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Komatsu PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Excavator Shop Manual UEN00084-07
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SERIAL NUMBERS:
PC210- K50001 and up
PC210LC- K50001 and up
PC210NLC- K50001 and up
PC230NHD-K50001 and up
PC240LC- K50001 and up
PC240NLC- K50001 and up
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Description
Komatsu PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Excavator Shop Manual
FILE DETAILS:
Komatsu PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8
Serial Number: K50001 and up
Book Code: UEN00084-07
Language: English
Pages: 1204
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Excavator Shop Manual
00 Index and foreword........................................................................................................................................... 3 Index....................................................................................................................................................... 3 Organization list of the shop manual.................................................................................................................... 4 Table of contents....................................................................................................................................... 6 00 Index and foreword........................................................................................................................................... 17 Foreword and general information............................................................................................................................ 17 Foreword and general information........................................................................................................................ 18 Safety notice....................................................................................................................................... 18 How to read the shop manual......................................................................................................................... 22 Explanation of terms for maintenance standard....................................................................................................... 24 Handling electric equipment and hydraulic component................................................................................................. 26 How to read electric wire code...................................................................................................................... 34 Method of disassembling and connecting push-pull type coupler....................................................................................... 37 Standard tightening torque table.................................................................................................................... 40 Conversion table.................................................................................................................................... 44 01 Specification................................................................................................................................................ 51 Specification and technical data............................................................................................................................ 51 Specification and technical data........................................................................................................................ 52 Specification dimension drawings.................................................................................................................... 52 Working range diagram............................................................................................................................... 53 Specifications...................................................................................................................................... 54 Weight table........................................................................................................................................ 58 Table of fuel, coolant and lubricants............................................................................................................... 62 10 Structure, function and maintenance standard................................................................................................................. 65 Engine and cooling system................................................................................................................................... 65 Engine and cooling system............................................................................................................................... 66 Engine related parts................................................................................................................................ 66 Radiator, oil cooler, aftercooler and fuel cooler................................................................................................... 67 Diesel Particulate Filter............................................................................................................................... 68 Diesel Particulate Filter - Component Parts......................................................................................................... 69 System Description.................................................................................................................................. 70 Regeneration........................................................................................................................................ 70 10 Structure, function and maintenance standard................................................................................................................. 73 Power train................................................................................................................................................. 73 Power train............................................................................................................................................. 74 Power train......................................................................................................................................... 74 Final drive......................................................................................................................................... 76 Swing machinery..................................................................................................................................... 78 Swing circle........................................................................................................................................ 82 10 Structure, function and maintenance standard................................................................................................................. 85 Undercarriage and frame..................................................................................................................................... 85 Undercarriage and frame................................................................................................................................. 86 Track frame and recoil spring....................................................................................................................... 86 Idler............................................................................................................................................... 88 Carrier roller...................................................................................................................................... 90 Track roller........................................................................................................................................ 91 Track shoe.......................................................................................................................................... 92 10 Structure, function and maintenance standard................................................................................................................. 99 Hydraulic system, Part 1.................................................................................................................................... 99 Hydraulic system, Part 1................................................................................................................................ 100 Hydraulic equipment layout drawing.................................................................................................................. 100 Hydraulic tank and filter............................................................................................................................... 102 Hydraulic pump...................................................................................................................................... 103 Hydraulic pump...................................................................................................................................... 104 Pilot oil filter.................................................................................................................................... 127 10 Structure, function and maintenance standard................................................................................................................. 129 Hydraulic system, Part 2.................................................................................................................................... 