Komatsu PC210-8 Install guide

UEN00084-06
HYDRAULIC
EXCAVATOR
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-8
SERIAL NUMBERS
PC210- K50001
and up
PC210LC- K50001
PC210NLC- K50001
PC230NHD-K50001
PC240LC- K50001
PC240NLC- K50001

PC210, 230, 240-8 1
UEN00093-06
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-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 1
Index
Organization list of the shop manual.................................................................................................... 2
Table of contents .................................................................................................................................. 4

UEN00093-06 00 Index and foreword
2PC210, 230, 240-8
Organization list of the shop manual 1
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. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs UEN00084-06
00 Index and foreword
Index UEN00093-06 q
Foreword and general information UEN00094-00
01 Specification
Specification and technical data UEN00095-02 q
10 Structure, function and maintenance standard
Engine and cooling system UEN00096-01
Power train UEN00097-00
Undercarriage and frame UEN00098-00
Hydraulic system, Part 1 UEN00099-01
Hydraulic system, Part 2 UEN00100-00
Hydraulic system, Part 3 UEN00160-03
Work equipment UEN00101-00
Cab and its attachments UEN00102-00
Electrical system UEN00103-03 q
Auto Grease system UEN00104-00
20 Standard value table
Standard service value table UEN00227-01
30 Testing and adjusting
Testing and adjusting, Part 1 UEN00228-04 q
Testing and adjusting, Part 2 UEN00229-01
Testing and adjusting, Part 3 UEN00230-00
40 Troubleshooting
General information on troubleshooting UEN00231-03 q
Troubleshooting by failure code (Display of code), Part 1 UEN00240-01
Troubleshooting by failure code (Display of code), Part 2 UEN00241-01
Troubleshooting by failure code (Display of code), Part 3 UEN00242-01
Troubleshooting by failure code (Display of code), Part 4 UEN00243-01
Troubleshooting of electrical system (E-mode) UEN00244-02

00 Index and foreword UEN00093-06
PC210, 230, 240-8 3
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
Hydraulic system UEN00663-02 q
Work equipment UEN00664-00
Cab related UEN00665-00
Electric components UEN00666-01 q
90 Diagrams and drawings
Hydraulic diagrams and drawings UEN00112-03 q
Electrical diagrams and drawings UEN00113-04 q

UEN00093-06 00 Index and foreword
4PC210, 230, 240-8
Table of contents 1
00 Index and foreword
Index UEN00093-06
Organization list of the shop manual ....................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information UEN00094-00
Foreword and general information .............................................................................................. 2
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code................................................................................................. 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data UEN00095-02
Specification and technical data .................................................................................................. 2
Specification dimension drawings............................................................................................ 2
Working range diagram ...........................................................................................................3
Specifications........................................................................................................................... 4
Weight table............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 12
10 Structure, function and maintenance standard
Engine and cooling system UEN00096-01
Engine and cooling system ......................................................................................................... 2
Engine related parts................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler........................................................................ 3
Diesel Particulate Filter ............................................................................................................... 4
Diesel Particulate Filter - Component Parts............................................................................. 5
System Description.................................................................................................................. 6
Regeneration ........................................................................................................................... 6
Power train UEN00097-00
Power train .................................................................................................................................. 2
Power train............................................................................................................................... 2
Final drive ................................................................................................................................ 4
Swing machinery ..................................................................................................................... 6
Swing circle.............................................................................................................................. 10
Undercarriage and frame UEN00098-00
Undercarriage and frame ............................................................................................................ 2
Track frame and recoil spring .................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
Hydraulic system, Part 1 UEN00099-01
Hydraulic system, Part 1 ............................................................................................................. 2
Hydraulic equipment layout drawing........................................................................................ 2
Hydraulic tank and filter ........................................................................................................... 4
Hydraulic pump........................................................................................................................ 5
Hydraulic pump........................................................................................................................ 6
Pilot oil filter ............................................................................................................................. 29

