KOMATSU PC230NHD-8 Hydraulic Excavator Service Manual

UEN00084-01 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 UEN00093-01 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

UEN00093-01 00 Index and foreword 2 PC210, 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 Tub 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 accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs UEN00084-01 q 00 Index and foreword Index UEN00093-01 q Foreword and general information UEN00094-00 01 Specification Specification and technical data UEN00095-00 10 Structure, function and maintenance standard Engine and cooling system UEN00096-00 Power train UEN00097-00 Undercarriage and frame UEN00098-00 Hydraulic system, Part 1 UEN00099-00 Hydraulic system, Part 2 UEN00100-00 Hydraulic system, Part 3 UEN00160-00 Work equipment UEN00101-00 Cab and its attachments UEN00102-00 Electrical system UEN00103-00 20 Standard value table Standard service value table UEN00227-00 30 Testing and adjusting Testing and adjusting, Part 1 UEN00228-00 Testing and adjusting, Part 2 UEN00229-00 Testing and adjusting, Part 3 UEN00230-00

00 Index and foreword UEN00093-01 PC210, 230, 240-8 3 40 Troubleshooting General information on troubleshooting UEN00231-00 Troubleshooting by failure code (Display of code), Part 1 UEN00240-00 Troubleshooting by failure code (Display of code), Part 2 UEN00241-00 Troubleshooting by failure code (Display of code), Part 3 UEN00242-00 Troubleshooting by failure code (Display of code), Part 4 UEN00243-00 Troubleshooting of electrical system (E-mode) UEN00244-00 Troubleshooting of hydraulic and mechanical system (H-mode) UEN00245-00 Troubleshooting of engine (S-mode) UEN00246-00 50 Disassembly and assembly Disassembly and assembly related information UEN00659-00 Q Engine cooling related UEN00660-00 Q Power train UEN00661-00 Q Under carriage and frame UEN00662-00 Q Hydraulic system UEN00663-00 Q Work equipment UEN00664-00 Q Cab related UEN00665-00 Q Electric components UEN00666-00 Q 90 Diagrams and drawings Hydraulic diagrams and drawings UEN00112-00 Electrical diagrams and drawings UEN00113-00

UEN00093-01 00 Index and foreword 4 PC210, 230, 240-8 Table of contents 1 00 Index and foreword Index UEN00093-01 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 UEN00095-00 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 UEN00096-00 Engine and cooling system ......................................................................................................... 2 Engine related parts................................................................................................................. 2 Radiator, oil cooler, aftercooler and fuel cooler ........................................................................ 3 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 UEN00099-00 Hydraulic system, Part 1 ............................................................................................................. 2 Hydraulic equipment layout drawing ........................................................................................ 2 Hydraulic tank and filter ........................................................................................................... 4 Hydraulic pump ........................................................................................................................ 5 Pilot oil filter ............................................................................................................................. 29 Hydraulic system, Part 2 UEN00100-00 Hydraulic system, Part 2 ............................................................................................................. 2 Control valve ............................................................................................................................ 2 CLSS ....................................................................................................................................... 15

00 Index and foreword UEN00093-01 PC210, 230, 240-8 5 Functions and operation by valve ............................................................................................ 20 Hydraulic system, Part 3 UEN00160-00 Hydraulic system, Part 3 ............................................................................................................. 3 Swing motor............................................................................................................................. 3 Center swivel joint ................................................................................................................... 12 Travel motor............................................................................................................................. 15 PPC valve ................................................................................................................................ 26 Work equipment and swing PPC valve ................................................................................... 26 Travel PPC valve ..................................................................................................................... 31 Service PPC valve (with EPC valve) ....................................................................................... 40 Service PPC valve ................................................................................................................... 46 Valve control ............................................................................................................................ 48 Solenoid valve ......................................................................................................................... 50 PPC Accumulator .................................................................................................................... 52 Return oil filter ......................................................................................................................... 53 Attachment circuit selector valve ............................................................................................. 54 Hydraulic cylinder .................................................................................................................... 56 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 UEN00103-00 Electrical system ......................................................................................................................... 2 Engine control .......................................................................................................................... 2 Electrical control system .......................................................................................................... 10 Monitor system ........................................................................................................................ 30 Sensor ..................................................................................................................................... 57 KOMTRAX terminal system..................................................................................................... 60 20 Standard value table Standard service value table UEN00227-00 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 UEN00228-00 Testing and adjusting, Part 1 ....................................................................................................... 3 Tools for testing, adjusting, and troubleshooting ..................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 7 Checking exhaust gas color .................................................................................................... 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