129 Hydraulic system, Part 2................................................................................................................................ 130 Control valve....................................................................................................................................... 130 CLSS................................................................................................................................................ 143 Functions and operation by valve.................................................................................................................... 148 Hydraulic drift prevention valve.................................................................................................................... 174 10 Structure, function and maintenance standard................................................................................................................. 187 Hydraulic system, Part 3.................................................................................................................................... 187 Hydraulic system, Part 3................................................................................................................................ 189 Swing motor......................................................................................................................................... 189 Centre swivel joint................................................................................................................................. 198 Travel motor........................................................................................................................................ 201 PPC valve........................................................................................................................................... 212 Valve control....................................................................................................................................... 232 ATT EPC Valve Assembly.............................................................................................................................. 234 Solenoid valve...................................................................................................................................... 236 PPC Accumulator..................................................................................................................................... 238 Return oil filter................................................................................................................................... 239 Attachment circuit selector valve................................................................................................................... 240 Quick coupler control valve - For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and PC240 K50001~K50303.............................................. 242 Quick coupler control valve - For PC210 K51095 - K53243, PC230 K50114 - K50286 and PC240 K50304 - K51093.).......................................... 244 Quick coupler control valve - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up.................................................. 246 Hydraulic cylinder.................................................................................................................................. 248 10 Structure, function and maintenance standard................................................................................................................. 253 Work equipment.............................................................................................................................................. 253 Work equipment.......................................................................................................................................... 254 Dimensions of components............................................................................................................................ 254 10 Structure, function and maintenance standard................................................................................................................. 261 Cab and its attachments..................................................................................................................................... 261 Cab and its attachments................................................................................................................................. 262 Air conditioner piping.............................................................................................................................. 262 10 Structure, function and maintenance standard................................................................................................................. 265 Electrical system........................................................................................................................................... 265 Electrical system....................................................................................................................................... 266 Engine control...................................................................................................................................... 266 Electrical control system........................................................................................................................... 274 Monitor system...................................................................................................................................... 300 Sensor.............................................................................................................................................. 331 PPC Levers.......................................................................................................................................... 334 KOMTRAX terminal system............................................................................................................................. 336 10 Structure, function and maintenance standard................................................................................................................. 339 Auto Grease system.......................................................................................................................................... 339 Outline of Auto Grease System........................................................................................................................... 340 20 Standard value table......................................................................................................................................... 355 Standard service value table................................................................................................................................ 355 Standard service value table............................................................................................................................ 356 Standard value table for engine related parts....................................................................................................... 356 Standard value table for chassis related parts...................................................................................................... 358 30 Testing and adjusting........................................................................................................................................ 377 Testing and adjusting, Part 1............................................................................................................................... 377 Testing and adjusting, Part 1........................................................................................................................... 379 Tools for testing, adjusting, and troubleshooting................................................................................................... 379 Measuring engine speed.............................................................................................................................. 382 Measuring intake air pressure (boost pressure)...................................................................................................... 383 Checking exhaust gas colour......................................................................................................................... 384 Adjusting valve clearance........................................................................................................................... 385 Measuring compression pressure...................................................................................................................... 387 Measuring blow-by pressure.......................................................................................................................... 389 Measuring engine oil pressure....................................................................................................................... 390 Handling fuel system parts.......................................................................................................................... 391 Releasing residual pressure from fuel system........................................................................................................ 391 Measuring fuel pressure............................................................................................................................. 392 Measuring fuel return rate and leakage.............................................................................................................. 