menu and pressing F6 switches to the clock For a camera-equipped machine, selecting adjustment screen.
Page 325 10 Structure, function and maintenance standard UEN00103-03 Economy mode adjustment Summer time Selecting ON for this sets the time forward Selecting the Economy mode adjustment from one hour. Setting OFF returns to the ordi- the user menu and pressing F6 switches to the nary time.
Page 326 UEN00103-03 10 Structure, function and maintenance standard Idle stop guidance function This function displays guidance to control unneces- sary fuel consumption. It is displayed only when all the following conditions are met. Energy saving guidance display of the service menu is specified to ON. No operation is made at least 5 min.
Page 327 10 Structure, function and maintenance standard UEN00103-03 Service meter check function Display LCD check function If you continuously pressing auto-deceleration Continuously pressing the buzzer cancel switch (1) and buzzer cancel switch (2) at the switch (1) and F2 at the same time on the same time when setting the starting switch to password input screen or normal screen the OFF position, the service meter will appear...
Page 328 UEN00103-03 10 Structure, function and maintenance standard User code/failure code display function1 If there is any problem in machine operation, the user code and failure code are displayed on the monitor to advise the operator of the steps to take. These codes appear on the normal screen.
Page 329 10 Structure, function and maintenance standard UEN00103-03 Sensor The signals from the sensors are input to the monitor panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Type of When When Sensor name sensor normal abnormal...
Page 330 UEN00103-03 10 Structure, function and maintenance standard Fuel level sensor Float Connector Cover Variable resistor Air cleaner clogging sensor PC210, 230, 240-8...
Page 331 10 Structure, function and maintenance standard UEN00103-03 Coolant level sensor Reserve tank Float Sensor Connector PC210, 230, 240-8...
Page 332 UEN00103-03 10 Structure, function and maintenance standard PPC Levers LH PPC Lever Lever Gaiter Harness Connector PC210, 230, 240-8...
Page 333 10 Structure, function and maintenance standard UEN00103-03 RH PPC Lever Lever Gaiter Harness Connector PC210, 230, 240-8...
Page 334 UEN00103-03 10 Structure, function and maintenance standard KOMTRAX terminal system The KOMTRAX terminal system consists of a KOMTRAX communication modem, communi- cation antenna, machine monitor, and GPS antenna. This system transmits various kinds of machine information wirelessly. Persons to operate the KOMTRAX can refer to the infor- mation at office to provide various kinds of services for customers.
Page 335 10 Structure, function and maintenance standard UEN00103-03 KOMTRAX communication modem TH300 Communication antenna connection Outline Connector A (14 poles) The KOMTRAX communication modem is a Connector B (10 poles) wireless communication device to transmit var- ious kinds of machine information or GPS posi- tion information the monitor obtains from n e t w o r k s i g n a l s o r i n p u t s i g n a l s i n t h e machine.
Page 337 UEN00104-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K52393 and up PC210LC-8 K52393 and up PC210NLC-8 K52393 and up PC230NHD-8 K50213 and up PC240LC-8 K50630 and up PC240NLC-8 K50630 and up 10 Structure, function and...
Page 338 UEN00104-00 10 Structure, function and maintenance standard Outline of Auto Grease System KSP00100 Distribution Block Distribution Block Distribution Block In-Cab Display Pressure switch KSP00099 Schematic PC210, 230, 240-8...
Page 339 10 Structure, function and maintenance standard UEN00104-00 Assembly Greasing system generally consists of the following components (see figure 1): 1. Electrically-driven plunger-pump with grease reservoir 2. Control unit (integrated in the pump housing) 3. Distribution blocks 4. Metering units 5. Secondary grease lines 6.
Page 340 UEN00104-00 10 Structure, function and maintenance standard (b) Distribution Blocks and Metering Units Various types of metering units with the greasing system are available, each with a different grease output. Each greasing point can receive the correct dose of grease per greasing cycle by a careful choice of the type of metering unit.
Page 341 10 Structure, function and maintenance standard UEN00104-00 The table below is an overview of the metering unit numbers and their grease capacity. KSP00100 Position Metering Unit Grease Capacity 0.400 0.400 0.150 0.100 0.150 0.050 0.400 0.050 0.400 0.200 1.000 0.100 1.000 2.000 0.200...
Page 342 UEN00104-00 10 Structure, function and maintenance standard The Greasing Cycle Every greasing cycle consists of four phases. The greasing cycles are carried out alternately by the grease lines A and B (see figure 3). The 5/2 valve, which is integrated in the pump housing, determines which pri- mary grease line is connected to the pump and which is connected to the grease reservoir.
Page 343 10 Structure, function and maintenance standard UEN00104-00 Greasing cycle B Greasing cycle B begins when the control unit restarts the pump. During pumping phase B and re-grease phase B, the control unit still has the 5/2 valve energized, causing the pump to be connected to primary grease line B.
Page 344 UEN00104-00 10 Structure, function and maintenance standard The heart of the pump is an electrical-driven plunger-pump. This pump consists of three radially-placed fixed cylinders and plungers (5, see figure 4). The electro-motor drives the axle through the mechanical drive. A cam (4) is fixed on the axle that moves the three plungers to and fro, so the grease is pumped to the distribu- tion blocks through the primary grease line.
Page 345 10 Structure, function and maintenance standard UEN00104-00 For an extensive description of the greasing cycle and the influence of the position of the 5/2 magnetic valve on the greasing cycle, see paragraph 3 The Greasing Cycle. (b) Metering units ATTENTION: Do not open the metering units.
Page 346 UEN00104-00 10 Structure, function and maintenance standard Phase 3 Grease is pumped into channel (6) of the metering unit (pumping phase B) through primary channel B (see figure 4.4). Because of the grease pressure, plunger (3) is pushed back leftwards, passed channel (8). The grease fills chamber (7) and pushes plunger (4) back to the left.
Page 347 10 Structure, function and maintenance standard UEN00104-00 (c ) Grease pressure switch The principle of operation of the grease pressure switch is explained in three phases. Phase 1 During this phase both channels A and B are not under pressure (see figure 4.6). There is also no pressure in chamber (1).
Page 348 UEN00104-00 10 Structure, function and maintenance standard Phase 3 (pumping phase B) During pumping phase B grease is pressed into channel B (see figure 4.8). While the grease pressure is built up, chamber (11) fills with grease (through channel 12). The grease pressure pushes piston (6) to the left. Because of that the channel (8) is opened, causing the grease to flow to chamber (1) through channel (7) and channel (9).
Page 349 10 Structure, function and maintenance standard UEN00104-00 The length of the greasing cycles The meaning of the various phases of the greasing cycle is described in paragraph 3. (further see figure 4.9.) The duration of a greasing cycle (adjustment range: 0 ... 1440 minutes) is defined as the period that expires between two successive pumping phases: beginning from the start of one pumping phase and ending at the start of the next pumping phase.
Page 350 UEN00104-00 10 Structure, function and maintenance standard Reaction of the system to grease pressure malfunctions. When the required grease pressure during several pumping phases is not reached, it indicates e.g., a leak in a primary line. To prevent the contents of the reservoir being pumped into the environment, the greasing sys- tem should be shut down.
Page 351 10 Structure, function and maintenance standard UEN00104-00 Indication Meaning 1. The pump is not powered. Check fuses and connections to earth. Imme- The red lamp (6) flashes as diate action required. soon as the ignition has been 2. The connection between the in-cab display and pump is defective, switched on.
Page 353 UEN00227-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 20 Standard value table Standard service value table Standard service value table ...........................
Page 354 UEN00227-01 20 Standard value table Standard service value table Standard value table for engine related parts PC210, 210LC, 210NLC, 230NHD-8 Applicable model PC210, 210LC, 210NLC, 230NHD-8 Engine SAA6D107E-1 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine High idle 2,060 ±...
Page 355 20 Standard value table UEN00227-01 PC240LC, 240NLC-8 Applicable model PC240LC, 240NLC-8 Engine SAA6D107E-1 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine High idle 2,160 ± 70 2,160 ± 70 • Coolant Engine speed temperature: Low idle 1,050 ±...
Page 356 UEN00227-01 20 Standard value table Standard value table for chassis related parts PC210, 210LC, 210NLC, 230NHD-8 Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Engine coolant temperature: Within operating range •...
Page 357 20 Standard value table UEN00227-01 Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine 15.7 ± 3.9 Max. 24.5 Boom control lever {kg} {1.6 ± 0.4} {Max. 2.5} 15.7 ± 3.9 Max.
Page 358 UEN00227-01 20 Standard value table Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range • Engine running at high idle deg. Max. 100 Max.
Page 359 20 Standard value table UEN00227-01 Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine [PC210/LC/NLC] [PC210/LC/NLC] • Hydraulic oil 24 ± 2.5 21.5 – 27.5 temperature: Within sec. operating range [PC230NHD] [PC230NHD] •...
Page 360 UEN00227-01 20 Standard value table Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range RAISE sec. 3.3 ± 0.4 Max. 4.7 • Engine running at high idle •...
Page 361 20 Standard value table UEN00227-01 Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode Boom •...
Page 362 UEN00227-01 20 Standard value table Applicable model PC210, 210LC, 210NLC, 230NHD-8 Standard lower limit of Cate- Item Measurement condition Unit Standard value gory delivery • Pump speed (rpm): 2,000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump Performance of (MPa {kg/cm }): P1...
Page 363 20 Standard value table UEN00227-01 PC240LC, 240NLC-8 Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within 2 pumps at relief operating range 1,940 ±...
Page 364 UEN00227-01 20 Standard value table Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine 15.7 ± 3.9 Max. 24.5 Boom control lever {kg} {1.6 ± 0.4} {Max. 2.5} 15.7 ± 3.9 Max. 24.5 Arm control lever {kg} {1.6 ±...
Page 365 20 Standard value table UEN00227-01 Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode deg.
Page 366 UEN00227-01 20 Standard value table Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within sec. 24 ± 2.5 21.5 – 27.5 operating range • Engine running at high idle •...
Page 367 20 Standard value table UEN00227-01 Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range RAISE sec. 3.4(+0.5/–0.3) Max. 4.9 • Engine running at high idle •...
Page 368 UEN00227-01 20 Standard value table Applicable model PC240LC, 240NLC-8 Standard value for new Cate- Item Measurement condition Unit Judgement criteria gory machine • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode Boom •...
Page 369 20 Standard value table UEN00227-01 Applicable model PC240LC, 240NLC-8 Standard lower limit of Cate- Item Measurement condition Unit Standard value gory delivery • Pump speed (rpm): 2,000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump Performance of (MPa {kg/cm }): P1 l/min...
Page 370 UEN00227-01 20 Standard value table For all models (Posture of machine for measur- Travel 1: Travel speed (without load) ing performance and measurement procedure) Control valve: spool stroke Travel 2: Travel speed (actual run), travel deviation Swing 1: Swing brake angle, time taken to start swing, time taken to swing Travel 3: Travel deviation Swing 2: Hydraulic drift of swing...
Page 371 20 Standard value table UEN00227-01 Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed equipment Work equipment 5: Boom time lag Work equipment 2: Boom speed PC210, 230, 240-8...
Page 372 UEN00227-01 20 Standard value table Work equipment 6: Arm time lag Work equipment 7: Bucket time lag Work equipment 8: Characteristics of PC flow control valve PC210, 230, 240-8...
Page 373 20 Standard value table UEN00227-01 PC210, 230, 240-8...
Page 375 UEN00228-04 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 1...........................
Page 376 UEN00228-04 30 Testing and adjusting Measuring swing circle bearing clearance ..................24 Checking and adjusting track shoe tension..................25 Measuring and adjusting oil pressure in work equipment, swing, and travel circuits ......27 Measuring control circuit basic pressure .................... 31 Measuring and adjusting oil pressure in pump PC control circuit............
Page 377 30 Testing and adjusting UEN00228-04 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting Sym- Testing/Adjusting item Part No. Part name Remarks Measuring intake air pres- – 101 – 200 kPa 799-201-2202 Boost gauge kit sure (boost pressure) {–...
Page 378 UEN00228-04 30 Testing and adjusting Sym- Testing/Adjusting item Part No. Part name Remarks Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 799-101-5002 Hydraulic tester {25, 60, 400, 600 kg/cm Measuring basic pressure Pressure gauge: 58.8 MPa 790-261-1204 Digital hydraulic tester of control circuit {600 kg/cm 799-101-5220 Nipple Size: 10 ×...
Page 379 30 Testing and adjusting UEN00228-04 Sym- Testing/Adjusting item Part No. Part name Remarks Removal and installation of engine coolant temper- — (Not set yet) Socket 1 21 mm deep socket ature sensor a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see “Trou- bleshooting (General information on troubleshooting), List of T-boxes and T-adapters”.
Page 380 UEN00228-04 30 Testing and adjusting Measuring engine speed Measuring high idle speed Start the engine and set the fuel control a Measure the engine speed with the monitoring dial in the high idle (MAX) position. function of the machine monitor. Set the working mode in the power mode a Measure the engine speed under the following (P) and turn the auto-decelerator OFF.
Page 381 30 Testing and adjusting UEN00228-04 Measuring intake air pressure Run the engine at middle or higher speed and bleed oil from the hose. (boost pressure) a Insert the connecting parts of the gauge a Measuring tools for intake air pressure (boost and hose about a half and open the self- pressure) seal on the hose side repeatedly, and the...
Page 382 UEN00228-04 30 Testing and adjusting Checking exhaust gas colour a Checking tools for exhaust gas colour Symbol Part No. Part name 799-210-9001 Handy smoke checker Commercially Smoke meter available Stop the machine on a level ground and lower the work equipment to the ground. Be careful not to touch any hot part when removing or installing the checking tools.
Page 383 30 Testing and adjusting UEN00228-04 Adjusting valve clearance Rotate the crankshaft forward with gear B1 and set wide slit (b) of the rotation sensor ring a Measuring tools for valve clearance to projection top (a) of front cover. a Projection top (a) must be within the range Symbol Part No.
Page 384 UEN00228-04 30 Testing and adjusting Adjust the valve clearance according to the fol- lowing procedure. While fixing adjustment screw (3), loosen locknut (4). Insert thickness gauge B2 in the clearance between rocker arm (5) and crosshead (6) and adjust the valve clearance with adjustment screw (3).
Page 385 30 Testing and adjusting UEN00228-04 Measuring compression pressure a Measuring tools for compression pressure Symbol Part No. Part name 795-502-1590 Compression gauge 795-799-6700 Puller 795-790-4410 Adapter 6754-11-3130 Gasket Stop the machine on a level ground and lower the work equipment to the ground. a Measure the compression pressure under the following condition.
Page 386 UEN00228-04 30 Testing and adjusting Disconnect CE03 connector (5) of the engine After finishing measurement, remove the controller. measuring tools and return the removed parts. a Install the injector and inlet connector If the connector is not disconnected, the engine will start during measure- according to the following procedure.
Page 387 30 Testing and adjusting UEN00228-04 Measuring blow-by pressure a Measuring tools for blow-by pressure Symbol Part No. Part name 799-201-1504 Blow-by checker 799-790-3300 Blow-by tool Stop the machine on a level ground and lower the work equipment to the ground. a Measure the blow-by pressure under the fol- lowing condition.
Page 388 UEN00228-04 30 Testing and adjusting Measuring engine oil pressure a Measuring tools for engine oil pressure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester Stop the machine on a level ground and lower the work equipment to the ground. a Measure the engine oil pressure under the fol- lowing condition.
Page 389 30 seconds after the engine is a Precautions for replacing fuel filter cartridge stopped. Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts cartridge. are removed, the residual pressure in the fuel Since the common rail fuel injection system circuit must be released completely.
Page 390 UEN00228-04 30 Testing and adjusting Measuring fuel pressure a Measuring tools for fuel pressure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester Adapter 6732-81-3170 (10 × 1.0 mm o R1/8) 6215-81-9710 O-ring 799-401-2320 Hydraulic tester Stop the machine on a level ground and lower the work equipment to the ground.
Page 391 30 Testing and adjusting UEN00228-04 Measuring pressure in fuel return circuit Open the engine hood and remove fuel pressure pickup plug (2) from the fuel return block. After finishing measurement, remove the measuring tools and return the removed parts. Fuel pressure pickup plug: Install nipple [3] of hydraulic tester F1 and 24 ±...
Page 392 UEN00228-04 30 Testing and adjusting Measuring fuel return rate and leakage a Measuring tools for fuel return rate and leak- Symbol Part No. Part name (Not set yet) Supply pump testing tool (Not set yet) Pressure limiter testing tool (Not set yet) Injector testing tool Commercially Measuring cylinder...
Page 393 30 Testing and adjusting UEN00228-04 If the engine cannot be started, you may measure the fuel return rate while rotating the engine with the starting motor. Do not rotate for more than 20 seconds continu- ously, however, for protection of the starting motor.
Page 394 UEN00228-04 30 Testing and adjusting Bleeding air from fuel circuit a If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. Stop the machine on a level ground and lower the work equipment to the ground.
Page 395 30 Testing and adjusting UEN00228-04 a Air bleeding route of fuel circuit Fuel tank o Pre-filter o Feed pump o Main filter o Metering unit o Fuel tank PC210, 230, 240-8...
Page 396 UEN00228-04 30 Testing and adjusting Checking fuel circuit for leakage Check the fuel piping and devices for fuel leak- age. Very high pressure is generated in the high- a Check mainly around the high-pressure pressure circuit of the fuel system. If fuel c i r c u i t pa r ts c o a t e d w i t h t h e c o l o u r leaks while the engine is running, it is dan- checker for fuel leakage.
Page 397 30 Testing and adjusting UEN00228-04 Checking and adjusting air Adjusting conditioner compressor belt a If the belt deflection is abnormal, adjust it according to the following procedure. tension Stop the machine on a level ground and Loosen bolts (1) and (2). lower the work equipment to the ground.
Page 398 UEN00228-04 30 Testing and adjusting Measuring swing circle bearing Set the arm almost perpendicular to the ground and lower the boom until the front track clearance shoe floats. a Measuring tools for swing circle bearing clear- a At this time the front of the upper structure ance rises and the rear lowers.
Page 399 30 Testing and adjusting UEN00228-04 Checking and adjusting track Adjusting shoe tension a If the track shoe tension is abnormal, adjust it according to the following procedure. Checking Run the engine at low idle and drive the Increasing tension machine forward by the length of track on Add grease through grease fitting (1) with ground, and then stop slowly.
Page 400 UEN00228-04 30 Testing and adjusting Decreasing tension Loosen valve (2) to discharge grease, and then tighten it. Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the high- pressure grease in it. To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on...
Page 401 30 Testing and adjusting UEN00228-04 Measuring and adjusting oil PC240-8 pressure in work equipment, swing, and travel circuits a Measuring and adjusting tools for oil pressure in work equipment, swing, and travel circuits Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 ×...
Page 402 UEN00228-04 30 Testing and adjusting a The actuators in the table are arranged in the order when the control valve is seen Actuator Valve relieved from the front of the machine (and an (R unload valve) (R main relief valve) attachment is installed to the service Service Safety-suction valve...
Page 403 30 Testing and adjusting UEN00228-04 a The pressure measured when the main the safety-suction valve of the control v a l v e f o r l o w e r i n g t h e b o o m i s relief valve of the control valve is relieved).
Page 404 UEN00228-04 30 Testing and adjusting Approx. 20.5 MPa {Approx. 209 kg/cm While fixing adjustment screw (9), tighten While fixing holder (6), tighten locknut (7). locknut (10). Locknut: 49 – 58.8 Nm {5 – 6 kgm} Locknut: 78 – 103 Nm {8 – 10.5 kgm} Connect pilot hose (5).