UEN00093-01 00 Index and foreword 6 PC210, 230, 240-8 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 Checking parts which cause hydraulic drift of work equipment ............................................... 48 Releasing residual pressure from hydraulic circuit .................................................................. 50 Measuring oil leakage .............................................................................................................. 51 Bleeding air from each part ...................................................................................................... 54 Checking cab tipping stopper .................................................................................................. 57 Adjusting mirrors ...................................................................................................................... 58 Testing and adjusting, Part 2 UEN00229-00 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 UEN00231-00 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 .................................................................................................. 35 Troubleshooting by failure code (Display of code), Part 1 UEN00240-00 Failure codes table .................................................................................................................. 3 Before carrying out troubleshooting when failure code is displayed ........................................ 8 Information in troubleshooting table......................................................................................... 12 Failure code [989L00] Engine Controller Lock Caution 1 ........................................................ 14 Failure code [989M00] Engine Controller Lock Caution 2 ....................................................... 14 Failure code [989N00] Engine Controller Lock Caution 3........................................................ 15 Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 15 Failure code [AB00KE] Charge Voltage Low ........................................................................... 16 Failure code [B@BAZG] Eng Oil Press. Low........................................................................... 18 Failure code [B@BAZK] Eng Oil Level Low............................................................................. 18 Failure code [B@BCNS] Eng Water Overheat ........................................................................ 19 Failure code [B@BCZK] Eng Water Level Low ....................................................................... 19 Failure code [B@HANS] Hydr Oil Overheat ............................................................................ 20 Failure code [CA111] EMC Critical Internal Failure.................................................................. 20 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..................................................... 21 Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 22 Failure code [CA123] Chg Air Press Sensor Low Error ........................................................... 24 Failure code [CA131] Throttle Sensor High Error .................................................................... 26 Failure code [CA132] Throttle Sensor Low Error ..................................................................... 28 Failure code [CA144] Coolant Temp Sens High Error ............................................................. 30 Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 32 Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 34 Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 36

00 Index and foreword UEN00093-01 PC210, 230, 240-8 7 Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 38 Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 40 Failure code [CA221] Ambient Press Sens High Error ............................................................ 42 Failure code [CA222] Ambient Press Sens Low Error ............................................................. 44 Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 46 Failure code [CA234] Eng Overspeed ..................................................................................... 47 Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 48 Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 49 Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 50 Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 52 Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................... 54 Failure code [CA324] Inj #3 (L#3) Open/Short Error ............................................................... 56 Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................... 58 Failure code [CA331] Inj #2 (L#2) Open/Short Error ............................................................... 60 Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 62 Troubleshooting by failure code (Display of code), Part 2 UEN00241-00 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 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 UEN00242-00 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

UEN00093-01 00 Index and foreword 8 PC210, 230, 240-8 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 UEN00243-00 Failure code [DXA8KA] PC-EPC (F) Sol Discon ..................................................................... 4 Failure code [DXA8KB] PC-EPC (F) Sol Short ........................................................................ 6 Failure code [DXA9KA] PC-EPC (R) Sol Discon ..................................................................... 8 Failure code [DXA9KB] PC-EPC (R) Sol Short ....................................................................... 10 Failure code [DXE0KA] LS-EPC Sol Discon............................................................................ 12 Failure code [DXE0KB] LS-EPC Sol Short .............................................................................. 14 Failure code [DXE4KA] Service Current EPC Discon ............................................................. 16 Failure code [DXE4KB] Service Current EPC Short ................................................................ 18 Failure code [DXE5KA] Merge-divider Main Sol Discon .......................................................... 20 Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................ 22 Failure code [DXE6KA] Merge-divider LS Sol Discon ............................................................. 24 Failure code [DXE6KB] Merge-divider LS Sol Short ................................................................ 26 Failure code [DY20KA] Wiper Working Abnormality................................................................ 28 Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 30 Failure code [DY2CKA] Washer Drive Discon ......................................................................... 32 Failure code [DY2CKB] Washer Drive Short ........................................................................... 34 Failure code [DY2DKB] Wiper Drive (For) Short ..................................................................... 36 Failure code [DY2EKB] Wiper Drive (Rev) Short ..................................................................... 38 Troubleshooting of electrical system (E-mode) UEN00244-00 Before carrying out troubleshooting of electrical system ......................................................... 3 Information in troubleshooting table......................................................................................... 5 E-1 When starting switch turned ON, machine monitor displays nothing ................................ 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 8 E-3 Engine does not start (Engine does not turn) .................................................................... 11 E-4 Preheater does not operate .............................................................................................. 14 E-5 Automatic warm-up system does not operate (in cold season) ........................................ 16 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ...... 18 E-7 Precaution lights up while engine is running ..................................................................... 20 E-8 Emergency stop item lights up while engine is running .................................................... 25 E-9 Engine coolant temperature gauge does not indicate normally ........................................ 26 E-10 Hydraulic oil temperature gauge does not indicate normally .......................................... 27 E-11 Fuel level gauge does not indicate normally ................................................................... 29 E-12 Contents of display by machine monitor are different from applicable machine ............. 31 E-13 Machine monitor does not display some items ............................................................... 31 E-14 Function switch does not work ........................................................................................ 31 E-15 Auto-decelerator does not operate normally ................................................................... 32 E-16 Working mode does not change ..................................................................................... 33 E-17 Travel speed does not change ........................................................................................ 34 E-18 Alarm buzzer cannot be stopped .................................................................................... 35 E-19 Windshield wiper and window washer do not operate .................................................... 36 E-20 Power maximizing function does not operate normally ................................................... 38 E-21 Swing holding brake does not operate normally ............................................................. 40 E-22 Travel alarm does not sound or does not stop sounding ................................................ 42 E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 44 E-24 When starting switch is turned OFF, service meter is not displayed ............................... 56

KOMATSU PC230NHD-8 Hydraulic Excavator Service Manual

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