394 Bleeding air from fuel circuit...................................................................................................................... 396 Checking fuel circuit for leakage................................................................................................................... 398 Checking and adjusting air conditioner compressor belt tension...................................................................................... 399 Measuring swing circle bearing clearance............................................................................................................ 400 Checking and adjusting track shoe tension........................................................................................................... 401 Measuring and adjusting oil pressure in work equipment, swing, and travel circuits.................................................................. 403 Measuring control circuit basic pressure............................................................................................................ 407 Measuring and adjusting oil pressure in pump PC control circuit..................................................................................... 408 Measuring and adjusting oil pressure in pump LS control circuit..................................................................................... 412 Measuring solenoid valve output pressure............................................................................................................ 418 Measuring PPC valve output pressure................................................................................................................. 421 Adjusting play of work equipment and swing PPC valves............................................................................................... 423 Measuring and adjusting quick coupler control valve output pressure - For PC210 K50001 - K53423, PC230 K50001 - K50286 and PC240 K50001 - K51093.... 424 Measuring and adjusting quick coupler control valve output pressure - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up.......... 425 Checking parts which cause hydraulic drift of work equipment........................................................................................ 426 Releasing residual pressure from hydraulic circuit.................................................................................................. 428 Measuring oil leakage............................................................................................................................... 429 Bleeding air from each part......................................................................................................................... 432 Checking cab tipping stopper........................................................................................................................ 435 Adjusting mirrors................................................................................................................................... 436 Adjusting mirrors................................................................................................................................... 438 30 Testing and adjusting........................................................................................................................................ 441 Testing and adjusting, Part 2............................................................................................................................... 441 Testing and adjusting, Part 2........................................................................................................................... 442 Special functions of machine monitor................................................................................................................ 442 30 Testing and adjusting........................................................................................................................................ 507 Testing and adjusting, Part 3............................................................................................................................... 507 Testing and adjusting, Part 3........................................................................................................................... 508 Handling high-voltage circuit of engine controller.................................................................................................. 508 Preparation work for troubleshooting of electrical system........................................................................................... 509 Procedure for testing diodes........................................................................................................................ 513 Pm Clinic service................................................................................................................................... 515 Warning............................................................................................................................................. 517 Pm Clinic service................................................................................................................................... 521 40 Troubleshooting.............................................................................................................................................. 529 General information on troubleshooting...................................................................................................................... 529 General information on troubleshooting.................................................................................................................. 530 Points to remember when troubleshooting............................................................................................................. 530 Sequence of events in troubleshooting............................................................................................................... 531 Check before troubleshooting........................................................................................................................ 532 Classification and procedures for troubleshooting................................................................................................... 533 How to read electric wire code...................................................................................................................... 537 Connection table for connector pin numbers.......................................................................................................... 540 T-boxes and T-adapters table........................................................................................................................ 571 40 Troubleshooting.............................................................................................................................................. 577 Troubleshooting by failure code (Display of code), Part 1................................................................................................... 577 Troubleshooting by failure code (Display of code), Part 1............................................................................................... 579 Failure codes table................................................................................................................................. 579 Before carrying out troubleshooting when failure code is displayed.................................................................................. 584 Before carrying out troubleshooting when failure code is displayed.................................................................................. 585 Information in troubleshooting table................................................................................................................ 590 Failure code [989L00] Engine Controller Lock Caution 1.............................................................................................. 592 Failure code [989M00] Engine Controller Lock Caution 2.............................................................................................. 592 Failure code [989N00] Engine Controller Lock Caution 3.............................................................................................. 593 Failure code [AA10NX] Air Cleaner Clogging.......................................................................................................... 593 Failure code [AB00KE] Charge Voltage Low............................................................................................................ 594 Failure code [B@BAZG] Eng Oil Press. Low............................................................................................................ 596 Failure code [B@BAZK] Eng Oil Level Low............................................................................................................. 596 Failure code [B@BCNS] Eng Water Overheat............................................................................................................ 597 Failure code [B@BCZK] Eng Water Level Low........................................................................................................... 597 Failure code [B@HANS] Hydr Oil Overheat............................................................................................................. 598 Failure code [CA111] EMC Critical Internal Failure.................................................................................................. 