Page 405 30 Testing and adjusting UEN00228-04 Measuring control circuit basic Start the engine, set the working mode in the power mode (P), and turn the auto-decelerator pressure OFF. a Measuring tools for control circuit basic pres- sure Run the engine at high idle, set all the levers and pedals for work equipment control, swing Symbol Part No.
Page 406 UEN00228-04 30 Testing and adjusting Measuring and adjusting oil PC210/230-8 pressure in pump PC control circuit a Measuring and adjusting tools for oil pressure in pump PC control circuit Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 ×...
Page 407 30 Testing and adjusting UEN00228-04 After finishing measurement, remove the PC240-8 measuring tools and return the removed parts. Measuring PC-EPC valve output pressure Open the side cover of the pump room and remove oil pressure pickup plugs (5) and (6). (5): Front PC-EPC valve output pressure pickup plug (6): Rear PC-EPC valve output pressure...
Page 408 UEN00228-04 30 Testing and adjusting PC valves (7) and (8) according to the proce- dure shown below. PC240-8 As the working load increases, the engine speed lowers remarkably. The engine speed is normal but the work equipment speed is low. (7): Front pump PC valve (8): Rear pump PC valve a The width across flats of the PC valve locknut...
Page 409 30 Testing and adjusting UEN00228-04 Loosen locknut (9). a Before loosening the locknut, make coun- ter mark at the adjustment screw end so that you can see the position of the lock- nut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
Page 410 UEN00228-04 30 Testing and adjusting Measuring and adjusting oil PC210/230-8 pressure in pump LS control circuit a Measuring and adjusting tools for oil pressure in pump LS control circuit Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2701 Differential pressure gauge 799-101-5220 Nipple (10 ×...
Page 411 30 Testing and adjusting UEN00228-04 a Measuring condition and method of judgment: If the pressures are in the PC240-8 following ratio, the LS valve is normal. Operation of lever and ratio of oil pressures Measured oil All control Travel lever pressure levers and moved half-...
Page 412 UEN00228-04 30 Testing and adjusting (5): Front LS pressure pickup plug (6): Rear LS pressure pickup plug PC210/230-8 PC210/230-8 PC240-8 PC240-8 The figure shows the LS pressure side. Install nipples M3 and connect it to differ- PC210/230-8 ential pressure gauge M2 or the oil pres- sure gauge of hydraulic tester M1.
Page 413 30 Testing and adjusting UEN00228-04 Measuring LS-EPC valve output pressure Run the engine, push up the track shoe on Open the side cover of the pump room the side to be measured with the work and remove oil pressure pickup plug (7). equipment, and prepare for running track shoe idle.
Page 414 UEN00228-04 30 Testing and adjusting Adjusting Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. (8): Front pump LS valve (9): Rear pump LS valve PC210/230-8 Start the engine. Run the engine at high idle, operate the travel speed switch and travel lever, and measure the output pressure in each...
Page 415 30 Testing and adjusting UEN00228-04 Locknut: 49 – 68.6 Nm {5 – 7 kgm} After finishing adjustment, check again that the LS differential pressure is normal according to the above described measurement procedure. PC210, 230, 240-8...
Page 416 UEN00228-04 30 Testing and adjusting a When measuring with hoses (2) – (6), Measuring solenoid valve output remove the undercover of the control pressure valve. a Measuring tools for solenoid valve output pres- sure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter (Size 02) Stop the machine on a level ground and...
Page 417 30 Testing and adjusting UEN00228-04 a If the output pressure is as follows, the solenoid valve is normal. Solenoid valve Output pressure 0 MPa {0 kg/cm (Demagnetization) ON (Excitation) 2.9 MPa {30 kg/cm After finishing measurement, remove the measuring tools and return the removed parts. PC210, 230, 240-8...
Page 418 UEN00228-04 30 Testing and adjusting Operation table of PPC lock solenoid valve Operating condition Operation Lock Lock lever Free Operation table of 2-stage relief solenoid valve Operating condition Operation Overheat 1st setting is ON Overheat 2nd setting is ON All of work equipment, swing, and travel signals are OFF Swing lock switch is ON Travel signal is ON L mode is selected...
Page 419 30 Testing and adjusting UEN00228-04 Measuring PPC valve output pressure Connecting points of PPC piping a The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. The col- ours in ( ) are the colours of the bands installed for distinction of the pipes.
Page 420 UEN00228-04 30 Testing and adjusting a Measuring tools for PPC valve output pressure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter (Size 02) 799-401-3200 Adapter (Size 03) Stop the machine on a level ground and lower the work equipment to the ground.
Page 421 30 Testing and adjusting UEN00228-04 Adjusting play of work equipment and swing PPC valves a If the right and left work equipment levers have large play, adjust them according to the follow- ing procedure. Remove the work equipment and swing PPC valve assembly.
Page 422 UEN00228-04 30 Testing and adjusting Measuring and adjusting quick Adjustment If the regulated pressure is not suitable for the coupler control valve output quick coupler to be installed adjust the pressure of pressure the regulating valve as follows: a Measuring and adjusting tools for oil pressure in quick coupler circuit.
Page 423 30 Testing and adjusting UEN00228-04 Checking parts which cause Checking arm cylinder Stop the arm cylinder about 100 mm before hydraulic drift of work the IN stroke end and stop the engine. equipment a If the work equipment (cylinder) drifts hydrauli- cally, check to see if the cause is on the cylin- d e r p a c k i n g s i d e o r c o n t r o l v a l v e s i d e according to the following procedure.
Page 424 UEN00228-04 30 Testing and adjusting Checking PPC valve While the pressure in the accumulator is high, set the lock lever in the LOCK/FREE position and measure the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 5 seconds to heighten the pressure in the accumulator.
Page 425 30 Testing and adjusting UEN00228-04 Releasing residual pressure from Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is hydraulic circuit released completely. Releasing residual pressure from hydraulic tank Releasing residual pressure from swing Since the hydraulic tank is enclosed motor circuit and pressurized, release the residual...
Page 426 UEN00228-04 30 Testing and adjusting Measuring oil leakage Measuring oil leakage from arm cylinder Move the arm cylinder to the IN stroke end a Measuring tools for oil leakage and stop the engine. Release the residual pressure from Symbol Part No. Part name the piping on the arm cylinder Commercially...
Page 427 30 Testing and adjusting UEN00228-04 Measuring oil leakage from bucket cylinder Measuring oil leakage from swing motor Move the bucket cylinder to the CURL Disconnect 2 drain hoses (4) and block stroke end and stop the engine. the hose side with plugs. a Use the following parts to block the Release the residual pressure from the piping on the bucket cylinder...
Page 428 UEN00228-04 30 Testing and adjusting Measuring oil leakage from travel motor After finishing measurement, return the Remove the travel motor cover. removed parts. Run the engine, lock the travel mecha- nism, and stop the engine. Put pin [1] between the sprocket and track frame to lock the travel mechanism securely.
Page 429 30 Testing and adjusting UEN00228-04 Bleeding air from each part Air bleeding procedure Air bleeding item Bleeding air Checking oil Bleeding air Bleeding air from Starting Bleeding air level and from swing from travel hydraulic engine from cylinder starting Contents of work motor motor pump...
Page 430 UEN00228-04 30 Testing and adjusting Starting engine When running the engine after performing step 1, keep its speed at low idle for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel...
Page 431 30 Testing and adjusting UEN00228-04 While running the engine at high idle, per- Check the oil level by sight gauge (3) on form step 2). the rear side of the hydraulic tank. a If the oil level is below line L, it is While running the engine at low idle, move the piston rod to the stroke end and insufficient.
Page 432 UEN00228-04 30 Testing and adjusting Checking cab tipping stopper a Since the cab tipping stopper is a safety part, check it according to the following procedure. Remove the additional undercover from the rear of the operator's cab. a Perform this step only when the additional undercover is installed.
Page 433 30 Testing and adjusting UEN00228-04 PC210, 230, 240-8...
Page 434 UEN00228-04 30 Testing and adjusting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Adjusting mirrors PC210, 230, 240-8...
Page 435 30 Testing and adjusting UEN00228-04 Installing positions of mirrors Install mirrors (a1) and (b1) as shown in the figure. Mirror (a1): 120 mm (from stay top) Mirror (b1): 100 mm (from stay bottom) Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat.
Page 436 UEN00228-04 30 Testing and adjusting (For PC210 K51095 and up, PC230 K50114 and up, and PC240 K50304 and up.) Adjusting mirrors PC210, 230, 240-8...
Page 437 30 Testing and adjusting UEN00228-04 Installing positions of mirrors Install mirrors (a1) and (b1) as shown in the figure. Mirror (a1): 120 mm (from stay top) Mirror (b1): 100 mm (from stay bottom) Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat.
Page 439 UEN00229-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 30 Testing and adjusting Testing and adjusting, Part 2 Testing and adjusting, Part 2...........................
Page 440 UEN00229-01 30 Testing and adjusting Testing and adjusting, Part 2 Special functions of machine monitor Air conditioner specification PC210, 230, 240-8...
Page 441 30 Testing and adjusting UEN00229-01 Heater specification Upper section of machine monitor (Display sec- tion) (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambi- ent temperature and the condition of the bat- tery.
Page 442 This mode is used for special setting, testing, adjusting, or troubleshooting. Page Page t Operator mode (Outline) Service mode A Display of KOMATSU logo Monitoring A Display of inputting password Mechanical systems Abnormality A Display of check of breaker mode...
Page 443 30 Testing and adjusting UEN00229-01 a Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi- nary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch PC210, 230, 240-8...
Page 444 — — — 3 — KOMATSU logo is displayed for 2 seconds. before starting a After the KOMATSU logo is displayed for 2 Display of ending of maintenance seconds, the screen changes to “Display of — — — — 3 interval inputting password”, “Display of check of...
Page 445 30 Testing and adjusting UEN00229-01 Display of inputting password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective.
Page 446 UEN00229-01 30 Testing and adjusting Display of warning after check before starting Display of check of working mode and travel If any abnormality is detected by the check before speed starting, the warning monitor is displayed on the If the check before starting is finished normally, the screen.
Page 447 30 Testing and adjusting UEN00229-01 Display of end screen Selection of working mode When the starting switch is turned OFF, the end Select a working mode according to the following screen is displayed for 5 seconds. procedure. a Another message may be displayed on the While the ordinary screen is displayed, press end screen, depending on the message dis- the working mode selector switch, and the...
Page 448 UEN00229-01 30 Testing and adjusting When the ordinary screen is displayed again, Selection of travel speed large working mode monitor (a) is displayed for While the ordinary screen is displayed, if the travel 2 seconds, and then the setting of the working speed shifting switch is pressed, large travel speed mode is changed.
Page 449 30 Testing and adjusting UEN00229-01 Operation of windshield wiper Operation of air conditioner/heater While the ordinary screen is displayed, if the wiper While the ordinary screen is displayed, press the air switch is pressed, large wiper monitor (a) is dis- conditioner switch or heater switch, and the air con- played for 2 seconds and the windshield wiper ditioner adjustment screen or heater adjustment...
Page 450 UEN00229-01 30 Testing and adjusting Operation to display camera mode (if camera is Operation to display clock and service meter installed) While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and When a camera is installed, if [F3] is pressed, the clock alternately.
Page 451 30 Testing and adjusting UEN00229-01 (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Check of maintenance information Setting and display of user mode While the maintenance monitor or ordinary screen (Including KOMTRAX messages for user) is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6], screen is displayed.
Page 452 UEN00229-01 30 Testing and adjusting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) Check of maintenance information Setting and display of user mode While the maintenance monitor or ordinary screen (Including KOMTRAX messages for user) is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6], screen is displayed.
Page 453 30 Testing and adjusting UEN00229-01 [KOMTRAX message] Display of energy-saving guidance There are 2 types of KOMTRAX message; 1 is When the machine is set in a certain operating con- for the user and the other is for the service. dition, the energy-saving guidance screen is dis- For user: played automatically to urge the operator to the...
Page 454 UEN00229-01 30 Testing and adjusting Display of automatic judgment of breaker Display of user code and failure code If the operator performs breaker work in an If an abnormality which displays a user code and a improper working mode, the breaker automatic failure code occurs on the ordinary screen or cam- judgment screen is displayed to urge the operator era mode screen, all the information of the abnor-...
Page 455 30 Testing and adjusting UEN00229-01 a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual) User code Failure mode Action When emergency pump drive switch is at the up (emergency) Pump control system error position, normal operations become possible, but have inspection carried out immediately.
Page 456 UEN00229-01 30 Testing and adjusting Function of checking display of LCD (Liquid Function of checking service meter Crystal Display) To check the service meter while the starting switch is turned OFF, operate the numeral input switches While the ordinary screen is displayed, if the follow- as follows.
Page 457 30 Testing and adjusting UEN00229-01 Function of changing attachment/maintenance After the New password input screen is dis- played, input a new password with the numeral password input switches and confirm it with the function When changing the attachment/maintenance pass- switch. word used for the attachment setting function and a Set a new password of 4 –...
Page 458 UEN00229-01 30 Testing and adjusting If the screen to notify completion of setting is displayed and then the ordinary screen is dis- played, the password is changed successfully. PC210, 230, 240-8...
Page 459 30 Testing and adjusting UEN00229-01 a The items which can be selected in the Service mode service menu are as follows (including To change the operator mode to the service mode, some items which need special opera- perform the following operation. tions).
Page 460 UEN00229-01 30 Testing and adjusting Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc.
Page 461 30 Testing and adjusting UEN00229-01 Executing monitoring Changing machine setting mode After the “Executing monitoring screen” is dis- To change the setting of the working mode, played, perform the necessary operation of the travel speed, or auto-deceleration during moni- machine and check the monitoring information. toring, operate the corresponding switch under a Monitoring information is indicated by the current condition, and the mode setting...
Page 462 UEN00229-01 30 Testing and adjusting Monitoring items table Unit (Initial setting: ISO) Com- Code ponent Monitoring item (Display on screen) Remarks meter inch charge 00200 Controller Model Select — PUMP 00201 Machine ID — 01002 Engine speed r/min 01601 2nd Eng. Speed Command r/min PUMP 01100...
Page 463 30 Testing and adjusting UEN00229-01 Unit (Initial setting: ISO) Com- Code ponent Monitoring item (Display on screen) Remarks meter inch charge Swing ON•OFF PUMP Travel ON•OFF PUMP Boom Lower ON•OFF PUMP 01900 Pressure Switch 1 Boom Raise ON•OFF PUMP Arm Curl ON•OFF PUMP Arm Dump...
Page 464 UEN00229-01 30 Testing and adjusting Unit (Initial setting: ISO) Com- Code ponent Monitoring item (Display on screen) Remarks meter inch charge ON•OFF ON•OFF ON•OFF Monitor 3rd & 4th 04505 Row Switches SW10 ON•OFF SW11 ON•OFF SW12 ON•OFF SW13 ON•OFF Monitor 5th Row 04506 SW14 ON•OFF...
Page 465 30 Testing and adjusting UEN00229-01 Abnormality record (Mechanical system abnormality record) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical sys- tems, electrical systems, and air-conditioning sys- tem or heater system.
Page 466 UEN00229-01 30 Testing and adjusting Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset. Abnormality record (Electrical systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical sys- tems, electrical systems, and air-conditioning sys- tem.
Page 467 30 Testing and adjusting UEN00229-01 Resetting abnormality record After the “Electrical sys. error reset” While the “Electrical systems” screen is screen is displayed, operate the function displayed, perform the following operation switches. with the numeral input switches. [F5]: Return to “Electrical systems” Operation of switches (While pressing screen (Reset mode) [4], perform the operation in order):...
Page 468 UEN00229-01 30 Testing and adjusting Failure codes table User Alarm Component Category of Failure code Trouble (Displayed on screen) code buzzer in charge record Electrical 989L00 Engine Controller Lock Caution 1 system Electrical 989M00 Engine Controller Lock Caution 2 system Electrical 989N00 Engine Controller Lock Caution 3...
Page 469 30 Testing and adjusting UEN00229-01 User Alarm Component Category of Failure code Trouble (Displayed on screen) code buzzer in charge record Electrical CA323 Inj #5 (L#5) Open/Short Error system Electrical CA324 Inj #3 (L#3) Open/Short Error system Electrical CA325 Inj #6 (L#6) Open/Short Error system Electrical CA331...
Page 470 UEN00229-01 30 Testing and adjusting User Alarm Component Category of Failure code Trouble (Displayed on screen) code buzzer in charge record Electrical CA2556 Grid Htr Relay Volt Low Error system Electrical D19JKZ Personal Code Relay Abnormality MON2 system Electrical D862KA GPS Antenna Discon MON2 system...
Page 471 30 Testing and adjusting UEN00229-01 User Alarm Component Category of Failure code Trouble (Displayed on screen) code buzzer in charge record Electrical DXA9KA PC-EPC (R) Sol Discon PUMP system Electrical DXA9KB PC-EPC (R) Sol Short PUMP system Electrical DXE0KA LS-EPC Sol Discon PUMP system Electrical...
Page 472 UEN00229-01 30 Testing and adjusting a Entry order of items in table The items are entered in the order of their failure codes (incremental order). a User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis- tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Page 473 30 Testing and adjusting UEN00229-01 Abnormality record (Air-conditioning abnormal- Information displayed on “abnormality record” screen ity record/Heater abnormality record) On the air-conditioning system or heater sys- The machine monitor classifies and records the tem screen, the following information is dis- abnormalities which occurred in the past or which played.
Page 474 UEN00229-01 30 Testing and adjusting a The following items can be selected in the Maintenance record maintenance record. The machine monitor records the maintenance information of the filters, oils, etc., which the opera- 01 Engine oil change tor can display and check by the following opera- 02 Engine oil filter change tions.
Page 475 30 Testing and adjusting UEN00229-01 a The following items can be selected on Change of maintenance mode the Change of maintenance mode screen. The operating condition for maintenance function in the operation mode can be set and changed with 00 Maintenance mode on/off this menu.
Page 476 UEN00229-01 30 Testing and adjusting Contents of setting of each maintenance item Function of initializing all items After selecting each maintenance item, if the After selecting "All default value", if the screen screen is displayed, set the item with the func- is displayed, set with the function switches.
Page 477 30 Testing and adjusting UEN00229-01 a If [F6] is pressed without inputting a digit, Setting of telephone No. there is not information of telephone No. The telephone No. displayed when the user code/ Accordingly, no telephone No. is displayed failure code is displayed in the operator mode can in the operator mode.
Page 478 UEN00229-01 30 Testing and adjusting Default (Working mode with key ON) Mode at previous key-OFF: Final mode in previous operation is displayed when key Check or change various settings related to the is ON machine monitor and machine by "Default". [F3]: Move to lower item The function of working mode with key ON is used [F4]: Move to upper item...
Page 479 30 Testing and adjusting UEN00229-01 a When the machine is delivered, the SI unit Default (Setting of unit) system is set. Check or change various settings related to the machine monitor and machine by "Default". The unit setting function is used to select the unit of the data displayed for monitoring, etc.
Page 480 UEN00229-01 30 Testing and adjusting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). a When an attachment is installed, if this Default (With/Without attachment) setting is not carried out normally, the Check or change various settings related to the attachment cannot be set in the operator machine monitor and machine by "Default".
Page 481 30 Testing and adjusting UEN00229-01 (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) a When an attachment is installed, if this Default (With/Without attachment) setting is not carried out normally, the Check or change various settings related to the attachment cannot be set in the operator machine monitor and machine by "Default".