00 Index and foreword UEN00093-06
PC210, 230, 240-8 5
Hydraulic system, Part 2 UEN00100-00
Hydraulic system, Part 2 ............................................................................................................. 2
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 15
Functions and operation by valve............................................................................................ 20
Hydraulic system, Part 3 UEN00160-03
Hydraulic system, Part 3 ............................................................................................................. 3
Swing motor............................................................................................................................. 3
Centre swivel joint ................................................................................................................... 12
Travel motor............................................................................................................................. 15
PPC valve................................................................................................................................ 26
Valve control ............................................................................................................................ 46
ATT EPC Valve Assembly ....................................................................................................... 48
Solenoid valve ......................................................................................................................... 50
PPC Accumulator .................................................................................................................... 52
Return oil filter ......................................................................................................................... 53
Attachment circuit selector valve ............................................................................................. 54
Quick coupler control valve - For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and PC240
K50001~K50303...................................................................................................................... 56
Quick coupler control valve - For PC210 K51095 and up, PC230 K50114 and up and PC240
K50304 and up.) ...................................................................................................................... 58
Hydraulic cylinder .................................................................................................................... 60
Work equipment UEN00101-00
Work equipment .......................................................................................................................... 2
Dimensions of components ..................................................................................................... 2
Cab and its attachments UEN00102-00
Cab and its attachments.............................................................................................................. 2
Air conditioner piping ............................................................................................................... 2
Electrical system UEN00103-03
Electrical system ......................................................................................................................... 2
Engine control.......................................................................................................................... 2
Electrical control system.......................................................................................................... 10
Monitor system ........................................................................................................................ 36
Sensor ..................................................................................................................................... 67
PPC Levers ............................................................................................................................. 70
KOMTRAX terminal system..................................................................................................... 72
Auto Grease system UEN00104-00
Outline of Auto Grease System...................................................................................................2
Assembly ................................................................................................................................. 3
Components ............................................................................................................................ 3
The Greasing Cycle................................................................................................................. 6
Introduction.............................................................................................................................. 7
20 Standard value table
Standard service value table UEN00227-01
Standard service value table ....................................................................................................... 2
Standard value table for engine related parts .......................................................................... 2
Standard value table for chassis related parts......................................................................... 4
30 Testing and adjusting
Testing and adjusting, Part 1 UEN00228-04
Testing and adjusting, Part 1....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Measuring engine speed ......................................................................................................... 6
Measuring intake air pressure (boost pressure) ...................................................................... 7

UEN00093-06 00 Index and foreword
6PC210, 230, 240-8
Checking exhaust gas colour................................................................................................... 8
Adjusting valve clearance ........................................................................................................ 9
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 ................................................................................... 18
Bleeding air from fuel circuit .................................................................................................... 20
Checking fuel circuit for leakage.............................................................................................. 22
Checking and adjusting air conditioner compressor belt tension............................................. 23
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 ............................................ 32
Measuring and adjusting oil pressure in pump LS control circuit............................................. 36
Measuring solenoid valve output pressure .............................................................................. 42
Measuring PPC valve output pressure .................................................................................... 45
Adjusting play of work equipment and swing PPC valves ....................................................... 47
Measuring and adjusting quick coupler control valve output pressure .................................... 48
Checking parts which cause hydraulic drift of work equipment ............................................... 49
Releasing residual pressure from hydraulic circuit .................................................................. 51
Measuring oil leakage.............................................................................................................. 52
Bleeding air from each part...................................................................................................... 55
Checking cab tipping stopper .................................................................................................. 58
Adjusting mirrors...................................................................................................................... 60
Testing and adjusting, Part 2 UEN00229-01
Testing and adjusting, Part 2 ....................................................................................................... 2
Special functions of machine monitor ...................................................................................... 2
Testing and adjusting, Part 3 UEN00230-00
Testing and adjusting, Part 3 ....................................................................................................... 2
Handling high-voltage circuit of engine controller .................................................................... 2
Preparation work for troubleshooting of electrical system ....................................................... 3
Procedure for testing diodes....................................................................................................7
Pm Clinic service ..................................................................................................................... 9
40 Troubleshooting
General information on troubleshooting UEN00231-03
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Check before troubleshooting.................................................................................................. 4
Classification and procedures for troubleshooting................................................................... 5
How to read electric wire code................................................................................................. 9
Connection table for connector pin numbers ........................................................................... 12
T-boxes and T-adapters table .................................................................................................. 43
Troubleshooting by failure code (Display of code), Part 1 UEN00240-01
Failure codes table .................................................................................................................. 3
Before carrying out troubleshooting when failure code is displayed........................................ 8
Information in troubleshooting table......................................................................................... 14
Failure code [989L00] Engine Controller Lock Caution 1 ........................................................ 16
Failure code [989M00] Engine Controller Lock Caution 2 ....................................................... 16
Failure code [989N00] Engine Controller Lock Caution 3........................................................ 17
Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 17
Failure code [AB00KE] Charge Voltage Low ........................................................................... 18
Failure code [B@BAZG] Eng Oil Press. Low........................................................................... 20