598 Failure code [CA115] Eng Ne and Bkup Speed Sens Error............................................................................................... 599 Failure code [CA122] Chg Air Press Sensor High Error................................................................................................ 600 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................................. 602 Failure code [CA131] Throttle Sensor High Error..................................................................................................... 604 Failure code [CA132] Throttle Sensor Low Error...................................................................................................... 606 Failure code [CA144] Coolant Temp Sens High Error................................................................................................... 608 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................................... 610 Failure code [CA153] Chg Air Temp Sensor High Error................................................................................................. 612 Failure code [CA154] Chg Air Temp Sensor Low Error.................................................................................................. 614 Failure code [CA155] Chg Air Temp High Speed Derate................................................................................................. 616 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................................................... 618 Failure code [CA221] Ambient Press Sens High Error.................................................................................................. 620 Failure code [CA222] Ambient Press Sens Low Error................................................................................................... 622 Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................................. 624 Failure code [CA234] Eng Overspeed.................................................................................................................. 625 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................................................ 626 Failure code [CA271] IMV/PCV1 Short Error........................................................................................................... 627 Failure code [CA272] IMV/PCV1 Open Error............................................................................................................ 628 Failure code [CA322] Inj #1 (L#1) Open/Short Error.................................................................................................. 630 Failure code [CA323] Inj #5 (L#5) Open/Short Error.................................................................................................. 632 Failure code [CA324] Inj #3 (L#3) Open/Short Error.................................................................................................. 634 Failure code [CA325] Inj #6 (L#6) Open/Short Error.................................................................................................. 636 Failure code [CA331] Inj #2 (L#2) Open/Short Error.................................................................................................. 638 Failure code [CA332] Inj #4 (L#4) Open/Short Error.................................................................................................. 640 40 Troubleshooting.............................................................................................................................................. 643 Troubleshooting by failure code (Display of code), Part 2................................................................................................... 643 Troubleshooting by failure code (Display of code), Part 2............................................................................................... 645 Failure code [CA342] Calibration Code Incompatibility............................................................................................... 645 Failure code [CA351] Injectors Drive Circuit Error.................................................................................................. 646 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................................................... 648 Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................................. 650 Failure code [CA428] Water in Fuel Sensor High Error................................................................................................ 652 Failure code [CA429] Water in Fuel Sensor Low Error................................................................................................. 654 Failure code [CA435] Eng Oil Press Sw Error......................................................................................................... 656 Failure code [CA441] Battery Voltage Low Error...................................................................................................... 657 Failure code [CA442] Battery Voltage High Error..................................................................................................... 660 Failure code [CA449] Rail Press Very High Error..................................................................................................... 662 Failure code [CA451] Rail Press Sensor High Error................................................................................................... 664 Failure code [CA452] Rail Press Sensor Low Error.................................................................................................... 666 Failure code [CA488] Chg Air Temp High Torque Derate................................................................................................ 668 Failure code [CA553] Rail Press High Error.......................................................................................................... 668 Failure code [CA559] Rail Press Low Error........................................................................................................... 669 Failure code [CA689] Eng Ne Speed Sensor Error...................................................................................................... 670 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................................................ 672 Failure code [CA757] All Continuous Data Lost Error................................................................................................. 674 Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................................................... 676 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................................................. 678 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................................ 680 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................................. 681 Failure code [CA2249] Rail Press Very Low Error..................................................................................................... 682 Failure code [CA2311] IMV Solenoid Error............................................................................................................ 684 Failure code [CA2555] Grid Htr Relay Volt High Error................................................................................................ 686 Failure code [CA2556] Grid Htr Relay Volt Low Error................................................................................................. 688 Failure code [D19JKZ] Personal Code Relay Abnormality............................................................................................... 690 Failure code [D862KA] GPS Antenna Discon............................................................................................................ 692 Failure code [DA25KP] 5V Sensor 1 Power Abnormality................................................................................................. 693 Failure code [DA29KQ] Model Selection Abnormality................................................................................................... 700 40 Troubleshooting.............................................................................................................................................. 705 Troubleshooting by failure code (Display of code), Part 3................................................................................................... 705 Troubleshooting by failure code (Display of code), Part 3............................................................................................... 708 Failure code [DA2RMC] CAN Discon (Pump Con Detected)................................................................................................ 708 Failure code [DAFGMC] GPS Module Error.............................................................................................................. 710 Failure code [DAFRMC] CAN Discon (Monitor Detected)................................................................................................. 712 Failure code [DGH2KB] Hydr Oil Sensor Short......................................................................................................... 714 Failure code [DHPAMA] F Pump Press Sensor Abnormality............................................................................................... 716 Failure code [DHPBMA] R Pump Press Sensor Abnormality............................................................................................... 718 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................................................................... 