Page 482 UEN00229-01 30 Testing and adjusting Default (Setting of attachment/maintenance pass- Selecting Disable/Enable After the With/Without attachment screen is word) displayed, select the setting with the function Check or change various settings related to the switches. machine monitor and machine by "Default". Disable : Password screen is not dis- The function of setting attachment/maintenance played...
Page 483 30 Testing and adjusting UEN00229-01 Default (Setting of camera) Selecting camera setting After the camera setting screen is displayed, Check or change various settings related to the select the setting with the function switches. machine monitor and machine by "Default". OFF: Camera is not used The camera setting function is used to set installa- Original image: Image of connected cam-...
Page 484 UEN00229-01 30 Testing and adjusting a If ECO display is turned ON, ECO is dis- Default (Setting of ECO display) played when the screen changes to the Check or change various settings related to the ordinary screen. Even if the energy saving machine monitor and machine by "Default".
Page 485 30 Testing and adjusting UEN00229-01 Default (Setting of Breaker Detect) Selecting display setting After the "Breaker Detect" screen is displayed, Check or change various settings related to the select the setting with the function switches. machine monitor and machine by "Default". [F3]: Move to lower item The function of setting breaker automatic judgment [F4]: Move to upper item...
Page 486 UEN00229-01 30 Testing and adjusting Adjustment (Setting of Pump absorption torque Selecting absorption torque After the "Pump Absorption Torque (F)" screen (F)) is displayed, select a set value on the right side The operator can adjust various items related to the with the function switches.
Page 487 30 Testing and adjusting UEN00229-01 Adjustment (Setting of Pump absorption torque Selecting absorption torque After the "Pump Absorption Torque (R)" screen (R)) is displayed, select a set value on the right side The operator can adjust various items related to the with the function switches.
Page 488 UEN00229-01 30 Testing and adjusting Adjustment (Setting of travel Lo speed) Selecting travel Lo speed After the "Low Speed" setting screen is dis- The operator can adjust various items related to the played, select a set value on the right side with machine with the machine monitor.
Page 489 30 Testing and adjusting UEN00229-01 (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Adjustment (Setting of Attachment flow adjust- Selecting distribution of oil flow After the screen of "Attachment Flow Adjust- ment) ment" is displayed, select a set value on the The operator can adjust various items related to the right side with the function switches.
Page 490 UEN00229-01 30 Testing and adjusting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) Adjustment (Setting of Attachment EPC adjust- Selecting distribution of EPC current After the screen of "Attachment Flow Adjust- ment) ment" is displayed, select a set value on the The operator can adjust various items related to the right side with the function switches.
Page 491 30 Testing and adjusting UEN00229-01 (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) Adjustment (Setting of Attachment EPC1 ~ Selecting distribution of EPC current After the screen of "Attachment Flow Adjust- EPC4 adjustment) ment" is displayed, select a set value on the The operator can adjust various items related to the right side with the function switches.
Page 492 UEN00229-01 30 Testing and adjusting a Relationship between set value and distri- bution of current to attachment EPC. Distribution of flow to Code value attachment -35 mA -30 mA -25 mA -20 mA -15 mA -10 mA -5 mA 0 mA (default) +5 mA +10 mA +15 mA...
Page 493 30 Testing and adjusting UEN00229-01 (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up.) Default (Proportional Spec.) Every machine is defaulted to "Proportional Spec." before it leaves the factory. If a new monitor is installed - follow the procedure below Selecting Proportional Spec.
Page 494 UEN00229-01 30 Testing and adjusting Cylinder Cut-Out operation The operator can perform "Cylinder Cut-Out" oper- ation with the machine monitor. "Cylinder Cut-Out" operation means to run the engine with 1 or more fuel injectors disabled electri- cally to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal).
Page 495 30 Testing and adjusting UEN00229-01 [Reference] No injection cranking If a normally operating cylinder is Cut-Out, If the engine is operated after long storage of the the following phenomena occur. machine, it may be worn or damaged because of 1) Lowering of engine speed insufficient lubrication with oil.
Page 496 UEN00229-01 30 Testing and adjusting Starting no injection cranking Prohibiting no injection cranking If no injection cranking (Fuel injection in no cyl- If the operator tries to perform the no injection inders) becomes effective, that is displayed on cranking while the engine is running, the mes- the screen.
Page 497 30 Testing and adjusting UEN00229-01 Display of fuel consumption Display and function during measurement Clock mark (a) flashes during measurement. This function calculates the hourly fuel consump- a While the fuel consumption is being mea- tion from the actual fuel consumption in a measur- sured, the operator can work with the ing period and indicates it.
Page 498 UEN00229-01 30 Testing and adjusting Display of KOMTRAX (Terminal status) Contents of display of terminal status On the Terminal status screen, the following The setting condition and operating condition of items are displayed. KO M T RAX c an b e c h ec ke d w ith Dis pla y of Terminal type: Model name of KOMTRAX KOMTRAX setting.
Page 499 30 Testing and adjusting UEN00229-01 Display of KOMTRAX (GPS & communication Contents of display of GPS & communication status status) On the screen of GPS & communication sta- The setting condition and operating condition of tus, the following items are displayed. KOMTRAX can be checked with "KOMTRAX Set- Positioning: Positioning condition of GPS tings".
Page 500 UEN00229-01 30 Testing and adjusting Display of KOMTRAX (MODEM S/N: Model Contents of display of Modem S/N The serial No. of TH300 Modem is displayed. TH300) [F5]: Return to KOMTRAX settings screen The setting condition and operating condition of KO M T RAX c an b e c h ec ke d w ith Dis pla y of KOMTRAX setting.
Page 501 30 Testing and adjusting UEN00229-01 Display of KOMTRAX (IP address: Model Contents of display of IP address The telephone No. and IP address (2 systems) TH200) of TH200 MODEM are displayed. The setting condition and operating condition of [F5]: Return to KOMTRAX setting screen K O M TRA X c an be c hec k ed wit h Displa y of a The IP address is a No.
Page 502 UEN00229-01 30 Testing and adjusting Display of KOMTRAX message Display of message (with return mail function) If a box to enter a value with the numeral keys Special messages for the serviceman sent from the is displayed under the message, enter a KOMTRAX base station (a distributor, etc.) can be proper number with the numeral input switches checked with this function.
Page 503 30 Testing and adjusting UEN00229-01 PC210, 230, 240-8...
Page 505 UEN00230-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 30 Testing and adjusting Testing and adjusting, Part 3 Testing and adjusting, Part 3...........................
Page 506 UEN00230-00 30 Testing and adjusting Testing and adjusting, Part 3 Handling high-voltage circuit of engine controller The engine controller uses a high-voltage circuit (max. 65 V) to drive the injector. Accordingly, the high-voltage circuit is con- nected to the wiring harnesses and connec- tors between the engine controller and injector.
Page 507 30 Testing and adjusting UEN00230-00 Preparation work for Insert or connect troubleshooting T-adapt- ers in or to connectors CM01, CM02, and troubleshooting of electrical CM03 of machine monitor (4). system a Connectors CM02 and CM03 are of a When carrying out troubleshooting of an elec- the same type.
Page 508 UEN00230-00 30 Testing and adjusting a The connectors of the pump control- Pump controller Slide the operator's seat and seat stand to ler have a special locking mecha- the forward end. nism. Disconnect them according to Remove the 5 mounting bolts and cool & steps (a) –...
Page 509 30 Testing and adjusting UEN00230-00 a Removal and installation of sensor Connect troubleshooting T-adapters to con- nectors CK01 and CK02 of KOMTRAX A deep socket is necessary for removal communication module (13). and installation of the engine oil pressure a Cable (14) is for the communication switch.
Page 510 UEN00230-00 30 Testing and adjusting Supply pump IMV solenoid (FUEL REGU- Engine coolant temperature sensor (COOL- LATOR) ANT TEMP) a Disconnection and connection of con- a Disconnection and connection of con- nector nector The connector of the supply pump IMV The connector of the engine coolant tem- solenoid has a special locking mecha- perature sensor has a special locking...
Page 511 30 Testing and adjusting UEN00230-00 Procedure for testing diodes a Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure. a The conductive directions of the assembled- type diode are as follows. When using analog circuit tester Set the tester in the resistance range.
Page 512 UEN00230-00 30 Testing and adjusting PC210, 230, 240-8...
Page 513 30 Testing and adjusting UEN00230-00 Pm Clinic service Model name Serial No. Service meter T PC210/LC/NLC-8 T PC230NHD-8 User's name Date of execution Inspector Specifications Main components Attachments Shoe width T Standard T ( T Breaker T 600 mm Boom T Standard T ( T 700 mm Bucket T Standard T (...
Page 514 UEN00230-00 30 Testing and adjusting Items related to engine PC210, 230, 240-8...
Page 515 30 Testing and adjusting UEN00230-00 Items related to oil pressure Warning Test points reversed on PC210 / 230-8 pump PC210, 230, 240-8...
Page 516 UEN00230-00 30 Testing and adjusting Check sheet (PC210/LC/NLC-8/PC230NHD-8) Model Serial No. Service meter User's name Date of execution Inspector Engine Checking condition Standard Mea- Service limit Fuel Work- Auto- Operation of Check item Unit value for new sured Left knob value control decel-...
Page 517 30 Testing and adjusting UEN00230-00 Hydraulic drift of work equipment Checking condition Standard Mea- Service limit Fuel Work- Check item Unit value for new sured value control Checking posture, etc. machine value dial mode Boom top horizontal Hydraulic drift of Engine stopped Arm cylinder retracted fully Max.
Page 518 UEN00230-00 30 Testing and adjusting * Gauge changing work: Change hoses of gauges [3] and [4]. [3a] [4a] Checking condition 600K 600K 600K 600K Check item Fuel Work- Left knob Operation of work F pump R pump F pump R pump control Control switch...
Page 519 30 Testing and adjusting UEN00230-00 Pm Clinic service Model name Serial No. Service meter T PC240LC/NLC-8 User's name Date of execution Inspector Specifications Main components Attachments Shoe width T Standard T ( T Breaker T 600 mm Boom T Standard T ( T 700 mm Bucket T Standard T ( Check of oil/coolant level...
Page 520 UEN00230-00 30 Testing and adjusting Items related to engine PC210, 230, 240-8...
Page 521 30 Testing and adjusting UEN00230-00 Items related to engine PC210, 230, 240-8...
Page 522 UEN00230-00 30 Testing and adjusting Check sheet (PC240LC/NLC-8) Model Serial No. Service meter User's name Date of execution Inspector Engine Checking condition Standard Mea- Service limit Fuel Work- Auto- Operation of Check item Unit value for new sured Left knob value control decel-...
Page 523 30 Testing and adjusting UEN00230-00 Hydraulic drift of work equipment Checking condition Standard Mea- Service limit Fuel Work- Check item Unit value for new sured value control Checking posture, etc. machine value dial mode Boom top horizontal Hydraulic drift of Engine stopped Arm cylinder retracted fully Max.
Page 524 UEN00230-00 30 Testing and adjusting * Gauge changing work: Change hoses of gauges [3] and [4]. [3a] [4a] Checking condition 600K 600K 600K 600K Check item Fuel Work- Left knob Operation of work F pump R pump F pump R pump control Control switch...
Page 525 30 Testing and adjusting UEN00230-00 PC210, 230, 240-8...
Page 527 UEN00231-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting General information on troubleshooting General information on troubleshooting......................
Page 528 UEN00231-03 40 Troubleshooting General information on troubleshooting Points to remember when troubleshooting Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
Page 529 40 Troubleshooting UEN00231-03 Sequence of events in troubleshooting PC210, 230, 240-8...
Page 530 UEN00231-03 40 Troubleshooting Check before troubleshooting Item Criterion Remedy 1. Check of level and type of fuel — Add fuel 2. Check of fuel for foreign matter — Clean and drain 3. Check of hydraulic oil level Between H – L Add oil 4.
Page 531 40 Troubleshooting UEN00231-03 Classification and procedures for troubleshooting Classification for troubleshooting Mode Contents Display of code Troubleshooting by failure code E-mode Troubleshooting of electrical system H-mode Troubleshooting of hydraulic and mechanical system S-mode Troubleshooting of engine Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section.
Page 532 UEN00231-03 40 Troubleshooting Phenomena looking like troubles and troubleshooting Nos. Troubleshooting Phenomena looking like troubles Display E-mode H-mode S-mode of code Phenomena related to user code/failure code User code and failure code are displayed on ordinary screen of machine monitor Accord- When abnormality record is checked, failure code is displayed in ing to dis-...
Page 533 40 Troubleshooting UEN00231-03 Troubleshooting Phenomena looking like troubles Display E-mode H-mode S-mode of code 35 Time lag of work equipment is large H-12 When part of work equipment is relieved singly, other parts of work H-13 equipment move 37 Power maximizing function does not work H-14 38 Attachment circuit is not changed (when attachment is installed) H-29...
Page 534 UEN00231-03 40 Troubleshooting Troubleshooting Phenomena looking like troubles Display E-mode H-mode S-mode of code 69 Machine monitor cannot be set in service mode E-25 70 Monitoring function does not display lever control signal normally E-26 Other phenomena 71 KOMTRAX system does not operate normally E-27 PC210, 230, 240-8...
Page 535 40 Troubleshooting UEN00231-03 How to read electric wire code a In this section, electric wire codes specific to PC210 and PC240 are explained. In the electric circuit diagram, the material, thickness, and colour of each electric wire are indicated by sym- bols.
Page 536 UEN00231-03 40 Troubleshooting Dimensions AVS, AV, AEX, AVSS (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/ 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 Diameter of strand Conductor Sectional area 0.51 0.56 0.76 0.88 1.27...
Page 537 40 Troubleshooting UEN00231-03 Colour codes table (Table 4) Colour Code Colour of wire Colour Code Colour of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
Page 538 UEN00231-03 40 Troubleshooting Connection table for connector pin numbers a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. X type connector No.of T-adapter pins Male (female housing) Female (male housing)
Page 539 40 Troubleshooting UEN00231-03 SWP type connector No.of T-adapter pins Male (female housing) Female (male housing) Part No. 799-601-7050 Part No.: 08055-10681 Part No.: 08055-10691 799-601-7060 Part No.: 08055-10881 Part No.: 08055-10891 799-601-7310 Part No.: 08055-11281 Part No.: 08055-11291 799-601-7070 Part No.: 08055-11481 Part No.: 08055-11491 PC210, 230, 240-8...
Page 540 UEN00231-03 40 Troubleshooting SWP type connector No. of T-adapter pins Male (female housing) Female (male housing) Part No. 799-601-7320 Part No.: 08055-11681 Part No.: 08055-11691 Terminal part No.: Terminal part No.: • Electric wire size: 0.85 • Electric wire size: 0.85 —...
Page 541 40 Troubleshooting UEN00231-03 M type connector No.of T-adapter Part pins Male (female housing) Female (male housing) Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080 799-601-7090 Part No.: 08056-00271 Part No.: 08056-00281 799-601-7110 Part No.: 08056-00371 Part No.: 08056-00381 799-601-7120 Part No.: 08056-00471 Part No.: 08056-00481 799-601-7130 Part No.: 08056-00671...
Page 542 UEN00231-03 40 Troubleshooting S type connector No.of T-adapter pins Male (female housing) Female (male housing) Part No. 799-601-7140 Part No.: 08056-10871 Part No.: 08056-10881 (White 799-601-7150 Part No.: 08056-11071 Part No.: 08056-11081 (White 799-601-7350 Part No.: 08056-11271 Part No.: 08056-11281 (White 799-601-7330 Part No.: 08056-11671...
Page 543 40 Troubleshooting UEN00231-03 S type connector No.of T-adapter pins Male (female housing) Female (male housing) Part No. — (Blue) — — 799-601-7160 (Blue) Part No.: 08056-11272 Part No.: 08056-11282 799-601-7170 (Blue) Part No.: 08056-11672 Part No.: 08056-11682 PC210, 230, 240-8...
Page 544 UEN00231-03 40 Troubleshooting MIC type connector No.of T-adapter Part pins Male (female housing) Female (male housing) Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) — Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —...
Page 545 40 Troubleshooting UEN00231-03 MIC type connector No.of T-adapter Part pins Male (female housing) Female (male housing) 799-601-2730 Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2) 799-601-2740 Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2) Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760 —...
Page 546 UEN00231-03 40 Troubleshooting AMP040 type connector No.of T-adapter Part pins Male (female housing) Female (male housing) 799-601-7180 — Housing part No.: 79A-222-3430 (Q’ty: 5) 799-601-7190 — Housing part No.: 79A-222-3440 (Q’ty: 5) 799-601-7210 — Housing part No.: 79A-222-3450 (Q’ty: 5) 799-601-7220 —...
Page 547 40 Troubleshooting UEN00231-03 AMP070 type connector No.of T-adapter Part pins Male (female housing) Female (male housing) 799-601-7510 — Part No.: 08195-10210 799-601-7520 — Part No.: 08195-12210 799-601-7530 — Part No.: 08195-14210 799-601-7540 — Part No.: 08195-18210 799-601-7550 — Part No.: 08195-20210 PC210, 230, 240-8...
Page 548 UEN00231-03 40 Troubleshooting L type connector No.of T-adapter Part pins Male (female housing) Female (male housing) — — — Connector for PA No.of T-adapter Part pins Male (female housing) Female (male housing) — — — Bendix MS connector No.of T-adapter Part pins Male (female housing) Female (male housing)
Page 549 40 Troubleshooting UEN00231-03 KES 1 (Automobile) connector No.of T-adapter Part pins Male (female housing) Female (male housing) — Part No.: 08027-10210 (Natural colour) Part No.: 08027-10260 (Natural colour) 08027-10220 (Black) 08027-10270 (Black) — Part No.:08027-10310 Part No.:08027-10360 — Part No.: 08027-10410 (Natural colour) Part No.: 08027-10460 (Natural colour) 08027-10420 (Black) 08027-10470 (Black)
Page 550 UEN00231-03 40 Troubleshooting KES 1 (Automobile) connector No.of T-adapter Part pins Male (female housing) Female (male housing) — Part No.: 08027-10810 (Natural colour) Part No.: 08027-10860 (Natural colour) 08027-10820 (Black) 08027-10870 (Black) Connector for relay (Socket type) No.of T-adapter Part pins Male (female housing) Female (male housing)
Page 551 40 Troubleshooting UEN00231-03 F type connector No.of T-adapter pins Male (female housing) Female (male housing) Part No. — — — PC210, 230, 240-8...
Page 552 UEN00231-03 40 Troubleshooting [The pin No. is also marked on the connector (electric wire insertion end)] Type HD30 Series connector (shell T-adapter size Body (plug) Body (receptacle) Part No. code) Pin (male terminal) Pin (female terminal) 799-601-9210 Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102, 08191-11205, 08191-11206 08191-14105, 08191-14106...
Page 553 40 Troubleshooting UEN00231-03 [The pin No. is also marked on the connector (electric wire insertion end)] Type HD30 Series connector (shell T-adapter size Body (plug) Body (receptacle) Part No. code) Pin (male terminal) Pin (female terminal) 799-601-9230 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102 18-20 Pin (female terminal)
Page 554 UEN00231-03 40 Troubleshooting [The pin No. is also marked on the connector (electric wire insertion end)] Type HD30 Series connector (shell T-adapter size Body (plug) Body (receptacle) Part No. code) Pin (male terminal) Pin (female terminal) 799-601-9250 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102 24-9 Pin (female terminal)
Page 555 40 Troubleshooting UEN00231-03 [The pin No. is also marked on the connector (electric wire insertion end)] Type HD30 Series connector (shell T-adapter size Body (plug) Body (receptacle) Part No. code) Pin (male terminal) Pin (female terminal) 799-601-9270 Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102, 08191-71205, 08191-71206 08191-74105, 08191-74106...