00 Index and foreword UEN00093-06
PC210, 230, 240-8 7
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 .................................................... 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.................................................................... 28
Failure code [CA132] Throttle Sensor Low Error..................................................................... 30
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 32
Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 34
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 36
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 38
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 40
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 42
Failure code [CA221] Ambient Press Sens High Error............................................................ 44
Failure code [CA222] Ambient Press Sens Low Error............................................................. 46
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 48
Failure code [CA234] Eng Overspeed..................................................................................... 49
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 50
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 51
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 52
Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 54
Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................... 56
Failure code [CA324] Inj #3 (L#3) Open/Short Error ............................................................... 58
Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................... 60
Failure code [CA331] Inj #2 (L#2) Open/Short Error ............................................................... 62
Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 64
Troubleshooting by failure code (Display of code), Part 2 UEN00241-01
Failure code [CA342] Calibration Code Incompatibility ........................................................... 3
Failure code [CA351] Injectors Drive Circuit Error................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 8
Failure code [CA428] Water in Fuel Sensor High Error........................................................... 10
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 12
Failure code [CA435] Eng Oil Press Sw Error......................................................................... 14
Failure code [CA441] Battery Voltage Low Error..................................................................... 15
Failure code [CA442] Battery Voltage High Error .................................................................... 18
Failure code [CA449] Rail Press Very High Error.................................................................... 20
Failure code [CA451] Rail Press Sensor High Error................................................................ 22
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 24
Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 26
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 ............................................................. 32
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 34
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 36
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 39
Failure code [CA2249] Rail Press Very Low Error................................................................... 40
Failure code [CA2311] IMV Solenoid Error.............................................................................. 42
Failure code [CA2555] Grid Htr Relay Volt High Error............................................................. 44
Failure code [CA2556] Grid Htr Relay Volt Low Error ............................................................. 46
Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 48
Failure code [D862KA] GPS Antenna Discon ......................................................................... 50

UEN00093-06 00 Index and foreword
8PC210, 230, 240-8
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) .................................................. 4
Failure code [DAFGMC] GPS Module Error ............................................................................ 6
Failure code [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 8
Failure code [DGH2KB] Hydr Oil Sensor Short ....................................................................... 10
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 12
Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 14
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 16
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................... 18
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 20
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 22
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 24
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................. 26
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ............................................ 28
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 .................................................................. 40
Failure code [DWA2KA] Service Sol Discon............................................................................ 42
Failure code [DWA2KB] Service Sol Short .............................................................................. 43
Failure code [DWK0KA] 2-stage Relief Sol Discon ................................................................. 44
Failure code [DWK0KB] 2-stage Relief Sol Short.................................................................... 46
Troubleshooting by failure code (Display of code), Part 4 UEN00243-01
Failure code [DXA8KA] PC-EPC (F) Sol Discon ..................................................................... 3
Failure code [DXA8KB] PC-EPC (F) Sol Short........................................................................ 5
Failure code [DXA9KA] PC-EPC (R) Sol Discon ..................................................................... 7
Failure code [DXA9KB] PC-EPC (R) Sol Short ....................................................................... 9
Failure code [DXE0KA] LS-EPC Sol Discon............................................................................ 11
Failure code [DXE0KB] LS-EPC Sol Short .............................................................................. 13
Failure code [DXE4KA] Service Current EPC Discon ............................................................. 15
Failure code [DXE4KB] Service Current EPC Short................................................................ 17
Failure code [DXE5KA] Merge-divider Main Sol Discon.......................................................... 19
Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................ 21
Failure code [DXE6KA] Merge-divider LS Sol Discon ............................................................. 23
Failure code [DXE6KB] Merge-divider LS Sol Short................................................................ 25
Failure code [DY20KA] Wiper Working Abnormality................................................................ 27
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 29
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 ............................................................. 40
Failure code [DXE7KA] Service Current EPC2 Discon ........................................................... 41
Failure code [DXE7KB] Service Current EPC2 Short.............................................................. 42
Failure code [DXE8KA] Service Current EPC3 Discon ........................................................... 43
Failure code [DXE8KB] Service Current EPC3 Short.............................................................. 44
Failure code [DXE9KA] Service Current EPC4 Discon ........................................................... 45
Failure code [DXE9KB] Service Current EPC4 Short.............................................................. 46
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality ................................................ 49
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality ................................................ 51
Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality......................................... 53
Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality......................................... 55
Failure code [DFB3L8] Service Lever 1 Potentio Error............................................................ 57