720 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...................................................................................... 722 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality....................................................................................... 724 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality......................................................................................... 726 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality......................................................................................... 728 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...................................................................................... 730 Failure code [DHX1MA] Overload Sensor Abnormality (Analog).......................................................................................... 732 Failure code [DW43KA] Travel Speed Sol Discon....................................................................................................... 734 Failure code [DW43KB] Travel Speed Sol Short........................................................................................................ 736 Failure code [DW45KA] Swing Brake Sol Discon........................................................................................................ 738 Failure code [DW45KB] Swing Brake Sol Short......................................................................................................... 740 Failure code [DW91KA] Travel Junction Sol Discon.................................................................................................... 742 Failure code [DW91KB] Travel Junction Sol Short..................................................................................................... 744 Failure code [DWA2KA] Service Sol Discon............................................................................................................ 746 Failure code [DWA2KB] Service Sol Short............................................................................................................. 747 Failure code [DWK0KA] 2-stage Relief Sol Discon..................................................................................................... 748 Failure code [DWK0KB] 2-stage Relief Sol Short...................................................................................................... 750 40 Troubleshooting.............................................................................................................................................. 753 Troubleshooting by failure code (Display of code), Part 4................................................................................................... 753 Troubleshooting by failure code (Display of code), Part 4............................................................................................... 755 Failure code [DXA8KA] PC-EPC (F) Sol Discon......................................................................................................... 755 Failure code [DXA8KB] PC-EPC (F) Sol Short.......................................................................................................... 757 Failure code [DXA9KA] PC-EPC (R) Sol Discon......................................................................................................... 759 Failure code [DXA9KB] PC-EPC (R) Sol Short.......................................................................................................... 761 Failure code [DXE0KA] LS-EPC Sol Discon............................................................................................................. 763 Failure code [DXE0KB] LS-EPC Sol Short.............................................................................................................. 765 Failure code [DXE4KA] Service Current EPC Discon.................................................................................................... 767 Failure code [DXE4KB] Service Current EPC Short..................................................................................................... 769 Failure code [DXE5KA] Merge-divider Main Sol Discon................................................................................................. 771 Failure code [DXE5KB] Merge-divider Main Sol Short.................................................................................................. 773 Failure code [DXE6KA] Merge-divider LS Sol Discon................................................................................................... 775 Failure code [DXE6KB] Merge-divider LS Sol Short.................................................................................................... 777 Failure code [DY20KA] Wiper Working Abnormality..................................................................................................... 779 Failure code [DY20MA] Wiper Parking Abnormality..................................................................................................... 781 Failure code [DY2CKA] Washer Drive Discon........................................................................................................... 783 Failure code [DY2CKB] Washer Drive Short............................................................................................................ 785 Failure code [DY2DKB] Wiper Drive (For) Short....................................................................................................... 787 Failure code [DY2EKB] Wiper Drive (Rev) Short....................................................................................................... 789 Failure code [DXEAKA] Service Current EPC1 Discon................................................................................................... 791 Failure code [DXEAKB] Service Current EPC1 Short.................................................................................................... 792 Failure code [DXE7KA] Service Current EPC2 Discon................................................................................................... 793 Failure code [DXE7KB] Service Current EPC2 Short.................................................................................................... 794 Failure code [DXE8KA] Service Current EPC3 Discon................................................................................................... 795 Failure code [DXE8KB] Service Current EPC3 Short.................................................................................................... 796 Failure code [DXE9KA] Service Current EPC4 Discon................................................................................................... 797 Failure code [DXE9KB] Service Current EPC4 Short.................................................................................................... 798 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality.......................................................................................... 801 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality.......................................................................................... 803 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality...................................................................................... 805 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality...................................................................................... 807 Failure code [DFB3L8] Service Lever 1 Potentio Error................................................................................................ 809 Failure code [DFB4L8] Service Lever 2 Potentio Error................................................................................................ 810 40 Troubleshooting.............................................................................................................................................. 813 Troubleshooting of electrical system (E-mode)............................................................................................................... 813 Troubleshooting of electrical system (E-mode)........................................................................................................... 815 Before carrying out troubleshooting of electrical system................................................................................................ 815 Troubleshooting of electrical system (E-mode)........................................................................................................... 816 Information in troubleshooting table.................................................................................................................... 819 E-1 When starting switch turned ON, machine monitor displays nothing.................................................................................... 820 E-2 When starting switch turned ON (before starting engine), basic check item lights up................................................................. 822 E-3 Engine does not start (Engine does not turn)........................................................................................................ 825 E-4 Preheater does not operate.......................................................................................................................... 828 E-5 Automatic warm-up system does not operate (in cold season).......................................................................................... 830 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked..................................................................... 832 E-7 Precaution lights up while engine is running........................................................................................................ 