Page 556 UEN00231-03 40 Troubleshooting [The pin No. is also marked on the connector (electric wire insertion end)] Type HD30 Series connector (shell T-adapter size Body (plug) Body (receptacle) Part No. code) Pin (male terminal) Pin (female terminal) 799-601-9290 Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104, 08191-91205, 08191-91206 08191-94105, 08191-94106...
Page 557 40 Troubleshooting UEN00231-03 [The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector No.of T-adapter pins Body (plug) Body (receptacle) Part No. 799-601-9020 Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type) 08192-22200 (fine wire type) 08192-22100 (fine wire type) 799-601-9030 Part No.: 08192-13200 (normal type)
Page 558 UEN00231-03 40 Troubleshooting [The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector No.of pins Body (plug) Body (receptacle) T-adapter Part No. 8GR: 799-601-9060 799-601-9070 799-601-9080 8BR: 799-601-9090 Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type) 08192-2820 (fine wire type)
Page 559 40 Troubleshooting UEN00231-03 [The pin No. is also marked on the connector (electric wire insertion end)] DTP Series connector No.of pins Body (plug) Body (receptacle) T-adapter Part No. 799-601-4260 Part No.:6261-81-2810 [The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector No.of T-adapter Part...
Page 560 UEN00231-03 40 Troubleshooting [The pin No. is also marked on the connector (electric wire insertion end)] DRC26 Series connector No.of T-adapter Part pins Male pin (female housing) Female pin (male housing) 799-601-9360 (Kit: 799-601-9300) — Part No.:08194-01101 799-601-9350 (Kit: 799-601-9300) —...
Page 561 40 Troubleshooting UEN00231-03 DRC26 Series connector No.of T-adapter Part pins Male pin (female housing) Female pin (male housing) 799-601-4390 -06a — Part No.: 207-06-K1050 06: Key position The pin No. is also marked on the connector (electric wire insertion end)] DRC12, 16 Series connector No.of T-adapter Part...
Page 562 UEN00231-03 40 Troubleshooting AMP connector for pump controller (CH700) N o . o f T-adapter Part Controller side (plug) pins — Harness side (receptacle) Part No.:7880-70-9040 799-601-4280 Controller side (plug) — Harness side (receptacle) Part No.:7880-70-9010 PC210, 230, 240-8...
Page 563 40 Troubleshooting UEN00231-03 BOSCH connector for engine Boost (air intake) pressure and temperature sensor (95 engine) N o . o f T-adapter Part pins Sensor side (plug) Harness side (receptacle) 799-601-4380 — — Common rail (fuel) pressure sensor (95, 107, 114 engine) Sensor side (plug) Harness side (receptacle) 799-601-4190...
Page 564 UEN00231-03 40 Troubleshooting SUMITOMO connector for engine Boost (air intake) pressure and temperature sensor (107, 114 engine) N o . o f T-adapter Part pins Sensor side (plug) Harness side (receptacle) 799-601-4230 (Kit: 799-601-4101) (Kit: 799-601-4201) — — Boost (air intake) pressure sensor (125, 170, 12V140 engine) Sensor side (plug) Harness side (receptacle) 799-601-4250...
Page 565 40 Troubleshooting UEN00231-03 CANNON connector for engine Boost (air intake) pressure and temperature sensor (140 engine) N o . o f T-adapter Part pins Sensor side (plug) Harness side (receptacle) 799-601-4110 (Kit: 799-601-4101) (Kit: 799-601-4201) A Without pin (4) A Without pin (4) AMP connector for engine Common rail (fuel) sensor (125, 140, 170, 12V140 engine) N o .
Page 566 UEN00231-03 40 Troubleshooting FRAMTOME connector for engine Ambient pressure sensor (107, 114 engine) N o . o f T-adapter Part pins Sensor side (plug) Harness side (receptacle) 799-601-4140 (Kit: 799-601-4101) (Kit: 799-601-4201) — — NE speed sensor (95, 107, 114, 125, 140, 170, 12V140 engine) and CAM sensor (95, 107, 114 engine) Sensor side (plug) Harness side (receptacle) 799-601-4130...
Page 567 40 Troubleshooting UEN00231-03 FRAMTOME connector for engine Hydraulic switch (95, 107, 114 engine) N o . o f T-adapter Part pins Switch side (plug) Harness side (receptacle) 799-601-4160 (Kit: 799-601-4101) (Kit: 799-601-4201) A Without pin (2) A Without pin (2) PACKARD connector for engine Temperature sensor of coolant, fuel and lubricating oil (95, 107, 114, 125, 140, 170, 12V140 engine) N o .
Page 568 UEN00231-03 40 Troubleshooting DT series connector for engine WIF (water in fuel) sensor (107, 114, engine) N o . o f T-adapter Part pins Body (plug) Body (receptacle) 799-601-9020 (Kit: 799-601-4101) (Kit: 799-601-4201) Part No. :08192-12200 (normal type) Part No. :08192-12100 (normal type) 08192-22200 (fine wire type) 08192-22100 (fine wire type) EGR (by-pass) valve stroke sensor (125, 140, 170, engine)
Page 569 40 Troubleshooting UEN00231-03 T-boxes and T-adapters table a The Nos. in the columns are the part Nos. of the T-boxes, T-adapters, and other parts. The Nos. in the lines are the kit Nos. of the T-adapter kits. T-adapter kit Identifica- Part No.
Page 570 UEN00231-03 40 Troubleshooting T-adapter kit Identifica- Part No. Part name tion sym- q q q 799-601-7060 Adapter for SWP SW8P 799-601-7310 Adapter for SWP SW12P 799-601-7070 Adapter for SWP SW14P 799-601-7320 Adapter for SWP SW16P 799-601-7080 Adapter for M (T-adapter) q q q 799-601-7090 Adapter for M q q q...
Page 571 40 Troubleshooting UEN00231-03 T-adapter kit Identifica- Part No. Part name tion sym- 799-601-9220 Adapter for HD30-18 D18-14 799-601-9230 Adapter for HD30-18 D18-20 799-601-9240 Adapter for HD30-18 D18-21 799-601-9250 Adapter for HD30-24 D24-9 799-601-9260 Adapter for HD30-24 D24-16 799-601-9270 Adapter for HD30-24 D24-21 799-601-9280 Adapter for HD30-24 D24-23...
Page 572 UEN00231-03 40 Troubleshooting T-adapter kit Identifica- Part No. Part name tion sym- Socket for engine (CRI-T3) 799-601-4230* 1,2,3,4 Air intake pressure/temp. 799-601-4260 Adapter for controller (ENG) DTP4 799-601-4211 Adapter for controller (ENG) DRC50 Socket for engine (CR1-T3) - 799-601-4380 (95) 1,2,3,4T Air intake pressure/temp.
Page 573 40 Troubleshooting UEN00231-03 PC210, 230, 240-8...
Page 575 UEN00240-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 576 UEN00240-01 40 Troubleshooting Failure code [CA111] EMC Critical Internal Failure ................22 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............... 23 Failure code [CA122] Chg Air Press Sensor High Error..............24 Failure code [CA123] Chg Air Press Sensor Low Error ..............26 Failure code [CA131] Throttle Sensor High Error................
Page 577 40 Troubleshooting UEN00240-01 Troubleshooting by failure code (Display of code), Part 1 Failure codes table User Alarm Device in Category Failure code Trouble (Displayed on screen) code buzzer charge of history Electrical 989L00 Engine Controller Lock Caution 1 system Electrical 989M00 Engine Controller Lock Caution 2 system...
Page 578 UEN00240-01 40 Troubleshooting User Alarm Device in Category Failure code Trouble (Displayed on screen) code buzzer charge of history Electrical CA227 Sens Supply 2 Volt High Error system Mechani- CA234 Eng Overspeed cal system Electrical CA238 Ne Speed Sens Supply Volt Error system Electrical CA271...
Page 579 40 Troubleshooting UEN00240-01 User Alarm Device in Category Failure code Trouble (Displayed on screen) code buzzer charge of history Electrical CA559 Rail Press Low Error system Electrical CA689 Eng Ne Speed Sensor Error system Electrical CA731 Eng Bkup Speed Sens Phase Error system Electrical CA757...
Page 580 UEN00240-01 40 Troubleshooting User Alarm Device in Category Failure code Trouble (Displayed on screen) code buzzer charge of history Electrical DHSAMA Swing RH PPC Press Sensor Abnormality PUMP system Electrical DHSBMA Swing LH PPC Press Sensor Abnormality PUMP system Electrical DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP...
Page 581 40 Troubleshooting UEN00240-01 User Alarm Device in Category Failure code Trouble (Displayed on screen) code buzzer charge of history Electrical DXE6KB Merge-divider LS Sol Short PUMP system Electrical DY20KA Wiper Working Abnormality PUMP system Electrical DY20MA Wiper Parking Abnormality PUMP system Electrical DY2CKA...
Page 582 UEN00240-01 40 Troubleshooting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Before carrying out troubleshooting when failure code is displayed Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions).
Page 583 40 Troubleshooting UEN00240-01 (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up) Before carrying out troubleshooting when failure code is displayed Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions).
Page 584 UEN00240-01 40 Troubleshooting Locations of fusible links PC240 PC210 / 230 Location of fuse box and fuse Nos. PC210, 230, 240-8...
Page 585 40 Troubleshooting UEN00240-01 Troubles that occur when power supply of pump controller is defective a The controller power supply (F01-17) of the pump controller drives the controller system. Accordingly, if it is turned off, the controller cannot control the system and the troubles shown below occur simulta- neously (The following is an example of the troubles).
Page 586 UEN00240-01 40 Troubleshooting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Troubles that occur when power supply of pump controller is defective a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids and relays.
Page 587 40 Troubleshooting UEN00240-01 (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up). Troubles that occur when power supply of pump controller is defective a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids and relays.
Page 588 UEN00240-01 40 Troubleshooting Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code Failure code Display on Trouble Trouble name displayed in abnormality record machine monitor Display on machine machine moni- monitor...
Page 589 40 Troubleshooting UEN00240-01 Related circuit diagram This drawing is a part of the electric circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/merg- ing point: Shows the ends of branch or source of merging within the parts of the same wiring harness.
Page 590 UEN00240-01 40 Troubleshooting Failure code [989L00] Engine Controller Lock Caution 1 User code Failure code Engine controller lock caution 1 Trouble (Machine monitor system) — 989L00 Contents of • Engine controller lock is detected (Factor 1). trouble Action of • None in particular. machine monitor •...
Page 591 40 Troubleshooting UEN00240-01 Failure code [989N00] Engine Controller Lock Caution 3 User code Failure code Engine controller lock caution 3 Trouble (Machine monitor system) — 989N00 Contents of • Engine controller lock is detected (Factor 3). trouble Action of • Tries automatic resetting. machine monitor •...
Page 592 UEN00240-01 40 Troubleshooting Failure code [AB00KE] Charge Voltage Low User code Failure code Charge voltage low Trouble (Machine monitor system) — AB00KE Contents of • While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V). trouble Action of •...
Page 593 40 Troubleshooting UEN00240-01 Circuit diagram related to preheating/starting of engine and charge of battery PC210, 230, 240-8...
Page 594 UEN00240-01 40 Troubleshooting Failure code [B@BAZG] Eng Oil Press. Low User code Failure code Engine oil pressure low Trouble (Engine controller system) — B@BAZG Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres- trouble sure (sensor contact opened).
Page 595 40 Troubleshooting UEN00240-01 Failure code [B@BCNS] Eng Water Overheat User code Failure code Engine coolant overheat Trouble (Engine controller system) — B@BCNS Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating trouble of engine coolant (above about 102°C). Action of •...
Page 596 UEN00240-01 40 Troubleshooting Failure code [B@HANS] Hydr Oil Overheat User code Failure code Hydraulic oil overheat Trouble (Pump controller system) — B@HANS Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of trouble hydraulic oil (above about 102°C).
Page 597 40 Troubleshooting UEN00240-01 Failure code [CA115] Eng Ne and Bkup Speed Sens Error User code Failure code Engine Ne and Bkup speed sensor error Trouble (Engine controller system) CA115 Contents of • Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal. trouble Action of •...
Page 598 UEN00240-01 40 Troubleshooting Failure code [CA122] Chg Air Press Sensor High Error User code Failure code Charge air pressure sensor high error Trouble (Engine controller system) CA122 Contents of • Pressure signal circuit of boost pressure/temperature sensor detected high voltage. trouble Action of •...
Page 599 40 Troubleshooting UEN00240-01 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC210, 230, 240-8...
Page 600 UEN00240-01 40 Troubleshooting Failure code [CA123] Chg Air Press Sensor Low Error User code Failure code Charge air pressure sensor low error Trouble (Engine controller system) CA123 Contents of • Pressure signal circuit of boost pressure/temperature sensor detected low voltage. trouble Action of •...
Page 601 40 Troubleshooting UEN00240-01 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC210, 230, 240-8...
Page 602 UEN00240-01 40 Troubleshooting Failure code [CA131] Throttle Sensor High Error User code Failure code Throttle sensor high error Trouble (Engine controller system) CA131 Contents of • Signal circuit of fuel control dial detected high voltage. trouble • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just Action of before detection of trouble and continues operation.
Page 603 40 Troubleshooting UEN00240-01 Circuit diagram related to fuel control dial PC210, 230, 240-8...
Page 604 UEN00240-01 40 Troubleshooting Failure code [CA132] Throttle Sensor Low Error User code Failure code Throttle sensor low error Trouble (Engine controller system) CA132 Contents of • Signal circuit of fuel control dial detected low voltage. trouble • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just Action of before detection of trouble and continues operation.
Page 605 40 Troubleshooting UEN00240-01 Circuit diagram related to fuel control dial PC210, 230, 240-8...
Page 606 UEN00240-01 40 Troubleshooting Failure code [CA144] Coolant Temp Sens High Error User code Failure code Coolant temperature sensor high error Trouble (Engine controller system) CA144 Contents of • Signal circuit of coolant temperature sensor detected high voltage. trouble Action of •...
Page 607 40 Troubleshooting UEN00240-01 Circuit diagram related to coolant temperature sensor PC210, 230, 240-8...
Page 608 UEN00240-01 40 Troubleshooting Failure code [CA145] Coolant Temp Sens Low Error User code Failure code Coolant temperature sensor low error Trouble (Engine controller system) CA145 Contents of • Signal circuit of coolant temperature sensor detected low voltage. trouble Action of •...
Page 609 40 Troubleshooting UEN00240-01 Circuit diagram related to coolant temperature sensor PC210, 230, 240-8...
Page 610 UEN00240-01 40 Troubleshooting Failure code [CA153] Chg Air Temp Sensor High Error User code Failure code Charge air temperature sensor high error Trouble (Engine controller system) CA153 Contents of • Temperature signal circuit of boost pressure/temperature sensor detected high voltage. trouble Action of •...
Page 611 40 Troubleshooting UEN00240-01 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC210, 230, 240-8...
Page 612 UEN00240-01 40 Troubleshooting Failure code [CA154] Chg Air Temp Sensor Low Error User code Failure code Charge air temperature sensor low error Trouble (Engine controller system) CA154 Contents of • Temperature signal circuit of boost pressure/temperature sensor detected low voltage. trouble Action of •...
Page 613 40 Troubleshooting UEN00240-01 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC210, 230, 240-8...
Page 614 UEN00240-01 40 Troubleshooting Failure code [CA155] Chg Air Temp High Speed Derate User code Failure code Charge air temperature high speed derate Trouble (Engine controller system) CA155 Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit. trouble Action of •...
Page 615 40 Troubleshooting UEN00240-01 PC210, 230, 240-8...
Page 616 UEN00240-01 40 Troubleshooting Failure code [CA187] Sens Supply 2 Volt Low Error User code Failure code Sensor power supply 2 voltage low error Trouble (Engine controller system) CA187 Contents of • Low voltage was detected in sensor power supply 2 circuit. trouble •...
Page 617 40 Troubleshooting UEN00240-01 Circuit diagram related to sensor power supply 2 PC210, 230, 240-8...
Page 618 UEN00240-01 40 Troubleshooting Failure code [CA221] Ambient Press Sens High Error User code Failure code Ambient pressure sensor high error Trouble (Engine controller system) CA221 Contents of • High voltage was detected in signal circuit of ambient pressure sensor. trouble Action of •...
Page 619 40 Troubleshooting UEN00240-01 Circuit diagram related to ambient pressure sensor PC210, 230, 240-8...
Page 620 UEN00240-01 40 Troubleshooting Failure code [CA222] Ambient Press Sens Low Error User code Failure code Ambient pressure sensor low error Trouble (Engine controller system) CA222 Contents of • Low voltage was detected in signal circuit of ambient pressure sensor. trouble Action of •...
Page 621 40 Troubleshooting UEN00240-01 Circuit diagram related to ambient pressure sensor PC210, 230, 240-8...
Page 622 UEN00240-01 40 Troubleshooting Failure code [CA227] Sens Supply 2 Volt High Error User code Failure code Sensor power supply 2 voltage high error Trouble (Engine controller system) CA227 Contents of • High voltage was detected in sensor power supply 2 circuit. trouble •...
Page 623 40 Troubleshooting UEN00240-01 Failure code [CA234] Eng Overspeed User code Failure code Engine overspeed Trouble (Engine controller system) — CA234 Contents of • Engine speed exceeded control upper speed limit. trouble Action of • Stops injection until engine speed lowers to normal level. controller Problem that appears on...
Page 624 UEN00240-01 40 Troubleshooting Failure code [CA238] Ne Speed Sens Supply Volt Error User code Failure code Ne speed sensor power supply voltage error Trouble (Engine controller system) CA238 Contents of • Low voltage was detected in power supply circuit of engine Ne speed sensor. trouble Action of •...
Page 625 40 Troubleshooting UEN00240-01 Failure code [CA271] IMV/PCV1 Short Error User code Failure code IMV/PCV1 short circuit error Trouble (Engine controller system) CA271 Contents of • Short circuit was detected in drive circuit of supply pump actuator. trouble Action of • None in particular. controller •...
Page 626 UEN00240-01 40 Troubleshooting Failure code [CA272] IMV/PCV1 Open Error User code Failure code IMV/PCV1 open error Trouble (Engine controller system) CA272 Contents of • Opening was detected in drive circuit of supply pump actuator. trouble Action of • None in particular. controller Problem that •...
Page 627 40 Troubleshooting UEN00240-01 PC210, 230, 240-8...
Page 628 UEN00240-01 40 Troubleshooting Failure code [CA322] Inj #1 (L#1) Open/Short Error User code Failure code Injector #1 (L#1) open/short circuit error Trouble (Engine controller system) CA322 Contents of • Opening or short circuit was detected in drive circuit of No. 1 injector. trouble Action of •...
Page 629 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 1 injector PC210, 230, 240-8...
Page 630 UEN00240-01 40 Troubleshooting Failure code [CA323] Inj #5 (L#5) Open/Short Error User code Failure code Injector #5 (L#5) open/short circuit error Trouble (Engine controller system) CA323 Contents of • Opening or short circuit was detected in drive circuit of No. 5 injector. trouble Action of •...
Page 631 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 5 injector PC210, 230, 240-8...
Page 632 UEN00240-01 40 Troubleshooting Failure code [CA324] Inj #3 (L#3) Open/Short Error User code Failure code Injector #3 (L#3) open/short circuit error Trouble (Engine controller system) CA324 Contents of • Opening or short circuit was detected in drive circuit of No. 3 injector. trouble Action of •...
Page 633 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 3 injector PC210, 230, 240-8...
Page 634 UEN00240-01 40 Troubleshooting Failure code [CA325] Inj #6 (L#6) Open/Short Error User code Failure code Injector #6 (L#6) open/short circuit error Trouble (Engine controller system) CA325 Contents of • Opening or short circuit was detected in drive circuit of No. 6 injector. trouble Action of •...
Page 635 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 6 injector PC210, 230, 240-8...
Page 636 UEN00240-01 40 Troubleshooting Failure code [CA331] Inj #2 (L#2) Open/Short Error User code Failure code Injector #2 (L#2) open/short circuit error Trouble (Engine controller system) CA331 Contents of • Opening or short circuit was detected in drive circuit of No. 2 injector. trouble Action of •...
Page 637 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 2 injector PC210, 230, 240-8...
Page 638 UEN00240-01 40 Troubleshooting Failure code [CA332] Inj #4 (L#4) Open/Short Error User code Failure code Injector #4 (L#4) open/short circuit error Trouble (Engine controller system) CA332 Contents of • Opening or short circuit was detected in drive circuit of No. 4 injector. trouble Action of •...
Page 639 40 Troubleshooting UEN00240-01 Circuit diagram related to No. 4 injector PC210, 230, 240-8...
Page 641 UEN00241-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 642 UEN00241-01 40 Troubleshooting Failure code [CA553] Rail Press High Error..................26 Failure code [CA559] Rail Press Low Error..................27 Failure code [CA689] Eng Ne Speed Sensor Error ................28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..............30 Failure code [CA757] All Continuous Data Lost Error ................
Page 643 40 Troubleshooting UEN00241-01 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA342] Calibration Code Incompatibility User code Failure code Calibration code incompatibility Trouble (Engine controller system) CA342 Contents of • Incompatibility of data occurred in engine controller. trouble Action of •...
Page 644 UEN00241-01 40 Troubleshooting Failure code [CA351] Injectors Drive Circuit Error User code Failure code Injectors Drive Circuit Error Trouble (Engine controller system) CA351 Contents of • There is error in drive power circuit of injector. trouble Action of • Limits output and continues operation. controller •...
Page 645 40 Troubleshooting UEN00241-01 Circuit diagram related to engine controller PC210, 230, 240-8...
Page 646 UEN00241-01 40 Troubleshooting Failure code [CA352] Sens Supply 1 Volt Low Error User code Failure code Sensor power supply 1 voltage low error Trouble (Engine controller system) CA352 Contents of • Low voltage was detected in sensor power supply 1 circuit. trouble Action of •...
Page 647 40 Troubleshooting UEN00241-01 Circuit diagram related to sensor power supply 1 PC210, 230, 240-8...
Page 648 UEN00241-01 40 Troubleshooting Failure code [CA386] Sens Supply 1 Volt High Error User code Failure code Sensor power supply 1 voltage high error Trouble (Engine controller system) CA386 Contents of • High voltage was detected in sensor power supply 1 circuit. trouble Action of •...
Page 649 40 Troubleshooting UEN00241-01 PC210, 230, 240-8...
Page 650 UEN00241-01 40 Troubleshooting Failure code [CA428] Water in Fuel Sensor High Error User code Failure code Water-in-fuel sensor high error Trouble (Engine controller system) CA428 Contents of • High voltage was detected in signal circuit of water-in-fuel sensor. trouble Action of •...
Page 651 40 Troubleshooting UEN00241-01 Circuit diagram related to water-in-fuel sensor PC210, 230, 240-8...
Page 652 UEN00241-01 40 Troubleshooting Failure code [CA429] Water in Fuel Sensor Low Error User code Failure code Water-in-fuel sensor low error Trouble (Engine controller system) CA429 Contents of • Low voltage was detected in signal circuit of water-in-fuel sensor. trouble Action of •...
Page 653 40 Troubleshooting UEN00241-01 Circuit diagram related to water-in-fuel sensor PC210, 230, 240-8...
Page 654 UEN00241-01 40 Troubleshooting Failure code [CA435] Eng Oil Press Sw Error User code Failure code Engine oil pressure switch error Trouble (Engine controller system) CA435 Contents of • There is error in signal circuit of engine oil pressure switch. trouble Action of •...
Page 655 40 Troubleshooting UEN00241-01 Failure code [CA441] Battery Voltage Low Error User code Failure code Battery voltage low error Trouble (Engine controller system) CA441 Contents of • There is low voltage in controller power supply circuit. trouble Action of • None in particular. controller Problem that •...
Page 656 UEN00241-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between fuse No. 19 – machine wiring harness – engine controller may be defective. Check them directly. Defective wiring harness • Looseness of connector, breakage of lock, or breakage of seal connector Possible causes •...
Page 657 40 Troubleshooting UEN00241-01 Circuit diagram related to engine controller power supply PC210, 230, 240-8...
Page 658 UEN00241-01 40 Troubleshooting Failure code [CA442] Battery Voltage High Error User code Failure code Battery voltage high error Trouble (Engine controller system) CA442 Contents of • There is high voltage (36 V or higher) in controller power supply circuit. trouble Action of •...
Page 659 40 Troubleshooting UEN00241-01 Circuit diagram related to engine controller power supply PC210, 230, 240-8...
Page 660 UEN00241-01 40 Troubleshooting Failure code [CA449] Rail Press Very High Error User code Failure code Common rail pressure very high error Trouble (Engine controller system) CA449 Contents of • There is high pressure error in common rail circuit. trouble Action of •...
Page 661 40 Troubleshooting UEN00241-01 PC210, 230, 240-8...
Page 662 UEN00241-01 40 Troubleshooting Failure code [CA451] Rail Press Sensor High Error User code Failure code Common rail pressure sensor high error Trouble (Engine controller system) CA451 Contents of • There is high voltage in signal circuit of common rail pressure sensor. trouble Action of •...
Page 663 40 Troubleshooting UEN00241-01 Circuit diagram related to common rail pressure sensor PC210, 230, 240-8...
Page 664 UEN00241-01 40 Troubleshooting Failure code [CA452] Rail Press Sensor Low Error User code Failure code Common rail pressure sensor low error Trouble (Engine controller system) CA452 Contents of • There is low voltage in signal circuit of common rail pressure sensor. trouble Action of •...
Page 665 40 Troubleshooting UEN00241-01 Circuit diagram related to common rail pressure sensor PC210, 230, 240-8...
Page 666 UEN00241-01 40 Troubleshooting Failure code [CA488] Chg Air Temp High Torque Derate User code Failure code Charge air temperature high torque derate Trouble (Engine controller system) CA488 Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit. trouble Action of •...
Page 667 40 Troubleshooting UEN00241-01 Failure code [CA559] Rail Press Low Error User code Failure code Common rail pressure low error Trouble (Engine controller system) CA459 Contents of • There is low pressure error in common rail circuit. trouble Action of • None in particular. controller •...
Page 668 UEN00241-01 40 Troubleshooting Failure code [CA689] Eng Ne Speed Sensor Error User code Failure code Engine Ne speed sensor error Trouble (Engine controller system) CA689 Contents of • There is error in signal from engine Ne speed sensor. trouble Action of •...
Page 669 40 Troubleshooting UEN00241-01 Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between engine Ne speed sensor – engine wiring harness – engine controller may be defective. Check them directly. Defective wiring harness • Looseness of connector, breakage of lock, or breakage of seal Possible causes connector •...
Page 670 UEN00241-01 40 Troubleshooting Failure code [CA731] Eng Bkup Speed Sens Phase Error User code Failure code Engine Bkup speed sensor phase error Trouble (Engine controller system) CA731 Contents of • Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor trouble Action of •...
Page 671 40 Troubleshooting UEN00241-01 PC210, 230, 240-8...
Page 672 UEN00241-01 40 Troubleshooting Failure code [CA757] All Continuous Data Lost Error User code Failure code All continuous data lost error Trouble (Engine controller system) CA757 Contents of • All data in engine controller are lost. trouble Action of • None in particular. controller Problem that •...
Page 673 40 Troubleshooting UEN00241-01 Circuit diagram related to engine controller power supply PC210, 230, 240-8...
Page 674 UEN00241-01 40 Troubleshooting Failure code [CA778] Eng Bkup Speed Sensor Error User code Failure code Engine Bkup speed sensor error Trouble (Engine controller system) CA778 Contents of • There is error in signal from engine Bkup speed sensor. trouble Action of •...
Page 675 40 Troubleshooting UEN00241-01 Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between engine Bkup speed sensor – engine wir- ing harness – engine controller may be defective. Check them directly. Defective wiring harness Possible causes • Looseness of connector, breakage of lock, or breakage of seal connector and standard •...
Page 676 UEN00241-01 40 Troubleshooting Failure code [CA1633] KOMNET Datalink Timeout Error User code Failure code KOMNET Datalink timeout error Trouble (Engine controller system) CA1633 Contents of • Engine controller detected communication error in KOMNET communication circuit between pump trouble controller and machine monitor. Action of •...
Page 677 40 Troubleshooting UEN00241-01 Circuit diagram related to CAN communication PC210, 230, 240-8...
Page 678 UEN00241-01 40 Troubleshooting Failure code [CA2185] Throt Sens Sup Volt High Error User code Failure code Throttle sensor supply voltage high error Trouble (Engine controller system) CA2185 Contents of • High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit. trouble •...
Page 679 40 Troubleshooting UEN00241-01 Failure code [CA2186] Throt Sens Sup Volt Low Error User code Failure code Throttle sensor supply voltage low error Trouble (Engine controller system) CA2186 Contents of • Low voltage was detected in throttle sensor power supply circuit. trouble •...
Page 680 UEN00241-01 40 Troubleshooting Failure code [CA2249] Rail Press Very Low Error User code Failure code Common rail pressure very low error Trouble (Engine controller system) CA2249 Contents of • There is low pressure error in common rail circuit. trouble Action of •...
Page 681 40 Troubleshooting UEN00241-01 PC210, 230, 240-8...
Page 682 UEN00241-01 40 Troubleshooting Failure code [CA2311] IMV Solenoid Error User code Failure code IMV solenoid error Trouble (Engine controller system) CA2311 Contents of • Resistance of supply pump actuator circuit is abnormally high or low. trouble Action of • None in particular. controller Problem that appears on...
Page 683 40 Troubleshooting UEN00241-01 Circuit diagram related to supply pump actuator (metering unit) PC210, 230, 240-8...
Page 684 UEN00241-01 40 Troubleshooting Failure code [CA2555] Grid Htr Relay Volt High Error User code Failure code Grid heater relay volt high error Trouble (Engine controller system) CA2555 Contents of • Disconnection was detected in drive circuit of intake air heater relay. trouble Action of •...
Page 685 40 Troubleshooting UEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC210, 230, 240-8...
Page 686 UEN00241-01 40 Troubleshooting Failure code [CA2556] Grid Htr Relay Volt Low Error User code Failure code Grid heater relay volt low error Trouble (Engine controller system) CA2556 Contents of • Short circuit was detected in drive circuit of intake air heater relay. trouble Action of •...
Page 687 40 Troubleshooting UEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC210, 230, 240-8...
Page 688 UEN00241-01 40 Troubleshooting Failure code [D19JKZ] Personal Code Relay Abnormality User code Failure code Personal code relay abnormality Trouble (KOMTRAX system in machine monitor) D19JKZ Contents of • Disconnection or short circuit was detected in personal code relay circuit. trouble •...
Page 689 40 Troubleshooting UEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC210, 230, 240-8...
Page 690 UEN00241-01 40 Troubleshooting Failure code [D862KA] GPS Antenna Discon User code Failure code GPS antenna disconnection Trouble (KOMTRAX system in machine monitor) — D862KA Contents of • Disconnection was detected in GPS antenna circuit. trouble Action of • None in particular. controller •...
Page 691 40 Troubleshooting UEN00241-01 Failure code [DA25KP] 5V Sensor 1 Power Abnormality Overload alarm monitor non-display specification User code Failure code 5V sensor power supply output 1 abnormality Trouble (Pump controller system) — DA25KP Contents of • Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V. trouble Action of •...
Page 692 UEN00241-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between C01 (female) (9) – Resis- J06 – P07 (female) (3) Min. 1 Mz tance [Swing RIGHT PPC pressure sensor system] Ground fault in wiring har- Wiring harness between C01 (female) (9) – Resis- ness (Short circuit with GND J06 –...
Page 693 40 Troubleshooting UEN00241-01 Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor non-display specification) PC210, 230, 240-8...
Page 694 UEN00241-01 40 Troubleshooting PC210, 230, 240-8...
Page 695 40 Troubleshooting UEN00241-01 Overload alarm monitor display specification User code Failure code 5V sensor power supply output 1 abnormality Trouble (Pump controller system) — DA25KP Contents of • Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V. trouble Action of •...
Page 696 UEN00241-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between C01 (female) (9) – Resis- J06 – P07 (female) (3) Min. 1 Mz tance [Swing RIGHT PPC pressure sensor system] Wiring harness between C01 (female) (9) – Resis- J06 –...
Page 697 40 Troubleshooting UEN00241-01 Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor display specification) PC210, 230, 240-8...
Page 698 UEN00241-01 40 Troubleshooting Failure code [DA29KQ] Model Selection Abnormality PC210, 210LC-8 User code Failure code Model selection abnormality Trouble (Pump controller system) — DA29KQ Contents of • Model code signal for model which is not registered in controller is input. trouble Action of •...
Page 699 40 Troubleshooting UEN00241-01 Circuit diagram related to model selection connector (PC210, 210LC-8) PC210, 230, 240-8...
Page 700 UEN00241-01 40 Troubleshooting PC240LC-8 User code Failure code Model selection abnormality Trouble (Pump controller system) — DA29KQ Contents of • Model code signal for model which is not registered in controller is input. trouble Action of • Changes input model code to code of default model (PC210) and continues control. controller •...
Page 701 40 Troubleshooting UEN00241-01 Circuit diagram related to model selection connector (PC240LC-8) PC210, 230, 240-8...
Page 703 UEN00242-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 704 UEN00242-01 40 Troubleshooting Failure code [DW43KA] Travel Speed Sol Discon ................30 Failure code [DW43KB] Travel Speed Sol Short ................32 Failure code [DW45KA] Swing Brake Sol Discon ................34 Failure code [DW45KB] Swing Brake Sol Short................. 36 Failure code [DW91KA] Travel Junction Sol Discon ................38 Failure code [DW91KB] Travel Junction Sol Short................
Page 705 40 Troubleshooting UEN00242-01 PC210, 230, 240-8...
Page 706 UEN00242-01 40 Troubleshooting Troubleshooting by failure code (Display of code), Part 3 Failure code [DA2RMC] CAN Discon (Pump Con Detected) User code Failure code CAN disconnection (Pump controller detected) Trouble (Pump controller system) DA2RMC Contents of • Pump controller detected communication error in CAN communication circuit between machine mon- trouble itor and engine controller.
Page 707 40 Troubleshooting UEN00242-01 Circuit diagram related to CAN communication PC210, 230, 240-8...
Page 708 UEN00242-01 40 Troubleshooting Failure code [DAFGMC] GPS Module Error User code Failure code GPS module operation error Trouble (KOMTRAX system in machine monitor) — DAFGMC Contents of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication trouble MODEM in 50 seconds after KOMTRAX is started.
Page 709 40 Troubleshooting UEN00242-01 PC210, 230, 240-8...
Page 710 UEN00242-01 40 Troubleshooting Failure code [DAFRMC] CAN Discon (Monitor Detected) User code Failure code CAN disconnection (Monitor detected) Trouble (Machine monitor system) DAFRMC Contents of • Machine monitor detected communication error in CAN communication circuit between pump con- trouble troller and engine controller. Action of •...
Page 711 40 Troubleshooting UEN00242-01 Circuit diagram related to CAN communication PC210, 230, 240-8...
Page 712 UEN00242-01 40 Troubleshooting Failure code [DGH2KB] Hydr Oil Sensor Short User code Failure code Hydraulic oil temperature sensor short Trouble (Pump controller system) — DGH2KB Contents of • Ground fault was detected in hydraulic oil temperature sensor circuit. trouble Action of •...
Page 713 40 Troubleshooting UEN00242-01 PC210, 230, 240-8...
Page 714 UEN00242-01 40 Troubleshooting Failure code [DHPAMA] F Pump Press Sensor Abnormality User code Failure code F pump pressure sensor abnormality Trouble (Pump controller system) — DHPAMA Contents of • Signal voltage of F pump pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 715 40 Troubleshooting UEN00242-01 Circuit diagram related to F pump pressure sensor PC210, 230, 240-8...
Page 716 UEN00242-01 40 Troubleshooting Failure code [DHPBMA] R Pump Press Sensor Abnormality User code Failure code R pump pressure sensor abnormality Trouble (Pump controller system) — DHPBMA Contents of • Signal voltage of R pump pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 717 40 Troubleshooting UEN00242-01 Circuit diagram related to R pump pressure sensor PC210, 230, 240-8...
Page 718 UEN00242-01 40 Troubleshooting Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality User code Failure code Arm curl PPC pressure sensor abnormality Trouble (Pump controller system) — DHS3MA Contents of • Signal voltage of arm curl PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 719 40 Troubleshooting UEN00242-01 Circuit diagram related to arm curl PPC pressure sensor PC210, 230, 240-8...
Page 720 UEN00242-01 40 Troubleshooting Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality User code Failure code Bucket curl PPC pressure sensor abnormality Trouble (Pump controller system) — DHS4MA Contents of • Signal voltage of bucket curl PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 721 40 Troubleshooting UEN00242-01 Circuit diagram related to bucket curl PPC pressure sensor PC210, 230, 240-8...
Page 722 UEN00242-01 40 Troubleshooting Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality User code Failure code Boom raise PPC pressure sensor abnormality Trouble (Pump controller system) — DHS8MA Contents of • Signal voltage of boom raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 723 40 Troubleshooting UEN00242-01 Circuit diagram related to boom raise PPC pressure sensor PC210, 230, 240-8...
Page 724 UEN00242-01 40 Troubleshooting Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality User code Failure code Swing right PPC pressure sensor abnormality Trouble (Pump controller system) — DHSAMA Contents of • Signal voltage of swing right PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 725 40 Troubleshooting UEN00242-01 Circuit diagram related to swing right PPC pressure sensor PC210, 230, 240-8...
Page 726 UEN00242-01 40 Troubleshooting Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality User code Failure code Swing left PPC pressure sensor abnormality Trouble (Pump controller system) — DHSBMA Contents of • Signal voltage of swing left PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 727 40 Troubleshooting UEN00242-01 Circuit diagram related to swing left PPC pressure sensor PC210, 230, 240-8...
Page 728 UEN00242-01 40 Troubleshooting Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality User code Failure code Bucket dump PPC pressure sensor abnormality Trouble (Pump controller system) — DHSDMA Contents of • Signal voltage of bucket dump PPC pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 729 40 Troubleshooting UEN00242-01 Circuit diagram related to bucket dump PPC pressure sensor PC210, 230, 240-8...
Page 730 UEN00242-01 40 Troubleshooting Failure code [DHX1MA] Overload Sensor Abnormality (Analog) User code Failure code Overload sensor (analog) Trouble (Pump controller system) — DHX1MA Contents of • Signal voltage of overload alarm pressure sensor circuit is below 0.3 V or above 4.4 V. trouble Action of •...