834 E-8 Emergency stop item lights up while engine is running............................................................................................... 839 E-9 Engine coolant temperature gauge does not indicate normally......................................................................................... 840 E-10 Hydraulic oil temperature gauge does not indicate normally......................................................................................... 841 E-11 Fuel level gauge does not indicate normally........................................................................................................ 843 E-12 Contents of display by machine monitor are different from applicable machine....................................................................... 845 E-13 Machine monitor does not display some items........................................................................................................ 845 E-14 Function switch does not work...................................................................................................................... 845 E-15 Auto-decelerator does not operate normally......................................................................................................... 846 E-16 Working mode does not change....................................................................................................................... 847 E-17 Travel speed does not change....................................................................................................................... 848 E-18 Alarm buzzer cannot be stopped..................................................................................................................... 849 E-18 Alarm buzzer cannot be stopped..................................................................................................................... 850 E-19 Windshield wiper and window washer do not operate.................................................................................................. 852 E-20 Power maximising function does not operate normally................................................................................................ 854 E-20 Power maximising function does not operate normally................................................................................................ 856 E-21 Swing holding brake does not operate normally...................................................................................................... 858 E-22 Travel alarm does not sound or does not stop sounding.............................................................................................. 860 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)........................................................... 862 E-24 When starting switch is turned OFF, service meter is not displayed................................................................................. 874 E-25 Machine monitor cannot be set in service mode...................................................................................................... 874 E-26 Monitoring function does not display lever control signal normally................................................................................. 875 E-27 KOMTRAX system does not operate normally........................................................................................................... 884 40 Troubleshooting.............................................................................................................................................. 887 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................................................. 887 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................................................. 890 System diagram of hydraulic and mechanical system................................................................................................... 890 Information in troubleshooting table................................................................................................................ 892 H-1 Speed or power of whole work equipment, swing, and travel is low................................................................................ 893 H-2 Engine speed lowers extremely or engine stalls.................................................................................................. 895 H-3 Work equipment, swing, and travel systems do not work........................................................................................... 896 H-4 Abnormal sound comes out from around hydraulic pump............................................................................................. 896 H-5 Auto-decelerator does not operate............................................................................................................... 897 H-6 Fine control performance or response is low..................................................................................................... 897 H-7 Speed or power of boom is low................................................................................................................... 898 H-8 Speed or power of arm is low.................................................................................................................... 899 H-9 Speed or power of bucket is low................................................................................................................. 900 H-10 Work equipment does not move singly............................................................................................................ 900 H-11 Hydraulic drift of work equipment is large..................................................................................................... 901 H-12 Time lag of work equipment is large............................................................................................................ 903 H-13 When part of work equipment is relieved singly, other parts of work equipment move............................................................. 903 H-14 Power maximizing function does not work........................................................................................................ 904 H-15 In compound operation of work equipment, speed of part loaded more is low...................................................................... 904 H-16 When machine swings and raises boom simultaneously, boom rising speed is low................................................................... 905 H-17 When machine swings and travels simultaneously, travel speed lowers largely.................................................................... 905 H-18 Machine deviates during travel................................................................................................................. 906 H-19 Travel speed is low............................................................................................................................ 907 H-20 Machine is not steered well or steering power is low........................................................................................... 908 H-21 Travel speed does not change or travel speed is low/high....................................................................................... 909 H-22 Travel system does not move (only one side).................................................................................................... 910 H-23 Upper structure does not swing................................................................................................................. 911 H-24 Swing acceleration or swing speed is low....................................................................................................... 913 H-25 Upper structure overruns remarkably when it stops swinging..................................................................................... 914 H-26 Large shock is made when upper structure stops swinging........................................................................................ 915 H-27 Large sound is made when upper structure stops swinging........................................................................................ 915 H-28 Hydraulic drift of swing is large.............................................................................................................. 916 H-29 Attachment circuit is not changed.............................................................................................................. 917 H-30 Oil flow in attachment circuit cannot be controlled............................................................................................ 917 Quick coupler....................................................................................................................................... 918 Quick coupler....................................................................................................................................... 920 Quick coupler....................................................................................................................................... 922 40 Troubleshooting.............................................................................................................................................. 927 Troubleshooting of engine (S-mode).......................................................................................................................... 927 Troubleshooting of engine (S-mode)...................................................................................................................... 929 Method of using troubleshooting chart............................................................................................................... 929 S-1 Starting performance is poor.................................................................................................................... 932 S-2 Engine does not start........................................................................................................................... 933 S-3 Engine does not pick up smoothly................................................................................................................ 936 S-4 Engine stops during operations.................................................................................................................. 937 S-5 Engine does not rotate smoothly................................................................................................................. 938 S-6 Engine lack output (or lacks power)............................................................................................................. 939 S-7 Exhaust smoke is black (incomplete combustion).................................................................................................. 941 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................... 942 S-9 Oil becomes contaminated quickly................................................................................................................ 943 S-10 Fuel consumption is excessive.................................................................................................................. 944 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................................................................... 945 S-12 Oil pressure drops............................................................................................................................. 946 S-13 Oil level rises (Entry of coolant/fuel)........................................................................................................ 947 S-14 Coolant temperature becomes too high (overheating)............................................................................................. 948 S-15 Abnormal noise is made......................................................................................................................... 949 S-16 Vibration is excessive......................................................................................................................... 950 S-17 Diesel Particulate Filter System............................................................................................................... 951 40 Troubleshooting.............................................................................................................................................. 953 Troubleshooting of Auto Grease system....................................................................................................................... 953 50 Disassembly and assembly..................................................................................................................................... 961 Disassembly and assembly related information................................................................................................................ 961 Disassembly and assembly related information............................................................................................................ 962 How to read this manual............................................................................................................................. 962 List of adhesives................................................................................................................................... 964 Special tool list................................................................................................................................... 967 Sketches of special tools........................................................................................................................... 972 50 Disassembly and assembly..................................................................................................................................... 977 Engine cooling related...................................................................................................................................... 977 Engine cooling related.................................................................................................................................. 978 Removal and installation of fuel supply pump assembly............................................................................................... 978 Removal and installation of fuel injector assembly.................................................................................................. 980 Removal and installation of engine front seal....................................................................................................... 987 Removal and installation of engine rear seal........................................................................................................ 990 Removal and installation of cylinder head assembly.................................................................................................. 993 Removal and installation of radiator assembly.......................................................................................................1005 Removal and installation of assembly hydraulic oil cooler assembly..................................................................................1008 Removal and installation of aftercooler assembly....................................................................................................1010 Removal and installation of fuel cooler assembly....................................................................................................1012 Removal and installation of engine and hydraulic pump assemblies....................................................................................1013 50 Disassembly and assembly.....................................................................................................................................1025 Power train.................................................................................................................................................1025 Power train.............................................................................................................................................1026 Removal and installation of final drive assembly....................................................................................................1026 Disassembly and assembly of final drive assembly....................................................................................................1028 Removal and installation of swing motor and swing machinery assembly................................................................................1044 Disassembly and assembly of swing motor and swing machinery assembly................................................................................1046 Removal and installation of swing circle assembly...................................................................................................1056 50 Disassembly and assembly.....................................................................................................................................1059 Under carriage and frame....................................................................................................................................1059 Under carriage and frame................................................................................................................................1060 Disassembly and assembly of carrier roller..........................................................................................................1060 Disassembly and assembly of track roller assembly...................................................................................................1063 Disassembly and assembly of idler assembly..........................................................................................................1065 Disassembly and assembly of recoil spring...........................................................................................................1068 Removal and installation of sprocket................................................................................................................1070 Expansion and installation of track shoe assembly...................................................................................................1071 Removal and installation of revolving frame assembly................................................................................................1073 Removal and installation of counterweight assembly..................................................................................................1075 50 Disassembly and assembly.....................................................................................................................................1077 Hydraulic system............................................................................................................................................1077 Hydraulic system........................................................................................................................................1078 