Page 731 40 Troubleshooting UEN00242-01 Circuit diagram related to overload alarm pressure sensor PC210, 230, 240-8...
Page 732 UEN00242-01 40 Troubleshooting Failure code [DW43KA] Travel Speed Sol Discon User code Failure code Travel speed solenoid system disconnection Trouble (Pump controller system) — DW43KA Contents of • When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit. trouble Action of •...
Page 733 40 Troubleshooting UEN00242-01 Circuit diagram related to travel speed shifting solenoid PC210, 230, 240-8...
Page 734 UEN00242-01 40 Troubleshooting Failure code [DW43KB] Travel Speed Sol Short User code Failure code Travel speed solenoid system short Trouble (Pump controller system) — DW43KB Contents of • When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit. trouble Action of •...
Page 735 40 Troubleshooting UEN00242-01 Circuit diagram related to travel speed shifting solenoid PC210, 230, 240-8...
Page 736 UEN00242-01 40 Troubleshooting Failure code [DW45KA] Swing Brake Sol Discon User code Failure code Swing holding brake solenoid system disconnection Trouble (Pump controller system) DW45KA Contents of • When output to swing holding brake solenoid was turned OFF, disconnection was detected in circuit. trouble Action of •...
Page 737 40 Troubleshooting UEN00242-01 Circuit diagram related to swing holding brake solenoid PC210, 230, 240-8...
Page 738 UEN00242-01 40 Troubleshooting Failure code [DW45KB] Swing Brake Sol Short User code Failure code Swing holding brake solenoid system short Trouble (Pump controller system) DW45KB Contents of • When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit. trouble Action of •...
Page 739 40 Troubleshooting UEN00242-01 Circuit diagram related to swing holding brake solenoid PC210, 230, 240-8...
Page 740 UEN00242-01 40 Troubleshooting Failure code [DW91KA] Travel Junction Sol Discon User code Failure code Travel junction solenoid system disconnection Trouble (Pump controller system) — DW91KA Contents of • When output to travel junction solenoid was turned ON, disconnection was detected in circuit. trouble Action of •...
Page 741 40 Troubleshooting UEN00242-01 Circuit diagram related to travel junction solenoid PC210, 230, 240-8...
Page 742 UEN00242-01 40 Troubleshooting Failure code [DW91KB] Travel Junction Sol Short User code Failure code Travel junction solenoid system short Trouble (Pump controller system) — DW91KB Contents of • When output to travel junction solenoid was turned ON, short circuit was detected in circuit. trouble Action of •...
Page 743 40 Troubleshooting UEN00242-01 Circuit diagram related to travel junction solenoid PC210, 230, 240-8...
Page 744 UEN00242-01 40 Troubleshooting Failure code [DWA2KA] Service Sol Discon User code Failure code Service solenoid disconnection Trouble (Pump controller system) — DWA2KA Contents of • When output to service solenoid is turned OFF, disconnection was detected in circuit. trouble Action of •...
Page 745 40 Troubleshooting UEN00242-01 Failure code [DWA2KB] Service Sol Short User code Failure code Service solenoid short Trouble (Pump controller system) — DWA2KB Contents of • When output to service solenoid is turned ON, short circuit was detected in circuit. trouble Action of •...
Page 746 UEN00242-01 40 Troubleshooting Failure code [DWK0KA] 2-stage Relief Sol Discon User code Failure code 2-stage relief solenoid disconnection Trouble (Pump controller system) — DWK0KA Contents of • When output to 2-stage relief solenoid is turned OFF, disconnection was detected in circuit. trouble Action of •...
Page 747 40 Troubleshooting UEN00242-01 Circuit diagram related to 2-stage relief solenoid PC210, 230, 240-8...
Page 748 UEN00242-01 40 Troubleshooting Failure code [DWK0KB] 2-stage Relief Sol Short User code Failure code 2-stage relief solenoid short Trouble (Pump controller system) — DWK0KB Contents of • When output to 2-stage relief solenoid is turned ON, short circuit was detected in circuit. trouble Action of •...
Page 749 40 Troubleshooting UEN00242-01 Circuit diagram related to 2-stage relief solenoid PC210, 230, 240-8...
Page 751 UEN00243-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 752 UEN00243-01 40 Troubleshooting Failure code [DY2CKA] Washer Drive Discon..................31 Failure code [DY2CKB] Washer Drive Short ..................33 Failure code [DY2DKB] Wiper Drive (For) Short ................35 Failure code [DY2EKB] Wiper Drive (Rev) Short ................37 Failure code [DXEAKA] Service Current EPC1 Discon..............39 Failure code [DXEAKB] Service Current EPC1 Short ................
Page 753 40 Troubleshooting UEN00243-01 Troubleshooting by failure code (Display of code), Part 4 Failure code [DXA8KA] PC-EPC (F) Sol Discon User code Failure code PC-EPC (F) solenoid system disconnection Trouble (Pump controller system) DXA8KA Contents of • When PC-EPC (F) solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 754 UEN00243-01 40 Troubleshooting Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC210, 230, 240-8...
Page 755 40 Troubleshooting UEN00243-01 Failure code [DXA8KB] PC-EPC (F) Sol Short User code Failure code PC-EPC (F) solenoid system short Trouble (Pump controller system) DXA8KB Contents of • When PC-EPC (F) solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 756 UEN00243-01 40 Troubleshooting Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC210, 230, 240-8...
Page 757 40 Troubleshooting UEN00243-01 Failure code [DXA9KA] PC-EPC (R) Sol Discon User code Failure code PC-EPC (R) solenoid system disconnection Trouble (Pump controller system) DXA9KA Contents of • When PC-EPC (R) solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 758 UEN00243-01 40 Troubleshooting Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC210, 230, 240-8...
Page 759 40 Troubleshooting UEN00243-01 Failure code [DXA9KB] PC-EPC (R) Sol Short User code Failure code PC-EPC (R) solenoid system short Trouble (Pump controller system) DXA9KB Contents of • When PC-EPC (R) solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 760 UEN00243-01 40 Troubleshooting Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC210, 230, 240-8...
Page 761 40 Troubleshooting UEN00243-01 Failure code [DXE0KA] LS-EPC Sol Discon User code Failure code LS-EPC solenoid system disconnection Trouble (Pump controller system) — DXE0KA Contents of • When LS-EPC solenoid was driven, disconnection was detected in circuit. trouble Action of • None in particular (Since no current flows, solenoid does not operate). controller •...
Page 762 UEN00243-01 40 Troubleshooting Circuit diagram related to LS-EPC solenoid PC210, 230, 240-8...
Page 763 40 Troubleshooting UEN00243-01 Failure code [DXE0KB] LS-EPC Sol Short User code Failure code LS-EPC solenoid system short Trouble (Pump controller system) — DXE0KB Contents of • When LS-EPC solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 764 UEN00243-01 40 Troubleshooting Circuit diagram related to LS-EPC solenoid PC210, 230, 240-8...
Page 765 40 Troubleshooting UEN00243-01 Failure code [DXE4KA] Service Current EPC Discon User code Failure code Service current EPC solenoid disconnection Trouble (Pump controller system) — DXE4KA Contents of • When service EPC solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 766 UEN00243-01 40 Troubleshooting Circuit diagram related to service EPC solenoid PC210, 230, 240-8...
Page 767 40 Troubleshooting UEN00243-01 Failure code [DXE4KB] Service Current EPC Short User code Failure code Service current EPC solenoid short Trouble (Pump controller system) — DXE4KB Contents of • When service EPC solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 768 UEN00243-01 40 Troubleshooting Circuit diagram related to service EPC solenoid PC210, 230, 240-8...
Page 769 40 Troubleshooting UEN00243-01 Failure code [DXE5KA] Merge-divider Main Sol Discon User code Failure code Merge-divider main solenoid disconnection Trouble (Pump controller system) — DXE5KA Contents of • When merge-divider main EPC solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 770 UEN00243-01 40 Troubleshooting Circuit diagram related to merge-divider main EPC solenoid PC210, 230, 240-8...
Page 771 40 Troubleshooting UEN00243-01 Failure code [DXE5KB] Merge-divider Main Sol Short User code Failure code Merge-divider main solenoid short Trouble (Pump controller system) — DXE5KB Contents of • When merge-divider main EPC solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 772 UEN00243-01 40 Troubleshooting Circuit diagram related to merge-divider main EPC solenoid PC210, 230, 240-8...
Page 773 40 Troubleshooting UEN00243-01 Failure code [DXE6KA] Merge-divider LS Sol Discon User code Failure code Merge-divider LS solenoid disconnection Trouble (Pump controller system) — DXE6KA Contents of • When merge-divider LS EPC solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 774 UEN00243-01 40 Troubleshooting Circuit diagram related to merge-divider LS EPC solenoid PC210, 230, 240-8...
Page 775 40 Troubleshooting UEN00243-01 Failure code [DXE6KB] Merge-divider LS Sol Short User code Failure code Merge-divider LS solenoid short Trouble (Pump controller system) — DXE6KB Contents of • When merge-divider LS EPC solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 776 UEN00243-01 40 Troubleshooting Circuit diagram related to merge-divider LS EPC solenoid PC210, 230, 240-8...
Page 777 40 Troubleshooting UEN00243-01 Failure code [DY20KA] Wiper Working Abnormality User code Failure code Wiper working abnormality Trouble (Pump controller system) — DY20KA Contents of • When windshield wiper works, W signal of working ends is not input. trouble Action of •...
Page 778 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 779 40 Troubleshooting UEN00243-01 Failure code [DY20MA] Wiper Parking Abnormality User code Failure code Wiper parking abnormality Trouble (Pump controller system) — DY20MA Contents of • When windshield wiper parks, P signal of storage area is not input. trouble Action of •...
Page 780 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 781 40 Troubleshooting UEN00243-01 Failure code [DY2CKA] Washer Drive Discon User code Failure code Window washer drive system disconnection Trouble (Pump controller system) — DY2CKA Contents of • When output to window washer drive system was turned OFF (when ground circuit was connected), trouble disconnection was detected in circuit.
Page 782 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 783 40 Troubleshooting UEN00243-01 Failure code [DY2CKB] Washer Drive Short User code Failure code Window washer drive system short Trouble (Pump controller system) — DY2CKB Contents of • When output to window washer drive system was turned ON (ground circuit was disconnected), trouble short circuit was detected in circuit.
Page 784 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 785 40 Troubleshooting UEN00243-01 Failure code [DY2DKB] Wiper Drive (For) Short User code Failure code Wiper motor drive forward system short Trouble (Pump controller system) — DY2DKB Contents of • When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit. trouble Action of •...
Page 786 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 787 40 Troubleshooting UEN00243-01 Failure code [DY2EKB] Wiper Drive (Rev) Short User code Failure code Wiper motor drive reverse system short Trouble (Pump controller system) — DY2EKB Contents of • When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit. trouble Action of •...
Page 788 UEN00243-01 40 Troubleshooting Circuit diagram related to windshield wiper and window washer PC210, 230, 240-8...
Page 789 40 Troubleshooting UEN00243-01 Failure code [DXEAKA] Service Current EPC1 Discon User code Failure code Service current EPC1 solenoid disconnection Trouble (Pump controller system) — DXEAKA Contents of • When service EPC1 solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 790 UEN00243-01 40 Troubleshooting Failure code [DXEAKB] Service Current EPC1 Short User code Failure code Service current EPC1 solenoid short Trouble (Pump controller system) — DXEAKB Contents of • When service EPC1 solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 791 40 Troubleshooting UEN00243-01 Failure code [DXE7KA] Service Current EPC2 Discon User code Failure code Service current EPC2 solenoid disconnection Trouble (Pump controller system) — DXE7KA Contents of • When service EPC2 solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 792 UEN00243-01 40 Troubleshooting Failure code [DXE7KB] Service Current EPC2 Short User code Failure code Service current EPC2 solenoid short Trouble (Pump controller system) — DXE7KB Contents of • When service EPC2 solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 793 40 Troubleshooting UEN00243-01 Failure code [DXE8KA] Service Current EPC3 Discon User code Failure code Service current EPC3 solenoid disconnection Trouble (Pump controller system) — DXE8KA Contents of • When service EPC3 solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 794 UEN00243-01 40 Troubleshooting Failure code [DXE8KB] Service Current EPC3 Short User code Failure code Service current EPC3 solenoid short Trouble (Pump controller system) — DXE8KB Contents of • When service EPC3 solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 795 40 Troubleshooting UEN00243-01 Failure code [DXE9KA] Service Current EPC4 Discon User code Failure code Service current EPC4 solenoid disconnection Trouble (Pump controller system) — DXE9KA Contents of • When service EPC4 solenoid was driven, disconnection was detected in circuit. trouble Action of •...
Page 796 UEN00243-01 40 Troubleshooting Failure code [DXE9KB] Service Current EPC4 Short User code Failure code Service current EPC4 solenoid short Trouble (Pump controller system) — DXE9KB Contents of • When service EPC4 solenoid was driven, short circuit was detected in circuit. trouble Action of •...
Page 797 40 Troubleshooting UEN00243-01 S e r v i c e EPC 1 1st S e r v i c e LH EPC 1 s t A t t 2nd S e r v i c e RH EPC LH EPC 1st S e r v i c e RH EPC S e r v i c e EPC 2 2nd S e r v i c e LH EPC...
Page 798 UEN00243-01 40 Troubleshooting PC210, 230, 240-8...
Page 799 40 Troubleshooting UEN00243-01 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality User code Failure code Trouble RH Lever main potentiometer (for 1st Att.) has failure — DFB1KZ Contents of • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts) trouble Action of •...
Page 800 UEN00243-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with Wiring harness between M22 (female) (9) - M22 5 Volts circuit) in (female) (6).
Page 801 40 Troubleshooting UEN00243-01 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality User code Failure code Trouble LH Lever main potentiometer (for 2nd Att.) has failure — DFB2KZ Contents of • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts) trouble Action of •...
Page 802 UEN00243-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with Wiring harness between M23 (female) (9) - M23 5 Volts circuit) in (female) (6).
Page 803 40 Troubleshooting UEN00243-01 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality User code Failure code Trouble RH Lever main potentiometer (for 1st Att.) has failure — DFB5KZ Contents of • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts) trouble Action of •...
Page 804 UEN00243-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with Wiring harness between M22 (female) (8) - M22 5 Volts circuit) in (female) (6).
Page 805 40 Troubleshooting UEN00243-01 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality User code Failure code Trouble LH Lever main potentiometer (for 2nd Att.) has failure — DFB6KZ Contents of • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts) trouble Action of •...
Page 806 UEN00243-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with Wiring harness between M23 (female) (8) - M23 5 Volts circuit) in (female) (6).
Page 807 40 Troubleshooting UEN00243-01 Failure code [DFB3L8] Service Lever 1 Potentio Error User code Failure code Trouble RH Lever main potentiometer (for 1st Att.) has failure — DFB3L8 Contents of • Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts) trouble Action of •...
Page 808 UEN00243-01 40 Troubleshooting Failure code [DFB4L8] Service Lever 2 Potentio Error User code Failure code Trouble LH Lever main potentiometer (for 2nd Att.) has failure — DFB4L8 Contents of • Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts) trouble Action of •...
Page 809 40 Troubleshooting UEN00243-01 LEVER LH (2nd ATT) LEVER RH (1st ATT) Sub Potentio 2 Sub Potentio 1 Main Potentio 2 Main Potentio 1 Pump Controller Potentio Power (+5 V) (Sub) 1st Service Potentio ANALOG GND (Main) 2nd Service Potentio 2nd Service Potentio (Sub) 1st Service Potentio (Main)
Page 810 UEN00243-01 40 Troubleshooting PC210, 230, 240-8...
Page 812 UEN00243-01...
Page 813 UEN00244-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 814 UEN00244-02 40 Troubleshooting E-12 Contents of display by machine monitor are different from applicable machine......33 E-13 Machine monitor does not display some items................33 E-14 Function switch does not work....................33 E-15 Auto-decelerator does not operate normally................34 E-16 Working mode does not change ....................35 E-17 Travel speed does not change....................
Page 815 40 Troubleshooting UEN00244-02 (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting of electrical system Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions).
Page 816 UEN00244-02 40 Troubleshooting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up) Troubleshooting of electrical system (E-mode) Before carrying out troubleshooting of electrical system Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions).
Page 817 40 Troubleshooting UEN00244-02 PC210, 230, 240-8...
Page 818 UEN00244-02 40 Troubleshooting Locations of fusible links PC240 PC210 / 230 Location of fuse box and fuse Nos. PC210, 230, 240-8...
Page 819 40 Troubleshooting UEN00244-02 Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Trouble which occurred in the machine Related infor- Information related to detected trouble or troubleshooting mation Cause...
Page 820 • When starting switch turned ON, machine monitor displays nothing. • When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass- word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check Related infor- working mode and travel speed, and ordinary screen in order.
Page 821 40 Troubleshooting UEN00244-02 Circuit diagram related to machine monitor power supply PC210, 230, 240-8...
Page 822 UEN00244-02 40 Troubleshooting E-2 When starting switch turned ON (before starting engine), basic check item lights up Trouble (1) Radiator coolant level monitor lights up red. • Although radiator coolant level monitor is basic check item, it is also checked while engine is running. Related infor- (If monitor lights up red while engine is running, carry out this troubleshooting, too.) mation...
Page 823 40 Troubleshooting UEN00244-02 Circuit diagram related to radiator coolant level switch PC210, 230, 240-8...
Page 824 UEN00244-02 40 Troubleshooting Trouble (2) Engine oil level monitor lights up red. Related infor- • Condition of engine oil level switch signal can be checked with monitoring function. mation (Code: 04501 Monitor input 2) Cause Standard value in normal state/Remarks on troubleshooting Lowering of engine oil level Engine oil level may be low.
Page 825 40 Troubleshooting UEN00244-02 E-3 Engine does not start (Engine does not turn) Trouble • Engine does not start (Engine does not turn). • Engine starting circuit has following 2 start lock mechanisms. Related infor- 1) Start lock with password of machine monitor mation 2) Start lock with lock lever Cause...
Page 826 UEN00244-02 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. Starting motor terminals Voltage Between B (SB) – Defective starting motor Power supply 20 –...
Page 827 40 Troubleshooting UEN00244-02 Circuit diagram related to preheating/starting of engine and charge of battery PC210, 230, 240-8...
Page 828 UEN00244-02 40 Troubleshooting E-4 Preheater does not operate Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash. • Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after).
Page 829 40 Troubleshooting UEN00244-02 Circuit diagram related to preheating/starting of engine and charge of battery PC210, 230, 240-8...
Page 830 UEN00244-02 40 Troubleshooting E-5 Automatic warm-up system does not operate (in cold season) Trouble • Automatic warm-up system does not operate (in cold season). • When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to 1,200 rpm. •...
Page 831 40 Troubleshooting UEN00244-02 PC210, 230, 240-8...
Page 832 UEN00244-02 40 Troubleshooting E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked Trouble (1) All work equipment, swing, and travel mechanism do not move. Related infor- mation Cause Standard value in normal state/Remarks on troubleshooting 1 Defective fuse No.
Page 833 40 Troubleshooting UEN00244-02 Trouble (2) All work equipment, swing, and travel mechanism cannot be locked. Related infor- mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lock lever switch S14 (female) Lock lever...