Removal and installation of center swivel joint assembly............................................................................................1078 Disassembly and assembly of center swivel joint assembly............................................................................................1080 Removal and installation of hydraulic tank assembly.................................................................................................1081 Removal and installation of control valve assembly..................................................................................................1084 Disassembly and assembly of control valve assembly..................................................................................................1089 Removal and installation of hydraulic pump assembly.................................................................................................1093 Removal and installation of oil seal in hydraulic pump input shaft..................................................................................1098 Disassembly and assembly of work equipment PPC valve assembly.......................................................................................1099 Disassembly and assembly of travel PPC valve assembly...............................................................................................1100 Disassembly and assembly of hydraulic cylinder assembly.............................................................................................1101 Disassembly and Assembly of Quick Coupler Valve - For PC210 K50001 - K53423, PC230 K50001 - K50286 and PC240 K50001 - K51093........................1107 Disassembly and Assembly of Quick Coupler Valve - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up..............................1108 50 Disassembly and assembly.....................................................................................................................................1111 Work equipment..............................................................................................................................................1111 Work equipment..........................................................................................................................................1112 Removal and installation of the work equipment assembly.............................................................................................1112 50 Disassembly and assembly.....................................................................................................................................1117 Cab related.................................................................................................................................................1117 Cab related.............................................................................................................................................1118 Removal and installation of operator's cab assembly.................................................................................................1118 Removal and installation of operator cab glass (stuck glass)........................................................................................1121 Removal and installation of front window assembly...................................................................................................1131 Removal and installation of floor frame assembly....................................................................................................1138 50 Disassembly and assembly.....................................................................................................................................1143 Electric components.........................................................................................................................................1143 Electric components.....................................................................................................................................1144 Removal and installation of air conditioner unit assembly...........................................................................................1144 Removal and installation of KOMTRAX communication modem assembly....................................................................................1147 Removal and installation of monitor assembly........................................................................................................1148 Removal and installation of pump controller assembly................................................................................................1150 Removal and installation of engine controller assembly..............................................................................................1151 90 Diagrams and drawings........................................................................................................................................1155 Hydraulic diagrams and drawings.............................................................................................................................1155 Hydraulic diagrams and drawings (for PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303)..................................................1157 Hydraulic circuit diagram 1/2.......................................................................................................................1157 Hydraulic circuit diagram 2/2.......................................................................................................................1159 Hydraulic diagrams and drawings (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up)..................................................1161 Hydraulic circuit diagram 1/2.......................................................................................................................1161 Hydraulic circuit diagram 2/2.......................................................................................................................1163 90 Diagrams and drawings........................................................................................................................................1167 Electrical diagrams and drawings............................................................................................................................1167 Electrical diagrams and drawings (for PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303).................................................1169 Electrical circuit diagram (1/5)....................................................................................................................1169 Electrical circuit diagram (2/5)....................................................................................................................1171 Electrical circuit diagram (3/5)....................................................................................................................1173 Electrical circuit diagram (4/5)....................................................................................................................1175 Electrical circuit diagram (5/5)....................................................................................................................1177 Electrical diagrams and drawings (For PC210 K51095 ~ K52292, PC230 K50114 ~ K50200 and PC240 K50304 ~ K50595)...........................................1179 Electrical circuit diagram (1/5)....................................................................................................................1179 Electrical circuit diagram (2/5)....................................................................................................................1181 Electrical circuit diagram (3/5)....................................................................................................................1183 Electrical circuit diagram (4/5)....................................................................................................................1185 Electrical circuit diagram (5/5)....................................................................................................................1187 Electrical diagrams and drawings (for PC210 K52293 and up, PC230 K50201 and up and PC240 K50596 and up).................................................1189 Electrical circuit diagram (1/5)....................................................................................................................1189 Electrical circuit diagram (2/5)....................................................................................................................1191 Electrical circuit diagram (3/5)....................................................................................................................1193 Electrical circuit diagram (4/5)....................................................................................................................1195 Electrical circuit diagram (5/5)....................................................................................................................1197 Connector arrangement diagram.......................................................................................................................1199 Electrical circuit diagram for air conditioner......................................................................................................1201
KOMATSU PC210-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 EXCAVATOR SHOP MANUAL UEN00084-07:
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