Page 834 UEN00244-02 40 Troubleshooting E-7 Precaution lights up while engine is running Trouble (1) Charge level monitor lights up red. Related infor- • Signal voltage of alternator can be checked with monitoring function. mation (Code: 04300 Charge voltage) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Page 835 40 Troubleshooting UEN00244-02 Circuit diagram related to preheating/starting of engine and charge of battery PC210, 230, 240-8...
Page 836 UEN00244-02 40 Troubleshooting Trouble (2) Fuel level monitor lights up red. Related infor- • Signal voltage of fuel sensor can be checked with monitoring function. mation (Code: 04200 Fuel sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting Fuel level may be low (below about 41 l). Check it and add fuel if Possible causes Low fuel level (when system and standard...
Page 837 40 Troubleshooting UEN00244-02 Circuit diagram related to air cleaner clogging switch PC210, 230, 240-8...
Page 838 UEN00244-02 40 Troubleshooting Trouble (4) Engine coolant temperature monitor lights up white. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to Related infor- machine monitor through communication system. mation • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting...
Page 839 40 Troubleshooting UEN00244-02 E-8 Emergency stop item lights up while engine is running Trouble (1) Engine coolant temperature monitor lights up red. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to Related infor- machine monitor through communication system.
Page 840 UEN00244-02 40 Troubleshooting E-9 Engine coolant temperature gauge does not indicate normally (1) While engine coolant temperature is rising normally, temperature gauge does not rise from white Trouble range (C). (2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H). •...
Page 841 40 Troubleshooting UEN00244-02 E-10 Hydraulic oil temperature gauge does not indicate normally (1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range Trouble (C). (2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). •...
Page 842 UEN00244-02 40 Troubleshooting (3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature mon- itor. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to Related infor- machine monitor through communication system.
Page 843 40 Troubleshooting UEN00244-02 E-11 Fuel level gauge does not indicate normally (1) While fuel is added, fuel level gauge does not rise from red range (E). Trouble (2) While fuel level is low, fuel level gauge does not lower from green range top (F) Related infor- •...
Page 844 UEN00244-02 40 Troubleshooting (3) Display of fuel level gauge is different from actual fuel level. Trouble (4) Display of fuel level gauge is different from display of fuel level monitor. Related infor- • Signal voltage of fuel level sensor can be checked with monitoring function. mation (Code: 04200 Fuel level sensor voltage) Cause...
Page 845 Monitoring code Normal display Possible causes and standard 1 Defective model code signal PC210-8: PC210 00200 Controller model code value in normal PC240-8: PC240 state If display of monitoring is abnormal, carry out troubleshooting for failure code [DA29KQ].
Page 846 UEN00244-02 40 Troubleshooting E-15 Auto-decelerator does not operate normally (1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go Trouble off. Related infor- • Condition of signal of auto-decelerator switch can be checked with monitoring function. mation (Code: 04504 Monitor 1st, 2nd line switches) Possible causes...
Page 847 40 Troubleshooting UEN00244-02 E-16 Working mode does not change Trouble (1) When working mode switch is operated, working mode selection screen is not displayed. Related infor- • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 mation Monitor 1st, 2nd line switches) Possible causes...
Page 848 UEN00244-02 40 Troubleshooting E-17 Travel speed does not change Trouble (1) When travel speed switch is operated, travel speed monitor does not change. Related infor- • Condition of signal of travel speed switch can be checked with monitoring function. mation (Code: 04504 Monitor 1st, 2nd line switches) Possible causes Cause...
Page 849 40 Troubleshooting UEN00244-02 (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). E-18 Alarm buzzer cannot be stopped Trouble • Alarm buzzer cannot be stopped. Related infor- • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. mation (Code: 04503 Monitor 1st, 2nd line switches) Possible causes...
Page 850 UEN00244-02 40 Troubleshooting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up) E-18 Alarm buzzer cannot be stopped Trouble • Alarm buzzer cannot be stopped, even pressing Alarm Buzzer Cancel sw [4] on Monitor panel.. Related infor- •...
Page 851 40 Troubleshooting UEN00244-02 Circuit Diagram for Quick Coupler system PC210, 230, 240-8...
Page 852 UEN00244-02 40 Troubleshooting E-19 Windshield wiper and window washer do not operate Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off. Related infor- • Condition of wiper switch signal can be checked with monitoring function. mation (Code: 04504 Monitor 1st, 2nd line switches) Possible causes...
Page 853 40 Troubleshooting UEN00244-02 Circuit diagram related to windshield wiper and window washer Trouble (3) When window washer switch is operated, window washer does not operate. Related infor- • Condition of window washer switch signal can be checked with monitoring function. mation (Code: 04504 Monitor 1st, 2nd line switches) Possible causes...
Page 854 UEN00244-02 40 Troubleshooting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). E-20 Power maximising function does not operate normally (1) When left knob switch is pressed, one-touch power maximizing monitor is not displayed. Trouble (2) When left knob switch is pressed, work equipment power is not increased. •...
Page 855 40 Troubleshooting UEN00244-02 Trouble (3) When left knob switch is released, work equipment power does not return to normal level. Related infor- • Condition of left knob switch signal can be checked with monitoring function. mation (Code: 02200 Switch input 1) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON...
Page 856 UEN00244-02 40 Troubleshooting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up) E-20 Power maximising function does not operate normally (1) When left knob switch is pressed, one-touch power maximizing monitor is not displayed. Trouble (2) When left knob switch is pressed, work equipment power is not increased.
Page 857 40 Troubleshooting UEN00244-02 Trouble (3) When left knob switch is released, work equipment power does not return to normal level. Related infor- • Condition of left knob switch signal can be checked with monitoring function. mation (Code: 02200 Switch input 1) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON...
Page 858 UEN00244-02 40 Troubleshooting E-21 Swing holding brake does not operate normally Trouble (1) When swing lock switch is operated, swing lock monitor does not light up or go off. • Condition of swing lock switch signal can be checked with monitoring function. Related infor- (Machine monitor system code: 04502 Monitor input 3) mation...
Page 859 40 Troubleshooting UEN00244-02 Circuit diagram related to swing holding brake solenoid PC210, 230, 240-8...
Page 860 UEN00244-02 40 Troubleshooting E-22 Travel alarm does not sound or does not stop sounding Trouble (1) Alarm does not sound during travel. Related infor- mation Cause Standard value in normal state/Remarks on troubleshooting 1 Defective fuse No. 15 If fuse is broken, circuit probably has ground fault. (See cause 4.) a Start engine and carry out troubleshooting.
Page 861 40 Troubleshooting UEN00244-02 Circuit diagram related to travel alarm and travel PPC oil pressure switch PC210, 230, 240-8...
Page 862 UEN00244-02 40 Troubleshooting E-23 Air conditioner does not operate normally (including air conditioner abnormality record) Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed. Related infor- • Condition of air conditioner switch signal can be checked with monitoring function. mation (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch) Possible causes...
Page 863 40 Troubleshooting UEN00244-02 Trouble (3) Air does not come out (Air flow is insufficient). Related infor- mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R20 (male) Resistance 140 –...
Page 864 UEN00244-02 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between R20 (female) (3) – Resist- Min. 1 Mz (wiring side) (36) ance Ground fault in wiring har- Wiring harness between R20 (female) (4) –...
Page 865 40 Troubleshooting UEN00244-02 Trouble (4) Air is not cooled (Cooling performance is insufficient). Related infor- mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON (coil side). R21 (male) Resistance 140 –...
Page 866 UEN00244-02 40 Troubleshooting (5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication Trouble condition “Abnormal” • While abnormality in communication is being detected, “CAN disconnection” is displayed. • If abnormality in communication has been detected and reset, “Abnormality” is displayed. Related infor- •...
Page 867 40 Troubleshooting UEN00244-02 Trouble (6) Air conditioner abnormality record: Setting condition “Abnormality” • If setting of air conditioner controller model is different from setting of machine monitor model, “Abnormality” is displayed. Related infor- • If “CAN disconnection” is displayed as communication condition, communication cannot be carried mation out normally.
Page 868 UEN00244-02 40 Troubleshooting Trouble (8) Air conditioner abnormality record: External air sensor “Unused” • External air sensor is not used in air conditioner system of this machine. Related infor- • If “CAN disconnection” is displayed as communication condition, communication cannot be carried mation out normally.
Page 869 40 Troubleshooting UEN00244-02 Trouble (10) Air conditioner abnormality record: Daylight sensor “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried Related infor- out normally. Accordingly, this condition is not displayed. mation • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
Page 870 UEN00244-02 40 Troubleshooting Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried Related infor- out normally. Accordingly, this condition is not displayed. mation • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
Page 871 40 Troubleshooting UEN00244-02 Trouble (12) Air conditioner abnormality record: A/M damper “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried Related infor- out normally. Accordingly, this condition is not displayed. mation • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
Page 872 UEN00244-02 40 Troubleshooting Trouble (13) Air conditioner abnormality record: Refrigerant “Abnormality” • If “CAN disconnection” is displayed as communication condition, communication cannot be carried Related infor- out normally. Accordingly, this condition is not displayed. mation • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.
Page 873 40 Troubleshooting UEN00244-02 Circuit diagram related to air conditioner PC210, 230, 240-8...
Page 874 UEN00244-02 40 Troubleshooting E-24 When starting switch is turned OFF, service meter is not displayed Trouble • When starting switch is turned OFF, service meter is not displayed. • While starting switch is at OFF position, if following switches are operated, service meter is displayed Related infor- at top centre of screen.
Page 875 40 Troubleshooting UEN00244-02 E-26 Monitoring function does not display lever control signal normally Trouble (1) Boom raise operation is not displayed normally by monitoring function. Related infor- • Monitoring code: 01900 Pressure switch 1 mation Possible causes Cause Standard value in normal state/Remarks on troubleshooting and standard Defective boom raise PPC value in normal...
Page 876 UEN00244-02 40 Troubleshooting Trouble (5) Boom lower operation is not displayed normally by monitoring function. Related infor- • Monitoring code: 01900 Pressure switch 1 mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Page 877 40 Troubleshooting UEN00244-02 Trouble (6) Arm dump operation is not displayed normally by monitoring function. Related infor- • Monitoring code: 01900 Pressure switch 1 mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Page 878 UEN00244-02 40 Troubleshooting Trouble (7) Swing operation is not displayed normally by monitoring function. Related infor- • Monitoring code: 01900 Pressure switch 1 mation Cause Standard value in normal state/Remarks on troubleshooting Possible causes Defective swing right PPC and standard Carry out troubleshooting for failure code [DHSAMA].
Page 879 40 Troubleshooting UEN00244-02 Circuit diagram related to travel PPC pressure switch and travel alarm PC210, 230, 240-8...
Page 880 UEN00244-02 40 Troubleshooting Trouble (9) Travel differential pressure is not displayed normally by monitoring function. Related informa- • Monitoring code: 01901 Pressure switch 2 tion Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Page 881 40 Troubleshooting UEN00244-02 PC210, 230, 240-8...
Page 882 UEN00244-02 40 Troubleshooting Trouble (10) Service operation is not displayed normally by monitoring function. Related infor- • Monitoring code: 01901 Pressure switch 2 mation Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Page 883 40 Troubleshooting UEN00244-02 Circuit diagram related to service PPC pressure switch PC210, 230, 240-8...
Page 884 UEN00244-02 40 Troubleshooting E-27 KOMTRAX system does not operate normally Trouble • KOMTRAX system does not operate normally. • If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following troubleshooting. Related infor- mation •...
Page 885 40 Troubleshooting UEN00244-02 PC210, 230, 240-8...
Page 887 UEN00245-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting...
Page 888 UEN00245-02 40 Troubleshooting H-12 Time lag of work equipment is large ..................17 H-13 When part of work equipment is relieved singly, other parts of work equipment move ..... 17 H-14 Power maximizing function does not work ................18 H-15 In compound operation of work equipment, speed of part loaded more is low ......18 H-16 When machine swings and raises boom simultaneously, boom rising speed is low ....
Page 889 40 Troubleshooting UEN00245-02 PC210, 230, 240-8...
Page 890 UEN00245-02 40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) System diagram of hydraulic and mechanical system PC210, 230, 240-8...
Page 891 40 Troubleshooting UEN00245-02 a This system diagram is a rough general hydraulic circuit diagram made as reference material for trou- bleshooting of the hydraulic and mechanical systems. PC210, 230, 240-8...
Page 892 UEN00245-02 40 Troubleshooting Information in troubleshooting table a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot- ing, understand that information fully. Trouble Trouble which occurred in machine Related Information related to detected trouble or troubleshooting information Cause Standard value in normal state/Remarks on troubleshooting...
Page 893 40 Troubleshooting UEN00245-02 H-1 Speed or power of whole work equipment, swing, and travel is low1 Trouble • Speed or power of whole work equipment, swing, and travel is low. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting...
Page 894 UEN00245-02 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Operation of levers and oil pressure ratio Measured oil Travel with no load pressure All levers in neutral (Lever operated half- way) Defective adjustment or mal-...
Page 895 40 Troubleshooting UEN00245-02 H-2 Engine speed lowers extremely or engine stalls Trouble • Engine speed lowers extremely or engine stalls. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 896 UEN00245-02 40 Troubleshooting H-3 Work equipment, swing, and travel systems do not work Trouble • Whole work equipment, swing, and travel systems do not work. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 897 40 Troubleshooting UEN00245-02 H-5 Auto-decelerator does not operate Trouble • Auto-decelerator does not operate. • Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated. Related Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel information circuit.
Page 898 UEN00245-02 40 Troubleshooting H-7 Speed or power of boom is low Trouble • Speed or power of boom is low Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 899 40 Troubleshooting UEN00245-02 H-8 Speed or power of arm is low Trouble • Speed or power of arm is low Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 900 UEN00245-02 40 Troubleshooting H-9 Speed or power of bucket is low Trouble • Speed or power of bucket is low. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 901 40 Troubleshooting UEN00245-02 H-11 Hydraulic drift of work equipment is large Trouble (1) Hydraulic drift of boom is large. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idling and carry out troubleshooting.
Page 902 UEN00245-02 40 Troubleshooting Trouble (3) Hydraulic drift of bucket is large. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 903 40 Troubleshooting UEN00245-02 H-12 Time lag of work equipment is large Trouble • Time lag of work equipment is large. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 904 UEN00245-02 40 Troubleshooting H-14 Power maximizing function does not work Trouble • Power maximizing function does not work. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 905 40 Troubleshooting UEN00245-02 H-16 When machine swings and raises boom simultaneously, boom rising speed is low Trouble • When machine swings and raises boom simultaneously, boom rising speed is low. Related • If speed of single boom raise operation is also low, carry out troubleshooting for "H-7 Speed or information power of boom is low"...
Page 906 UEN00245-02 40 Troubleshooting H-18 Machine deviates during travel Trouble • Machine deviates during travel. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 907 40 Troubleshooting UEN00245-02 H-19 Travel speed is low Trouble • Travel speed is low. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 908 UEN00245-02 40 Troubleshooting H-20 Machine is not steered well or steering power is low Trouble • Machine is not steered well or steering power is low Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and...
Page 909 Standard value in normal state/Remarks on troubleshooting Run engine at high idle and carry out troubleshooting (with monitoring function). Monitoring Travel speed Travel lever code: 01500 663 mA (PC210-8) 578 mA (PC240-8) (* Reference) Operated 424 mA (PC210-8) 641 mA (PC240-8) 1 Malfunction of LS-EPC valve...
Page 910 UEN00245-02 40 Troubleshooting H-22 Travel system does not move (only one side) Trouble • Travel system does not move (only one side). Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Defective seal of travel con- Seal of suction valve of travel control valve may have malfunction.
Page 911 40 Troubleshooting UEN00245-02 H-23 Upper structure does not swing Trouble (1) Upper structure does not swing in either direction. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 912 UEN00245-02 40 Troubleshooting Trouble (2) Upper structure swings only in one direction. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 913 40 Troubleshooting UEN00245-02 H-24 Swing acceleration or swing speed is low Trouble (1) Swing acceleration or swing speed is low in both directions. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Malfunction of swing control Spool of swing control valve may have malfunction.
Page 914 UEN00245-02 40 Troubleshooting H-25 Upper structure overruns remarkably when it stops swinging Trouble (1) Upper structure overruns remarkably when it stops swinging in both directions. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting •...
Page 915 40 Troubleshooting UEN00245-02 H-26 Large shock is made when upper structure stops swinging Trouble • Large shock is made when upper structure stops swinging. Related • Carry out all troubleshooting in power mode (P) of working mode. information Cause Standard value in normal state/Remarks on troubleshooting Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 916 UEN00245-02 40 Troubleshooting H-28 Hydraulic drift of swing is large Trouble (1) Hydraulic drift of swing is large (when swing holding brake is applied). • When swing lock switch is turned ON or when swing holding brake release switch is in normal posi- Related tion, swing holding brake operates and upper structure is fixed with disc brake.
Page 917 40 Troubleshooting UEN00245-02 H-29 Attachment circuit is not changed Attachment installation specification Trouble • Attachment circuit is not changed. • When attachment installation specification is employed, service circuit is changed as follows according to selected working mode. Related 1) ATT mode: Service circuit is changed to double acting circuit and safety valve is set to low pressure. information 2) B mode: Service circuit is changed to single acting circuit and safety valve is set to high pressure.
Page 918 UEN00245-02 40 Troubleshooting (For PC210 K50001-K51094, PC230 K50001-K50113 and PC240 K50001-K50303). Quick coupler Quick Coupler Drive Switch (Lamp) Power Supply Fuse Box Quick Coupler Buzzer T01 (Floorframe) Solenoid Valve for Quick Coupler T09 (Revoframe) REVOLVING FRAME QUICK COUPLER BA Trouble (1) Quick coupler cylinder will not extend Quick coupler block assembly has 2 cartridge valves in it, a 3 port pressure reducer to regulate the pressure to both the solenoid valve and quick coupler cylinder and a 4/2 solenoid operated...
Page 919 40 Troubleshooting UEN00245-02 Trouble (2) Quick coupler cylinder will not extend (but buzzer does not sound) Quick coupler block assembly has 2 cartridge valves in it, a 3 port pressure reducer to regulate the pressure to the both the solenoid valve and quick coupler cylinder and a 4/2 solenoid oper- ated directional control valve, this functions as follows: Related information -When operation switch in operators cab is in "ON"...
Page 920 UEN00245-02 40 Troubleshooting (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up) Quick coupler Trouble (1) Quick coupler cylinder will not extend Quick coupler block assembly has 2 cartridge valves in it, a 3 port pressure reducer to regulate the pressure to both the solenoid valve and quick coupler cylinder and a 4/2 solenoid operated Related information directional control valve, this functions as follows:...
Page 921 40 Troubleshooting UEN00245-02 Cause Remarks on troubleshooting Valve will not switch Prepare with starting switch OFF, then carry out trouble- shooting without turning starting switch ON. Defective solenoid coil V40 (male) between (1) (+ positive) and (2) ( - negative) resistance 30+/-1.5Ω...
Page 922 UEN00245-02 40 Troubleshooting PC210, 230, 240-8...
Page 923 40 Troubleshooting UEN00245-02 PC210, 230, 240-8...
Page 925 UEN00246-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 40 Troubleshooting Troubleshooting of engine (S-mode) Troubleshooting of engine (S-mode).......................
Page 926 UEN00246-02 40 Troubleshooting S-15 Abnormal noise is made ......................23 S-16 Vibration is excessive ........................ 24 S-17 Diesel Particulate Filter System....................25 PC210, 230, 240-8...
Page 927 40 Troubleshooting UEN00246-02 Troubleshooting of engine (S-mode) Method of using troubleshooting chart The troubleshooting chart consists of the "ques- tions", "check items", "causes", and "troubleshoot- ing" blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools.
Page 928 UEN00246-02 40 Troubleshooting <Example of troubleshooting> Exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Air cleaner clogging caution lamp is flashing].
Page 929 40 Troubleshooting UEN00246-02 If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. PC210, 230, 240-8...
Page 930 UEN00246-02 40 Troubleshooting S-1 Starting performance is poor General causes why starting performance is poor Causes Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically.
Page 931 40 Troubleshooting UEN00246-02 S-2 Engine does not start a) Engine does not turn Causes General causes why engine does not turn Internal parts of engine seized o See "S-4 Engine stops during operations Defective electrical system Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine Confirm recent repair history Degree of use of machine...
Page 932 UEN00246-02 40 Troubleshooting b) Engine turns but no exhaust smoke comes out Causes General causes why engine turns but no exhaust smoke comes Fuel is not being supplied Supply of fuel is extremely small Improper selection of fuel (particularly in winter) Confirm recent repair history Degree of use of machine Operated for long period...
Page 933 40 Troubleshooting UEN00246-02 c) Exhaust smoke comes but engine does not start (fuel is Causes being injected) General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel Confirm recent repair history...
Page 934 UEN00246-02 40 Troubleshooting S-3 Engine does not pick up smoothly General causes why engine does not pick up smoothly Causes Insufficient intake of air Insufficient supply of fuel Defective condition of fuel spray Improper selection of fuel Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system) Confirm recent repair history Degree of use of machine Operated for long period...
Page 935 40 Troubleshooting UEN00246-02 S-4 Engine stops during operations General causes why engine stops during operations Causes Seized parts inside engine Insufficient supply of fuel There is overheating Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine Confirm recent repair history Degree of use of machine Operated for long period...
Page 936 UEN00246-02 40 Troubleshooting S-5 Engine does not rotate smoothly General causes why engine does not rotate smoothly Causes Air in fuel system Defective speed sensor (Error at degree that it is not indicated) Confirm recent repair history Degree of use of machine Operated for long period Occurs at a certain speed range Q Q Q Q Q Occurs at low idle...
Page 937 40 Troubleshooting UEN00246-02 S-6 Engine lack output (or lacks power) General causes why engine lacks output Causes Insufficient intake of air Insufficient supply of fuel Defective spray condition of fuel Improper selection of fuel There is overheating o See "S-14 Coolant temperature becomes too high (Overheating)".
Page 938 UEN00246-02 40 Troubleshooting *1: Displayed failure codes [CA559] and [CA2249] *2: Displayed failure codes [CA122] and [CA123] PC210, 230, 240-8...
Page 939 40 Troubleshooting UEN00246-02 S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black Causes Insufficient intake of air Defective condition of fuel injection Improper selection of fuel There is overheating o See "S-14 Coolant temperature becomes too high (Overheating)".
Page 940 UEN00246-02 40 Troubleshooting S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive Causes Abnormal consumption of oil Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) External leakage of oil Wear of pats in lubrication system...
Page 941 40 Troubleshooting UEN00246-02 S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Causes Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Use of improper fuel Use of improper oil Operation under excessive load Confirm recent repair history E E E Degree of use of machine Operated for long period...
Page 942 UEN00246-02 40 Troubleshooting S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Causes Leakage of fuel Defective condition of fuel injection (fuel pressure, injection timing) Excessive injection of fuel Confirm recent repair history Degree of use of machine Operated for long period Q Q Q More than for other machines of same model Condition of fuel...
Page 943 40 Troubleshooting UEN00246-02 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) General causes why oil is in coolant Causes Internal leakage in lubrication system Internal leakage in cooling system Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased Oil level Gradually increased...
Page 944 UEN00246-02 40 Troubleshooting S-12 Oil pressure drops General causes why oil pressure drops Causes Leakage, clogging, wear of lubrication system Defective oil pressure control Improper selection of fuel (improper viscosity) Deterioration of oil due to overheating Confirm recent repair history Degree of use of machine Operated for long period Oil pressure monitor indicates low oil pressure Non-specified oil is being used...
Page 945 40 Troubleshooting UEN00246-02 S-13 Oil level rises (Entry of coolant/fuel) General causes why oil level rises Causes Coolant in oil (milky) Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant" Confirm recent repair history Degree of use of machine Operated for long period Fuel must be added more frequently...
Page 946 UEN00246-02 40 Troubleshooting S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too high Causes Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Problem in coolant circulation system Rise in oil temperature in power train o Carry out troubleshooting for machine Confirm recent repair history Degree of use of machine Operated for long period...
Page 947 40 Troubleshooting UEN00246-02 S-15 Abnormal noise is made General causes why abnormal noise is made Causes Abnormality due to defective parts Abnormal combustion Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting.
Page 948 UEN00246-02 40 Troubleshooting S-16 Vibration is excessive General causes why vibration is excessive Causes Defective parts (abnormal wear, breakage) Misalignment between engine and chassis Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out trouble- shooting for "S-15 Abnormal noise is made", too. Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased...
Page 949 40 Troubleshooting UEN00246-02 S-17 Diesel Particulate Filter System Fault Possible causes Tests Corrective actions Exhaust back pressure Exhaust gas temperature Examine machine duty Increase engine load to raise rises steadily too low for effective regen- cycle. Measure exhaust exhaust temperature. Avoid eration temperature on a hot unnecessary idling.
Page 951 UEN00247-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K52393 and up PC210LC-8 K52393 and up PC210NLC-8 K52393 and up PC230NHD-8 K50213 and up PC240LC-8 K50630 and up PC240NLC-8 K50630 and up 40 Troubleshooting Troubleshooting of Auto Grease system Finding malfunctions ..........................
Page 952 UEN00247-00 40 Troubleshooting Finding malfunctions General The greasing system is equipped as standard with an electronic control unit with a database. All relevant data concerning the functioning of the greasing system are stored in that database. This data can be read with a laptop and software.
Page 953 40 Troubleshooting UEN00247-00 Malfunction Cause Solution 2. Display still gives no sig- a. No supply voltage on the display a. Check the fuses and/or nal after 1 minute. feeder connection (grey wire no. 1). Replace or repair it if necessary. b.
Page 954 UEN00247-00 40 Troubleshooting General Malfunction Cause Solution 6. All grease points contain a. The adjusted greasing interval is too a. Adjust a shorter greasing no grease and no malfunc- long for the relevant application. time interval with the push- tion reports have been button (if present) or with the given and the signal lamp is laptop and software.
Page 955 40 Troubleshooting UEN00247-00 Malfunction Cause Solution 11. The green lamp flashes A continuous-test cycle is carried out. The green lamp goes off after (0,2 s on - 0,2 s off) continu- the test. This is after turning ously. off the key switch. 12.
Page 956 UEN00247-00 40 Troubleshooting Procedure to check the working of the pump and the 5/2-magnetic valve 1. Disconnect both grease lines (channel A and B) from the pump unit. WARNING: Some pressure can still be present in the channels. 2. Connect a pressure gauge to each channel of the pump unit. Use pressure gauges that are suitable for a grease pressure of 250 bar.
Page 957 40 Troubleshooting UEN00247-00 4. Restart the pump in channel A. When the grease leaks from channel B of this first distribution block, the leak must be found in this block. When the grease leaks from the disconnected line, the leak must be sought farther down the system. There- fore repeat this procedure every time using the next distribution block until the leak is found.
Page 959 UEN00659-00 HYDRAULIC EXCAVATOR PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 50 Disassembly and...
Page 960 79 T- care for safety of machine. means that they can not be supplied a: Know-how or precautions for work from Komatsu in Japan (i.e. locally : Type of coating material made parts). : Tightening torque : Quantity of oil or coolant to be added...
Page 961 Part No. of special tools starting with * *** **** 79 T- means that they can not be supplied from Komatsu in Japan (i.e. locally made parts). a General tools that are necessary for removal or installation are described as [1],[2]•••etc. and their part names, part numbers and quantities are not described.
Page 962 The recommended coating materials such as adhesives, gasket sealants, and greases used for disas- sembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list. Cate- Komatsu Part No. Q'ty Container...
Page 963 50 Disassembly and assembly UEN00659-00 Classi- Komatsu Part number Content Container Main feature, application fication code • To be used as lubricant (anti squeaking) for LM-G 09940-00051 sliding part. • To be used for press fit, shrink fit and prevent- ing scratching or seizure of thread.
Page 964 UEN00659-00 50 Disassembly and assembly Classi- Komatsu Part number Content Container Main feature, application fication code • "S" and "W" are used as glass adhesive Sunstar pen- compound in high temperature (April - guin seal 580 Polyethylene October) and in low temperature (October...
Page 965 50 Disassembly and assembly UEN00659-00 Special tool list Tool part number 79 QQQQ indicates an interchangeable part (locally produced) Necessity : ..Special tools which cannot be substituted and should be always installed (used) ..Special tools which are very useful if available. They can be substituted with com- mercially available tools.
Page 966 UEN00659-00 50 Disassembly and assembly Sym- Work item Part number Part name Work content t 1 N Q 796T-427-1510 Push tool 790-101-2510 Block 790-101-3310 Block 790-101-2610 790-101-2730 Adaptor Installation of bearing 01580-11613 790-101-2570 Plate 01643-31645 Washer 790-101-2102 Puller (30 ton) 790-101-1102 Pump t 1 N...
Page 967 50 Disassembly and assembly UEN00659-00 Sym- Work item Part number Part name Work content 791-630-3000 Remover & installer Cylinder Separation and installation of Track shoe assembly 790-101-1300 (980kN{100ton}) track shoe assembly 790-101-1102 Pump Hydraulic pump assem- t 1 N Q Press fit of input shaft oil seal 796T-467-2410 Push tool 790-101-2501...
Page 968 UEN00659-00 50 Disassembly and assembly Sym- Work item Part number Part name Work content 796-946-1330 Sleeve (For 723-46-40100) 796-946-1630 Sleeve (For 723-46-41100) 796-946-1830 Sleeve (For 723-46-43100 and 723-46-43400) Replacement of pressure Control valve assembly T 4 compensation valve seal 796-946-1930 Sleeve (For 723-46-46101 and 723-46-46300) 796-946-2230...
Page 969 50 Disassembly and assembly UEN00659-00 Sym- Work item Part number Part name Work content 796-900-1200 Remover • 796-900-1210 • Sleeve • 792-900-1520 • Plate • 799-900-1230 • Screw Work equipment • 796-900-1240 • Adapter Removal of foot pin assembly • 01643-33080 •...
Page 970 UEN00659-00 50 Disassembly and assembly Sketches of special tools Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A8 Plate F1 Push tool PC210, 230, 240-8...
Page 971 50 Disassembly and assembly UEN00659-00 Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. F3 Plate J2 Push tool PC210, 230, 240-8...
Page 972 UEN00659-00 50 Disassembly and assembly Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. J6 Push tool S Push tool PC210, 230, 240-8...
Page 973 50 Disassembly and assembly UEN00659-00 PC210, 230, 240-8...
Page 975 UEN00660-00 HYDRAULIC EXCAVATOR PC210-8 PC240LC-8 PC210LC-8 PC240NLC-8 PC210NLC-8 PC230NHD-8 Machine model Serial number PC210-8 K50001 and up PC210LC-8 K50001 and up PC210NLC-8 K50001 and up PC230NHD-8 K50001 and up PC240LC-8 K50001 and up PC240NLC-8 K50001 and up 50 Disassembly and...
Page 976 UEN00660-00 50 Disassembly and assembly Engine cooling related Remove fuel filter and bracket assembly (5). Removal and installation of fuel supply pump assembly Removal Disconnect the negative terminal (–) of the battery before starting with the work. Turn the upper structure by 90 degrees. Remove the cover under the fuel tank (B section).
Page 977 50 Disassembly and assembly UEN00660-00 13. Disconnect two tube clamps (10). [*1] Installation Installation is done in the reverse order of 14. Disconnect fuel return tube (11). [*2] removal. 15. Disconnect bracket (12). 16. Disconnect fuel return hose (13). a Figure: Refer to Removal. 17.
Page 978 UEN00660-00 50 Disassembly and assembly Removal and installation of fuel Disconnect bracket (6). [*1] injector assembly Remove hose, tube and air intake connector assembly (7). [*2] Special tools a Remove it without separating from the bracket. a Mark the hose edge and tube to show the Part number Part name original hose installation positions.
Page 979 50 Disassembly and assembly UEN00660-00 a (9) – (13): Unused numbers Disconnect fuel return hose (14). [*3] Disconnect fuel return hose (15). 10. Disconnect bracket (16). [*4] 11. Remove fuel block (17). [*5] 12. Disconnect connector (18). a Pull out connector (18) in the direction of the arrow while pushing up its lock with flat-head screwdriver [1].
Page 980 UEN00660-00 50 Disassembly and assembly 14. Remove bellows (20). [*7] 20. Remove blow-by duct (26). [*12] 15. Remove clamp (21) from the cylinder block 21. Remove head cover (27). [*13] and disconnect fuel supply tube (22). [*8] a FSP: Fuel supply pump 16.
Page 981 50 Disassembly and assembly UEN00660-00 a Keep records of installation position and direction of the crosshead (hole shape of a and b parts) (Install it in the same direc- tion when reinstalling.) 25. Remove retainers (32) and then remove six inlet connectors (33).
Page 982 UEN00660-00 50 Disassembly and assembly Installation Tighten inlet connector (33) with retainer (32) by hand. (Push it into the injector Fuel injector assembly hole.) a Check that there is no damage or dust on Tighten mounting bolts (34) for fuel injec- the fuel injector sleeve.
Page 983 50 Disassembly and assembly UEN00660-00 [*1] Rocker arm and crosshead assembly Bracket mounting bolt: Install rocker arm and crosshead assem- 43 ± 6 Nm {4.4 ± 0.6 kgm} bly (31). a When reusing the crosshead, install [*2] the same intake and exhaust valves Air intake connector mounting bolt: in the same direction because the 24 ±...
Page 984 UEN00660-00 50 Disassembly and assembly a Coat the two bolt threads on the inner [*7], [*8], [*9], [*10], [*11] side of the engine with sealant (LG-7). High-pressure pipes and common rail Mounting bolt: Do not use high-pressure pipes with bend- 24 ±...
Page 985 50 Disassembly and assembly UEN00660-00 Removal and installation of engine front seal Special tools Part number Part name t 1 N 1 795-799-6400 Seal puller Wrench 6 790-331-1120 (Angle) Removal Remove the radiator assembly referring to the Remove fan (8). [*1] section of Removing Radiator Assembly.
Page 986 UEN00660-00 50 Disassembly and assembly Installation 15. Remove seal (14). Install front seal (14) using tool A1. a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
Page 987 50 Disassembly and assembly UEN00660-00 Vibration damper Install vibration damper (13), aligning its dowel hole with dowel pin a of the crank- shaft. Tightening procedure of bolts (15) Tighten to a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm} in diagonal order. Loosen the bolts 180°.
Page 988 UEN00660-00 50 Disassembly and assembly Removal and installation of engine rear seal Special tools Part number Part name 2 795-799-6500 Seal puller Removal Remove the hydraulic pump assembly refer- ring to the section of Removing Hydraulic Pump Assembly. Remove seal (5) as follows. a Use care in the removal so that the crank shaft may not be damaged.
Page 989 50 Disassembly and assembly UEN00660-00 Installation Install the oil seal according to the following procedure. a Do not remove pilot [5] which is attached to oil seal (5) until oil seal (5) is inserted to the crankshaft. a Before installing the oil seal, de-grease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leak- age.
Page 990 UEN00660-00 50 Disassembly and assembly As in the case of measurement of radial Carry out the rest of installation in the reverse run out, bring the dial gauge probe into order to removal. contact with end surface b near the outer perimeter of the flywheel at a right angle.
Page 991 50 Disassembly and assembly UEN00660-00 Removal and installation of a Pull out the hose while pushing lock (L) from both sides. cylinder head assembly Disconnect fuel return hose (4). Special tools Remove fuel filter and bracket assembly (5). Part number Part name 3 795-799-6700 Primer...
Page 992 UEN00660-00 50 Disassembly and assembly 16. Disconnect fuel return hose (15). 10. Disconnect bracket (9). [*2] 17. Disconnect bracket (16). [*6] 18. Remove fuel block (17). [*7] 11. Remove hose, tube and air intake connector assembly (10). [*3] a Remove it without separating from the bracket.
Page 993 50 Disassembly and assembly UEN00660-00 26. Remove protection cover (26). 27. Loosen air tube clamp (27). [*11] 28. Loosen hose clamp (28). [*12] 22. Remove clamp (21) from the cylinder block and disconnect high-pressure pipe (22). [*9] a FSP: Fuel supply pump a Remove the bellows from the sleeve nut portions.
Page 994 UEN00660-00 50 Disassembly and assembly 31. Lift temporarily exhaust manifold and turbo charger assembly (80), and remove the remaining mounting bolts. [*14] 32. Lift off exhaust manifold and turbo charger assembly (80) to remove it. Exhaust manifold and turbo charger assembly: 25 kg 38.
Page 995 50 Disassembly and assembly UEN00660-00 41. Disconnect clamp (42). 45. Remove head cover (48). 42. Disconnect connector with water temperature sensor (43) and air intake pressure sensor (44). a Connector with water temperature sensor (43) Pull the lock (female side) to the outside. a Air intake pressure sensor (44): 1) Push lock (L1) and slide it.
Page 996 UEN00660-00 50 Disassembly and assembly a Be careful not to let any dust or foreign 47. Remove nuts (49) for the harnesses from the materials enter the fuel injector assembly injector. mounting portion. Harness color Cylinder No. White 1, 3, 5 Black 2, 4, 6 48.
Page 997 50 Disassembly and assembly UEN00660-00 Installation How to tighten mounting bolts (60) Cylinder head assembly a Tighten the bolts in the order shown Measure under head length a of all the below. cylinder head mounting bolts to check that 90 ± 3 Nm {9.2 ± 0.3 kgm} they are within the length limit.
Page 998 UEN00660-00 50 Disassembly and assembly Install rocker housing assembly (59). Assemble fuel injector assembly (56) to Mounting bolt: the cylinder head with its fuel inlet hole 24 ± 4 Nm {2.4 ± 0.4 kgm} facing the intake manifold side. Install push rods (57). Tighten bolts (55) three or four turns.
Page 999 50 Disassembly and assembly UEN00660-00 Rocker arm and crosshead assembly Install harnesses (49). a Harness installation position Install rocker arm and crosshead assem- bly (52). Harness color Cylinder No. a When reusing the crosshead, install White 1, 3, 5 the same intake and exhaust valves Black 2, 4, 6 in the same direction because the...
Page 1000 UEN00660-00 50 Disassembly and assembly Carry out the following installation in the reverse order to removal. [*1] Install muffler (8) after coating it with thermosetting sealant. Entire perimeter of E section: thermosetting sealant (equivalent of Holts Firegum) [*4] Radiator hose clamp: 10.8 –...
Page 1001 50 Disassembly and assembly UEN00660-00 a Coat the two bolt threads on the inner [*9], [*10] side of the engine with sealant (LG- High-pressure pipes and common rail Do not use high-pressure pipes with bend- Mounting bolt: ing modification. 24 ± 4 Nm {2.4 ± 0.4 kgm} Be sure to use a genuine high-pressure Install bellows (23) to each high-pressure pipe fixing clamp and observe strictly the...

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Summary of Contents for Komatsu PC210-8

Page 103: Hydraulic Pump

Page 201: Specifications

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